Welding Torch Training Feedback Using Path-Based Scoring
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Solution Overview
Problem
Welding training systems are expensive and often fail to adequately train operators to perform high-quality welds, particularly in manual welding operations.
Innovation Solution
A welding system incorporating a welding stand, sensing devices, and a computer with processors and memory to track and analyze welding operations, providing feedback and training through augmented and virtual reality, and integrating real and simulated welding to enhance operator skills.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding training systems are used, then operators can be trained for manual welding operations, but the training cost is high and training quality is insufficient
Solution Approach 1:
The patent creates a virtual copy of the welding environment and equipment that replicates real welding operations. The virtual welding system includes digital models of welding equipment, workpieces, and processes that mirror physical systems, allowing operators to practice and be evaluated on realistic welding tasks without requiring expensive physical training equipment for each scenario
Solution Approach 2:
The welding training system integrates multiple training modes (virtual reality, augmented reality, live arc welding) and evaluation capabilities into a single unified platform. This multi-functional system can adapt to different skill levels, welding positions, and equipment types, providing comprehensive training and assessment without requiring separate specialized systems for each training objective
2Adaptability or versatility
If multiple welding positions and orientations are trained, then operator versatility improves, but training time and complexity increase
Solution Approach 1:
The training system dynamically adjusts welding position and orientation scenarios based on operator progress and training objectives. The virtual environment can rapidly transform between different welding positions (flat, horizontal, vertical, overhead) and orientations without requiring physical reconfiguration of equipment, allowing operators to efficiently train on multiple positions within the same session
Solution Approach 2:
The system combines training for multiple welding positions and orientations into integrated training modules that can be completed in a single session. By merging virtual practice of different positions with automated evaluation, the system eliminates the need for separate training sessions for each position, reducing total training time while maintaining comprehensive skill development
3Manufacturing precision
If automated welding equipment is used, then welding precision improves, but operator skill development for manual operations deteriorates
Solution Approach 1:
The virtual reality and augmented reality components serve as intermediaries between automated welding systems and manual welding skill development. These intermediary layers provide realistic visual and haptic feedback that simulates manual welding conditions while leveraging the precision and data capabilities of automated systems to evaluate and guide operator performance
Solution Approach 2:
The system implements comprehensive feedback mechanisms that provide real-time guidance on welding technique, position, speed, and quality. Sensors and tracking systems monitor operator actions and provide immediate corrective feedback, allowing operators to develop manual welding skills with the precision guidance previously only available through automated systems or highly experienced instructors
Data Source
AI summary
A method for providing a welding score, comprising determining an initial position of a welding operation, determining a terminal position of the welding operation, determining a welding path between the initial position and the terminal position, and determining the welding score based on the welding path, wherein the welding score takes into account one or both of a time used for welding and a length of the welding path. A system comprising a welding torch, and a computer configured to: determine an initial position of a welding operation, determine a terminal position of the welding operation, determine a welding path between the initial position and the terminal position, determine a welding score, wherein the welding score takes into account a time used for welding and/or a length of the welding path, and comparing the welding score to a score threshold.