# Patent

## Title
Welding training system

## Abstract

A system for training welders that includes a data generating component, a data capturing component and a data processing and visualization component. The data generating component operates in real time and derives data from an actual manually-executed weld and further includes a weld process-specific jig, a calibration block positioned on the jig, wherein the geometric configuration of the calibration block is specific to a particular type of weld joint, a weld coupon positioned on the welding process-specific jig adjacent to the calibration block, a welding gun for use by a trainee, wherein the welding gun is operative to form the weld; and at least one target mounted on the welding gun that is recognized by the data processing and visualization component for providing multidimensional position and orientation feedback to the trainee.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application is a continuation-in-part of U.S. patent application Ser. No. 13/543,240, filed on Jul. 6, 2012 and entitled “System for Characterizing Manual Welding Operations,” which is a continuation-in-part of U.S. patent application Ser. No. 12/499,687 filed on Jul. 8, 2009 and entitled “Method and System for Monitoring and Characterizing the Creation of a Manual Weld” (now abandoned); and a continuation-in-part of U.S. patent application Ser. No. 12/966,570, filed on Dec. 13, 2010 and entitled “Welding Training System,” which is a continuation-in-part of U.S. patent application Ser. No. 12/499,687 filed on Jul. 8, 2009 and entitled “Method and System for Monitoring and Characterizing the Creation of a Manual Weld” (now abandoned) the entire disclosures of which are herein incorporated by reference.


BACKGROUND OF THE INVENTION
The described invention relates in general to a system for training welders, and more specifically to a system for providing useful information to a welding trainee by capturing, processing, and presenting in a viewable format, data generated by the welding trainee in manually executing an actual weld in real time.
The manufacturing industry's desire for efficient and economical welder training has been a well documented topic over the past decade as the realization of a severe shortage of skilled welders is becoming alarmingly evident in today's factories, shipyards, and construction sites. A rapidly retiring workforce, combined with the slow pace of traditional instructor-based welder training has been the impetus for the development of more effective training technologies. Innovations which allow for the accelerated training of the manual dexterity skills specific to welding, along with the expeditious indoctrination of arc welding fundamentals are becoming a necessity. The training system disclosed herein addresses this vital need for improved welder training and enables the monitoring of manual welding processes to ensure the processes are within permissible limits necessary to meet industry-wide quality requirements. To date, the majority of welding processes are performed manually, yet the field is lacking practical commercially available tools to track the performance of these manual processes. Thus, there is an ongoing need for an effective system for training welders to properly execute various types of welds under various conditions.
SUMMARY OF THE INVENTION
The following provides a summary of certain exemplary embodiments of the present invention. This summary is not an extensive overview and is not intended to identify key or critical aspects or elements of the present invention or to delineate its scope.
In accordance with one aspect of the present invention, a system for training welders is provided. This system includes a data generating component, a data capturing component, and a data processing and visualization component. The data generating component further includes a substrate; at least one support adjustably mounted on or to the substrate, wherein the support may be horizontally oriented or vertically oriented; a jig positioned on the at least one support for consistently retaining a weld coupon in a predetermined position; at least one calibration block positioned on the jig, wherein the geometric configuration of the calibration block is specific to a particular type of weld joint; a weld coupon positioned on the jig adjacent to the calibration block, wherein the weld coupon further includes at least one piece of weldable material, and wherein weld metal is actually deposited on the weldable material by a trainee during a training exercise to form a weld; a welding gun for use by the trainee, wherein the welding gun is operative to form the weld; and at least one target mounted on the welding gun. The data capturing component further includes at least one imaging device for capturing images of the target, wherein the at least one imaging device is mounted on or near the substrate such that the imaging device has a clear view of the at least one target mounted on the welding gun. The data processing and visualization component further includes: at least one computer for receiving and analyzing information captured by the data capturing component, wherein the at least one computer is running software that includes a training regimen module, wherein the training regimen module includes a variety of weld types and a series of acceptable welding process parameters associated with creating each weld type; an object recognition module for recognizing the target; and a data processing module for comparing the information in the training regimen module to the information processed by the object recognition module; and at least one display device in electrical communication with the at least one computer for allowing the trainee to visualize the processed data in real time, wherein the visualized data is operative to provide the trainee with useful feedback regarding the characteristics and quality of the weld.
In accordance with another aspect of the present invention, a system for training welders is also provided. This system includes a data generating component, a data capturing component, and a data processing and visualization component. The data generating component further includes a training stand; at least one support adjustably mounted on the training stand, wherein the support may be positioned in a variety of spatial orientations; at least one welding process-specific jig positioned on the at least one support; at least one calibration block positioned on the jig, wherein the geometric configuration of the calibration block is specific to a particular type of weld joint; a weld coupon positioned on the weld-specific jig adjacent to the calibration block, wherein the weld coupon further includes at least two pieces of material, and wherein a trainee actually forms a weld joint between the at least two pieces of material during a training exercise; a welding gun for use by the trainee, wherein the welding gun is operative to form the weld joint; and at least one target mounted on the welding gun. The data capturing component further includes at least one imaging device for capturing images of the target, wherein the at least one imaging device is mounted on or near the training stand such that the imaging device has a clear view of the at least one target mounted on the welding gun. The data processing and visualization component further includes at least one computer for receiving and analyzing information captured by the data capturing component, wherein the at least one computer is running software that includes a training regimen module, wherein the training regimen module includes a variety of weld types and a series of acceptable welding process parameters associated with creating each weld type; an object recognition module for recognizing the target; and a data processing module for comparing the information in the training regimen module to the information processed by the object recognition module; and at least one display device in electrical communication with the at least one computer for allowing the trainee to visualize the processed data in real time or immediately following the weld, wherein the visualized data is operative to provide the trainee with useful feedback regarding the characteristics and quality of the weld.
Additional features and aspects of the present invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the exemplary embodiments. As will be appreciated by the skilled artisan, further embodiments of the invention are possible without departing from the scope and spirit of the invention. Accordingly, the drawings and associated descriptions are to be regarded as illustrative and not restrictive in nature.



BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated into and form a part of the specification, schematically illustrate one or more exemplary embodiments of the invention and, together with the general description given above and detailed description given below, serve to explain the principles of the invention, and wherein:
FIG. 1 provides a somewhat simplified side view of a portable or semi-portable welding training system in accordance with an exemplary embodiment of the present invention;
FIG. 2 provides an isometric view of the horizontal fixture of the welding training system of FIG. 1;
FIG. 3 provides a front view of the horizontal fixture of the welding training system of FIG. 1;
FIG. 4 provides a side view of the vertical fixture of the welding training system of FIG. 1; and
FIG. 5 is a flow chart illustrating the flow of information through the data processing and visualization component of an exemplary embodiment of the present invention.



DETAILED DESCRIPTION OF THE INVENTION
Exemplary embodiments of the present invention are now described with reference to the Figures. Reference numerals are used throughout the detailed description to refer to the various elements and structures. In other instances, well-known structures and devices are shown in block diagram form for purposes of simplifying the description. Although the following detailed description contains many specifics for the purposes of illustration, a person of ordinary skill in the art will appreciate that many variations and alterations to the following details are within the scope of the invention. Accordingly, the following embodiments of the invention are set forth without any loss of generality to, and without imposing limitations upon, the claimed invention.
The present invention relates to an advanced system for welding instruction and training that provides an affordable tool for measuring manual welding technique and comparing that technique with established procedures. The training applications of this invention include: (i) screening applicant skill levels; (ii) assessing trainee progress over time; (iii) providing real-time coaching to reduce training time and costs; and (iv) periodically re-testing welder skill levels with quantifiable results. Processing monitoring and quality control applications include: (i) identification of deviations from preferred conditions in real time; (ii) documenting and tracking compliance with procedures over time; (iii) capturing in-process data for statistical process control purposes (e.g., heat input measurements); and (iv) identifying welders needing additional training.
The present invention, in various exemplary embodiments, measures torch motion and gathers process data during welding exercises using a single or multiple camera tracking system based on target image analysis. This invention is applicable to a wide range of processes including, but not necessarily limited to, GMAW, FCAW, SMAW, GTAW, and cutting. The invention is expandable to a range of work-piece configurations, including large sizes, various joint type, pipe, plate, and complex shapes. Measured parameters include work angle, travel angle, standoff distance, travel speed, weave, voltage, current, wire feed speed, and arc length. The training component of the present invention may be pre-populated with specific jobs or it may be customized by an instructor. Data is automatically saved and recorded, a post-weld analysis scores performance, and progress is tracked over time. This system may be used throughout an entire welding training program and may include both in-helmet and on-screen feedback. With reference now to the Figures, one or more specific embodiments of this invention shall be described in greater detail.
FIGS. 1-4 provide various views illustrative views of welding training system 10 in accordance with an exemplary embodiment the present invention. As shown in FIG. 1, portable training stand 20 includes a substantially flat base 22 for contact with a floor or other horizontal substrate, rigid vertical support column 24, camera or imaging device support 26, and pull pin 28 for adjusting the height of imaging device support 26. In most embodiments, welding training system 10 is intended to be portable or at least moveable from one location to another, therefore the overall footprint of base 22 is relatively small to permit maximum flexibility with regard to installation and use. As shown in FIG. 1, welding training system 10 may be used for training exercises that include horizontally or vertically oriented workpieces or both. In the exemplary embodiments shown in the Figures, training stand 20 is depicted as a unitary or integrated structure that is capable of supporting the other components of system. In other embodiments, stand 20 is absent and the various components of system 10 are supported by whatever suitable structural or supportive means may be available. Thus, within the context of this invention, “stand” 20 is defined as any single structure or, alternately, multiple structures that are capable of supporting the components of system 10.
With reference to FIGS. 2-3, training exercises that include horizontally oriented workpieces involve the use of horizontal fixture 30, which is slidably attached to vertical support column 24 by collar 34, which includes adjustment knob 36 for releasing collar 34 and allowing it to slide upward or downward on support column 24. Collar 34 is further supported on column 24 by cam roller assembly 31, which includes pull pin 32 for releasing cam roller assembly 31 and allowing it to slide upward or downward on support column 24. Horizontal fixture 30 includes training platform 38, which is used for flat and horizontal training positions, and which is supported by one or more brackets 40. In some embodiments, a shield 42 is attached to training platform 38 for protecting the surface of support column 24 from heat damage. Training platform 38 further includes at least one peg 44 for securing weld position-specific jig 46 to the surface of the training platform. The structural configuration or general characteristics of weld position-specific jig 46 are variable based on the type of weld process that is the subject of a particular training exercise. In the exemplary embodiment shown in the Figures, first 48 and second 50 structural components of weld position-specific jig 46 are set at right angles to one another and positioned on training platform 38 adjacent to calibration block 52. The specific geometric characteristics of calibration block 52 are also variable and correspond to the type of weld process that is the subject of a particular training exercise. The characteristics of weld coupon 54 are also variable based on the type of weld process that is the subject of a particular training exercise and in the exemplary embodiment shown in the Figures, first 56 and second 58 portions of weld coupon 54 are set at right angles to one another and positioned on weld position-specific jig 46 adjacent to calibration block 52.
With reference to FIG. 4, training exercises that include vertically oriented workpieces involve the use of vertical fixture 60, which is slidably attached to vertical support column 24 by collar 64, which includes adjustment knob 66 for releasing collar 64 and allowing it to slide upward or downward on support column 24. Collar 64 is further supported on column 24 by cam roller assembly 61, which includes pull pin 62 for releasing cam roller assembly 61 and allowing it to slide upward or downward on support column 24. Vertical fixture 60 is used for pipe and vertical training positions and includes grasping arms 68 for holding training platform 69 to which weld position-specific jig 70 is attached. The structural configuration or general characteristics of weld position-specific jig 70 are variable based on the type of weld process that is the subject of a particular training exercise. In the exemplary embodiment shown in the Figures, first 72 and second 74 structural components of weld position-specific jig 70 are set at right angles to one another and positioned on training platform 69 adjacent to calibration block 76. The specific geometric characteristics of calibration block 76 are also variable and correspond to the type of weld process that is the subject of a particular training exercise. The characteristics of weld coupon 78 are also variable based on the type of weld process that is the subject of a particular training exercise and in the exemplary embodiment shown in the Figures, first 80 and second 82 portions of weld coupon 78 are set at right angles to one another and positioned on weld position-specific jig 70 adjacent to calibration block 76.
As best shown in FIGS. 2-3, welding gun or torch 90, which in this invention is a an actual, completely functional welding gun (as opposed to a virtual welding gun or torch), includes nozzle 92, body 94, trigger 96, and at least one target 98, which is mounted on welding gun 90. When welding gun 90 is properly positioned within either calibration block 58 or calibration block 76, target 98 is in view of data capturing component 100, which typically includes at least one digital camera or imaging device. Target 98 (which many be one or more actual targets), when placed in a calibration block is used to “train” welding training system 10 to recognize a known object such that position and orientation data may be generated using images captured by data capturing component 100 during a training exercise. In some embodiments, the imaging device further includes a filter, target 98 further includes a light emitting component that emits light over a range of predetermined wavelengths, and the filter only accepts light corresponding to the predetermined wavelengths emitted by the light emitting component. This configuration reduces the negative impact that saturation of the imaging device by the light produced by a welding arc can create. As is detailed below and also in U.S. patent application Ser. No. 12/499,687 (incorporated herein by reference, in its entirety), data capturing component 100 is in electronic communication with data processing component 200 which is in electronic communication with data visualization component 300. In some embodiments, data processing component 200 and data visualization component 300 reside within or on the same computer-based system. These components of the present invention cooperate with one another during a welding training exercise to provide the trainee with useful information in real time.
As shown in FIG. 5, in an exemplary embodiment of the present invention, the flow of information through welding training system 10 occurs in six basic steps: (1) image capture 110; (2) image processing 112; (3) input of arc weld data 210, such as known or preferred weld parameters; (4) data processing 212; (5) data storage 214; and (5) data display 310. The input aspect of image capture step 110 includes capturing images of target 98 with one or more off-the shelf high-speed-vision cameras such as, for example, those operating at greater than 100 frames per second and having a gigabit-Ethernet connection, while the output aspect typically includes creating of an image file at over 100 frames per second. The input aspect of image processing step 112 includes analyzing individual images of the target looking for a match to a known “trained” object (i.e., the calibrated target). Upon recognition of a known object, position and orientation are calculated relative to the “trained” object position and orientation. Images are typically processed at a rate of more than 10 times per second. The output aspect of image processing step 112 includes creation of a text file that includes x-axis, y-axis, and z-axis positional data and roll, pitch, and yaw orientation data, as well as time stamps and software flags. The text file may be streamed or sent at a desired frequency. The input aspect of data processing step 212 includes raw positional and orientation data typically requested at about 15-20 times per second, while the output aspect includes transforming this raw data into useful welding parameters with algorithms specific to a selected process and joint type. The input aspect of data storage step 214 includes storing welding trial data as a *.dat file, while the output aspect includes saving the data for review and tracking, saving the date for review on a monitor at a later time, and/or reviewing the progress of the student at a later time. Student progress may include total practice time, total arc time, total arc starts, and individual parameter-specific performance over time. The input aspect of data display step 310 includes welding trial data that further includes work angle, travel angle, tip-to-work distance/torch offset, travel speed, torch proximity to axis, voltage, current, wire-feed speed, while the output aspect involves data that may viewed on a monitor, in-helmet display, heads-up display, or combinations thereof, wherein parameters are plotted on a time-based axis and compared to upper and lower thresholds or preferred variations, such as those trained by recording the motions of an expert welder. Current and voltage may be measured in conjunction with travel speed to determine heat input and the welding process parameters may be used to estimate arc length. Position data may be transformed into weld start position, weld stop position, weld length, weld sequence, welding progression, or combinations thereof and current and voltage may be measured in conjunction with travel speed to determine heat input.
The data processing and visualization components of the present invention (200 and 300 respectively) typically include at least one computer for receiving and analyzing information captured by the data capturing component 100. During operation of welding training system 10, this computer is typically running software that includes a training regimen module, an object recognition module, and a data processing module. The training regimen module includes a variety of weld types and a series of acceptable welding process parameters associated with creating each weld type. Any number of known or AWS weld joint types and the acceptable parameters associated with these weld joint types may be included in the training regimen module, which is accessed and configured by a course instructor prior to the beginning of a training exercise. The weld process and/or type selected by the instructor determine which weld process-specific jig, calibration block, and weld coupon are used for any given training exercise. The object recognition module is operative to train the system to recognize a known object (target 98) and for then using target 98 to calculate positional and orientation data for welding gun 90 as an actual manual weld is completed by a trainee. The data processing module compares the information in the training regimen module to the information processed by the object recognition module and outputs the comparative data to a display device such as a monitor or head-up display. The monitor allows the trainee to visualize the processed data in real time and the visualized data is operative to provide the trainee with useful feedback regarding the characteristics and quality of the weld.
The visual interface of welding training system 10 may include a variety of features related to the input of information, login, setup, calibration, practice, analysis, and progress tracking. The analysis screen typically displays the welding parameters found in the training regimen module, including (but not limited to) work angle, travel angle, contact tip-to-work distance/torch offset, travel speed, torch proximity to axis, voltage, current, and wire-feed speed. Multiple display variations are possible with the present invention.
While the present invention has been illustrated by the description of exemplary embodiments thereof, and while the embodiments have been described in certain detail, it is not the intention of the Applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention in its broader aspects is not limited to any of the specific details, representative devices and methods, and/or illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.

## Claims

1. A system for performance monitoring of welders, comprising:
(a) a data generating component, wherein the data generating component includes:
(i) at least one calibration block, wherein the at least one calibration block includes a geometric configuration, and wherein the geometric configuration is specific to a particular type of weld joint;
(ii) a weld coupon positioned adjacent to the calibration block, wherein the weld coupon further includes at least one piece of weldable material, and wherein a weld is actually produced;
(iii) a welding gun, wherein the welding gun is operative to form the weld; and
(iv) at least one target mounted on the welding gun;

(b) a data capturing component, wherein the data capturing component includes:
(i) at least one imaging device for capturing images of the target, wherein the at least one imaging device is mounted on or near the substrate such that the imaging device has a clear view of the at least one target mounted on the welding gun; and

(c) a data processing and visualization component, wherein the data processing and visualization component includes:
(i) at least one computer for receiving and analyzing information captured by the data capturing component, wherein the at least one computer is running software that includes:
(a) a welding procedures module, wherein the module includes a variety of weld types and a series of acceptable welding process parameters associated with creating each weld type;
(b) an object recognition module for recognizing the target; and
(c) a data processing module for comparing the information in the welding procedures module to the information processed by the object recognition module; and

(ii) at least one display device in electrical communication with the at least one computer for allowing the processed data to be visualized in real time or immediately following the weld, wherein the visualized data is operative to provide information regarding the performance on the production of the weld.

2. The system of claim 1, wherein the system further includes at least one electronic storage device for storing information for later review.

3. The system of claim 1, wherein the imaging device further includes a filter, wherein the target further includes a light emitting component that emits light over a predetermined range of wavelengths, and wherein the filter only accepts light corresponding to the predetermined range of wavelengths emitted by the light emitting component.

4. The system of claim 1, wherein the at least one imaging device is a camera.

5. The system of claim 1, wherein the output of the imaging device is image data.

6. The system of claim 1, wherein the welding gun has a position and orientation, and wherein the data processing and visualization component receives and analyzes data captured by the imaging device and recognizes the presence of the target in those images, wherein upon recognition of the target, the position and orientation of the welding gun are calculated relative to the position and orientation of the target.

7. The system of claim 1, wherein the data processing and visualization component outputs data which may consist of x-axis, y-axis, and z-axis position data and roll, pitch, and yaw orientation data, and wherein the data may be streamed to the display device or sent to the display device at a predetermined frequency.

8. The system of claim 7, wherein the data processing and visualization component transforms the position and orientation data into welding process parameters, wherein the welding process parameters include at least one of a work angle, a travel angle, a torch offset, a travel speed, a torch proximity to axis, a voltage, a current, and a wire-feed speed, and wherein the welding process parameters established from the position and orientation data are compared to the series of acceptable welding process parameters associated with creating each weld type.

9. The system of claim 8, wherein the current and voltage are measured in conjunction with travel speed to determine heat input.

10. The system of claim 8, wherein the welding process parameters are used to estimate arc length.

11. The system of claim 7, wherein the data processing and visualization component transforms the position data into weld start position, weld stop position, weld length, weld sequence, welding progression, or combinations thereof.

12. The system of claim 8, wherein the welding parameters established from the position and orientation data are plotted on a time-based axis and compared to a preferred variation for each parameter.

13. The system of claim 12, wherein the preferred variation is programmed by recording a sequence of motions performed by an expert welder.

14. The system of claim 1, wherein the display device is a monitor, a helmet display, a heads-up display, or combinations thereof.

15. A system for performance monitoring of welders, comprising:
(a) a data generating component, wherein the data generating component includes:
(i) at least one calibration block positioned on the jig, wherein the at least one calibration block includes a geometric configuration, and wherein the geometric configuration is specific to a particular type of weld joint;
(ii) a weld coupon positioned adjacent to the calibration block, wherein the weld coupon further includes at least one piece of weldable material, and wherein a weld is actually produced
(iii) a welding gun, wherein the welding gun is operative to form the weld; and
(iv) at least one target mounted on the welding gun;

(b) a data capturing component, wherein the data capturing component includes:
(i) at least one imaging device for capturing images of the target, wherein the at least one imaging device is mounted such that the imaging device has a clear view of the at least one target mounted on the welding gun; and

(c) a data processing and visualization component, wherein the data processing and visualization component includes:
(i) at least one computer for receiving and analyzing information captured by the data capturing component, wherein the at least one computer is running software that includes:
(a) a welding procedures module, wherein the module includes a variety of weld types and a series of acceptable welding process parameters associated with creating each weld type;
(b) an object recognition module for recognizing the target; and
(c) a data processing module for comparing the information in the welding procedures module to the information processed by the object recognition module; and

(ii) at least one display device in electrical communication with the at least one computer for allowing the processed data to be visualized in real time or immediately following the weld.

16. The system of claim 15, wherein the system further includes at least one electronic storage device for storing information for later review.

17. The system of claim 15, wherein the entire system is portable and may be moved and operated in a variety of different locations.

18. The system of claim 15, wherein the imaging device further includes a filter, wherein the target further includes a light emitting component that emits light over a predetermined range of wavelengths, and wherein the filter only accepts light corresponding to the predetermined range of wavelengths emitted by the light emitting component.

19. The system of claim 15, wherein the at least one imaging device is a camera.

20. The system of claim 15, wherein the welding gun has a position and orientation, and wherein the data processing and visualization component receives and analyzes image data captured by the imaging device and recognizes the presence of the target in those images, wherein upon recognition of the target, the position and orientation of the welding gun are calculated relative to the position and orientation of the target.

21. The system of claim 15, wherein the data processing and visualization component outputs data may consist of x-axis, y-axis, and z-axis position data and roll, pitch, and yaw orientation data, and wherein the data may be streamed to the display device or sent to the display device at a predetermined frequency.

22. The system of claim 21, wherein the data processing and visualization component transforms the position and orientation data into welding process parameters, wherein the welding process parameters include at least one of a work angle, a travel angle, a torch offset, a travel speed, a torch proximity to axis, a voltage, a current, and a wire-feed speed, and wherein the welding process parameters established from the position and orientation data are compared to the series of acceptable welding process parameters associated with creating each weld type.

23. The system of claim 22, wherein the current and voltage are measured in conjunction with travel speed to determine heat input.

24. The system of claim 22, wherein the welding process parameters are used to estimate arc length.

25. The system of claim 21, wherein the data processing and visualization component transforms the position data into weld start position, weld stop position, weld length, weld sequence, welding progression, or combinations thereof.

26. The system of claim 22, wherein the welding parameters established from the position and orientation data are plotted on a time-based axis and compared to a preferred variation for each parameter.

27. The system of claim 26, wherein the preferred variation is programmed by recording a sequence of motions performed by an expert welder.

28. The system of claim 15, wherein the display device is a monitor, a helmet display, a heads-up display, or combinations thereof.