System and method for manual welder training

Patent metadata

Field	Value
Publication number	US-9773429-B2
Application number	US-201414293700-A
Country	US
Kind code	B2
Filing date	Jun 2, 2014
Priority date	Jul 8, 2009
Publication date	Sep 26, 2017
Grant date	Sep 26, 2017

Abstract

A method for manual welder training that includes providing a welding training apparatus that includes both hardware and software components and that is operative to gather and process data in real time, wherein the data is derived from an actual training exercise conducted by a welding trainee; selecting training objectives from a predetermined number of predefined objectives; initializing a curriculum, wherein the curriculum is based on the selected training objectives; performing at least one training exercise, wherein the training exercise is a component of the curriculum; providing real-time feedback to the trainee, wherein the real-time feedback is based on the performance of the trainee during the training exercise; evaluating the performance of the trainee based on data gathered and processed during the training exercise; optionally, adapting the curriculum based on the trainee's performance evaluation; and awarding credentials or certifications to the trainee following successful completion of the curriculum.

First claim

What is claimed:

1. A welding system comprising:
(a) a data generating component, said data generating component comprising:
(i) a fixture, wherein the geometric characteristics of the fixture are predetermined;
(ii) a workpiece adapted to be mounted on the fixture, wherein the workpiece includes at least one joint to be welded, and wherein a vector extending along the joint to be welded defines an operation path;
(iii) a calibration device, wherein the calibration device includes at least two first point markers integral therewith, and wherein the geometric relationship between the first point markers and the operation path is predetermined; and
(iv) a welding tool, wherein the welding tool is operative to form a weld at the joint to be welded, wherein the welding tool defines a tool point and a tool vector, and wherein the welding tool includes a target attached to the welding tool, said target including a plurality of second point markers mounted thereon in a predetermined pattern, and wherein the predetermined pattern of the second point markers is operative to define a rigid body;

(b) a data capturing component, said data capturing component comprising an imaging system for capturing images of the point markers; and
(c) a data processing component, said data processing component operative to receive information from the data capturing component and then calculate:
(i) the position and orientation of the operation path relative to a three-dimensional space viewable by the imaging system;
(ii) the position of the tool point and orientation of the tool vector relative to the rigid body; and
(iii) the position of the tool point and orientation of the tool vector relative to the operation path,

wherein the welding system is operable to:
process data derived from an actual welding exercise conducted by a welding trainee;
receive one or more training objectives from a plurality of predefined objectives;
initialize a curriculum for the welding trainee, said curriculum being based on the training objectives;
monitor performance of a training exercise, wherein the training exercise is based on or is a component of the curriculum, said training exercise includes at least one execution task;
provide real-time feedback to the welding trainee, said real-time feedback being based on the performance of the welding trainee during the training exercise;
evaluate a performance of the welding trainee based on weld quality data collected during the training exercise; and
automatically modify the curriculum based on the performance of the welding trainee.

2. The welding system of claim 1 , wherein the welding system is operable to award credentials to the welding trainee following successful completion of the curriculum.

3. The welding system of claim 2 , wherein the awarding of credentials includes the awarding of portable badges, wherein the portable badges are awarded to the welding trainee based on the successful completion of one or more aspects of the curriculum, and wherein the successful completion of one or more aspects of the curriculum is recognized by one or more credentialing agencies or entities as representing at least one measurement of key performance metrics of welding proficiency.

4. The welding system of claim 1 , wherein the welding system is in communication with at least one cloud-based server.

5. The welding system of claim 1 , wherein the training objectives include one or more public objectives, private objectives, and combinations thereof.

6. The welding system of claim 1 , wherein the curriculum includes a series of predetermined tasks, and wherein the tasks are in the form of welding procedure specifications.

7. The welding system of claim 1 , wherein the curriculum includes one or more form variables, and wherein the form variables include one or more of: a process type; a joint type; a position; a material type; a thickness; a root gap; a root landing; an included angle; and combinations thereof.

8. The welding system of claim 1 , wherein the curriculum includes one or more execution variables, and wherein the execution variables include one or more of: a polarity; an electrode type; a work angle; a travel angle; an arc length; a travel speed; a tool placement; a current; a voltage; a weld size; or combinations thereof.

9. The welding system of claim 1 , wherein the curriculum includes one or more tasks for quizzes and tutorials, mechanical testing for certification objectives, and cleaning and joint preparation tasks.

10. The welding system of claim 1 , wherein the training exercise is performed in either arc-off mode or arc-on mode.

11. The welding system of claim 1 , wherein the real-time feedback is operative to highlight the differences between acceptable and unacceptable performance while allowing the welding trainee to visualize the at least one execution task, prevent the welding trainee from manipulating the welding tool in an improper manner, and guide the welding trainee to proper welding technique.

12. The welding system of claim 1 , wherein the real-time feedback includes at least one of automated audio coaching, instructor-assisted audio coaching, transfer mode feedback, augmented reality weld rendering, and combinations thereof.

13. The welding system of claim 12 , wherein the automated audio coaching includes real-time feedback in the form of automated voice commands, and wherein the automated voice commands include prerecorded audio files that are played to the welding trainee based on predetermined variables being outside of set control limits.

14. The welding system of claim 13 , wherein the predetermined variables are arranged in a hierarchy of high-priority variables to low-priority variables, and wherein the predetermined variables include in descending order of priority: a tool placement, a tool offset, a travel speed, a work angle, and a travel angle.

15. The welding system of claim 12 , wherein the instructor-assisted audio coaching includes interactive real-time feedback wherein an instructor remotely views the trainee during the training exercise through a welding lens used by the welding trainee, and wherein the instructor relays live audio feedback from a microphone to a wireless headset within a welding helmet worn by the welding trainee.

16. The welding system of claim 12 , wherein the transfer mode feedback provides real-time feedback for helping the welding trainee learn differences between transfer modes when transfer modes are present, wherein a microphone integrated into a welding helmet worn by the welding trainee measures the transfer mode by detecting a sound signal signature, and wherein the sound signal signature is then analyzed to determine if the transfer mode is short-circuit, globular, spray, or pulsed-spray.

17. The welding system of claim 12 , wherein the augmented reality weld rendering includes the use of sensors that provide real-time position and orientation values of both a welding helmet worn by the welding trainee and a welding tool used by the welding trainee in addition to processing data gathered during the training exercise to a cloud-based server, wherein the cloud-based server performs rendering calculations or finite element calculations, and wherein image data is generated based on these calculations and is superimposed over the welding trainee's view of a welding joint being created during a welding exercise.

18. The welding system of claim 17 , wherein the training exercise is performed in arc-off mode, and wherein the superimposed imagery includes one or more of a vir

Assignees

• Lincoln Global Inc

Inventors

• Boulware Paul Christopher
• Conrardy Christopher C
• Clark Douglas A
• Forquer M William

Classifications

• B23K9/295

  using consumable wire electrodes · CPC title

• B23K9/32

  Accessories · CPC title

• B23K9/173

  and of a consumable electrode · CPC title

• G09B25/02

  of industrial processes; of machinery · CPC title

• B23K9/0956

  using sensing means, e.g. optical · CPC title