Patent Description:
Welding is a process that has increasingly become ubiquitous in all industries. While such processes may be automated in certain contexts, a large number of applications continue to exist for manual welding operations, the success of which relies heavily on the proper use, configuration, and maintenance of welding equipment. Even experienced welding operators and technicians, however, often have difficulty configuring, monitoring, and maintaining these important parameters throughout welding processes.

Additionally, the welding industry suffers from a lack of skilled operators and service technicians. It is desirable to provide real-time configuration, instruction, maintenance, and service information regarding welding equipment processes to aid a weld operator or service technician in welding production.

Further limitations and disadvantages of conventional approaches to welding will become apparent to one of skill in the art, through comparison of such approaches with some aspects of the present method and system set forth in the remainder of this disclosure with reference to the drawings.

Earlier patent application <CIT> discloses a welding system and welding helmet, where the welding helmet is capable of providing an image representative of information from an associated welding operation where the image appears as a head-up display (HUD) in the welding helmet. <CIT> discloses a visual guidance and recognition system, whereby a work piece is recognized with the system, and a manipulator is accurately positioned with respect to the work piece so that the manipulator can accurately perform its function.

A portable computing device according to an aspect of the present invention is defined in claim <NUM>.

Methods and systems are provided for a portable user interface for a welding type system, substantially as illustrated by and described in connection with at least one of the figures, as set forth more completely in the claims.

Disclosed are examples of a portable computing device that can be configured to identify welding equipment, provide information regarding identified welding equipment, communicate with identified welding equipment, and configure identified welding equipment.

The welding industry suffers from a lack of skilled operators and service technicians. An operator may intend to perform welding-type activities using a welding system and/or perform maintenance on one or more components of a welding system. However, in some circumstances, an operator may be inexperienced with the particular task that the operator wishes to perform. This may occur, for example, when the operator <NUM> has little or no welding experience, when the operator has little or no familiarity with the equipment in the welding system, when the operator has not recently performed the task and does not remember one or more aspects of the task, or any other possible reason.

The present invention features a portable computing device that can assist an operator perform such tasks, see claim <NUM>. The portable computing device may be a smartphone, a tablet computer, a laptop computer, and/or any other type of computing device. As discussed in more detail below, the example portable computing device presents one or more interfaces to interactively provide information related to one or more welding-type devices. Example information includes, according to the present invention, equipment configuration instructions corresponding to one or more welding-type devices, and can further include weld training instructions to be performed using one or more of the welding-type devices, instructions for a user to manipulate the welding-type device(s) before the operator commences a welding type operation, instructions for the operator to manipulate the welding-type device(s) after completing the welding type operation, equipment servicing information (e.g., diagnostic techniques, repair instructions, component replacement instructions, etc.), maintenance information (e.g., cleaning information) consumable replacement instructions, and/or any other information or instructions that may be useful to the operator.

Disclosed example portable computing devices include a camera, a display device, and a processor. The processor is configured to: access one or more images captured by the camera; identify a welding-type device based on the one or more images; and, based on the identified welding-type device, present an interface configured to interactively provide information related to the identified welding-type device.

In some example portable computing devices, the processor is configured to display the one or more images via the display device. In some example portable computing devices, the processor is configured to access the images, display the one or more images, identify the welding-type device, and display the information related to the welding-type device, substantially in real-time. In some example portable computing devices, the processor is configured to wherein the processor is configured to overlay one or more graphics on the displayed images.

In some example portable computing devices, the processor is configured to identify one or more components of the welding-type device based on the one or more images. In some example portable computing devices, the interface includes component information corresponding to the one or more components, and the one or more components are identified after the welding-type device is identified in a predetermined threshold number of the images in the series of images.

In some example portable computing devices, the processor is configured identify the welding-type device via receiving information based on identifying electronically readable indicia present in the images. In some example portable computing devices, the processor is configured identify the welding-type device via performing image recognition processing on the image to identify a welding device model.

In some example portable computing devices, the processor is configured identify the welding-type device via performing image recognition processing to identify, based on the images, at least one of: a number of input devices; a type of at least one input device; a number of display devices; a display device type; model number text; a graphic logo; input device indicator text; an input device indicator graphic; a graphical arrangement; an arrangement of user input devices, output devices, or user input devices and output devices; a communication connector type; a communication connector location; a positive power stud terminal location; a negative power stud terminal location; an air vent location; a housing size; or a housing shape.

According to the present invention, the interface is configured to provide equipment configuration instructions corresponding to the identified welding-type device. In some example portable computing devices, the interface is configured to provide weld training instructions corresponding to the identified welding-type device.

Some example portable computing devices further include a communications device to communicate with welding equipment. In some examples, the weld training instructions include instructions for a user to manipulate the welding-type device before a user commences a welding-type operation. In some examples, the weld training instructions include instructions for a user to manipulate the welding-type device after completing the welding-type operation. Some example portable computing devices further include a machine readable memory, and the weld training instructions are stored on the memory. In some examples, the processor is configured to receive weld training instructions from a server. In some examples, instructions are provided via or include a video.

Some example portable computing devices further include a communications device to communicate with welding equipment. In some examples, the processor is configured to establish communications with the welding-type device via the communications device. In some examples, the portable computing device communicates with the welding-type device via one of: Bluetooth, Wi-Fi, ZigBee, or Z-Wave. Some example portable computing devices further include an input device. In some examples, the processor is configured to receive a user input from the input device, and to configure the welding-type device according to received user input.

In some example portable computing devices, the processor is configured to: receive information regarding the welding-type device, wherein the information includes images of interior components of the welding-type device; and display the images of the interior components of the welding-type device via the display device.

In some example portable computing devices, the processor is configured to: receive equipment service information regarding the welding-type device; and display the equipment service information via the display device.

In some example portable computing devices, the processor is configured to receive information from a server regarding the welding-type device, and display the information via the display device.

In some example portable computing devices, the display device is a touchscreen. In some example portable computing devices, the processor is configured to display or hide a simulated graphic in the interface in response to at least one of a gesture or an input to an input device coupled to the processor.

In some example portable computing devices, the processor is configured to receive, via an input device, a selection of a task to be performed using the identified welding-type device. The processor is also configured to display graphics in the interface, based on locations within the images of the one or more components that are associated with the graphics, in a sequence based on the task to be performed. In some example portable computing devices, the processor is configured display simulated graphics in the interface in the sequence by displaying one or more first ones of the simulated graphics corresponding to a first step of the task; receiving an indication that the first step of the task has been performed; ending display of the one or more first ones of the simulated graphics; and displaying one or more second ones of the simulated graphics corresponding to a second step of the task.

Disclosed example portable computing devices include a display device, an RFID antenna, and a processor. The processor is configured to identify a welding-type device based on an RFID signal; and based on the identified welding-type device, present an interface configured to interactively provide information related to the identified welding-type device.

In some example portable computing devices, the interface includes component information corresponding to the one or more components of the welding-type device. According to the present invention, the interface is configured to provide equipment configuration instructions corresponding to the identified welding-type device. In some example portable computing devices, the interface is configured provide weld training instructions corresponding to the identified welding-type device.

<FIG> is a diagram of an example welding system <NUM>. While the welding system <NUM> described herein is specifically presented as a gas metal arc welding (GMAW) system <NUM>, the welding system <NUM> may perform other welding-type processes (e.g., FCAW, FCAW-G, GTAW (TIG), SAW, SMAW, plasma cutting), other non-arc welding processes (e.g., friction stir, laser), auxiliary processes (e.g., induction heating, brazing, etc.) and/or hybrid-type processes, where an arc welding process is combined with an energy source, such as a laser, induction heating device, plasma, and so forth. The example welding system <NUM> may include one or more power sources, which may be used separately and/or in combination.

The example welding system <NUM> includes a welding power supply <NUM> (i.e., a welding power source), a welding wire feeder <NUM>, a gas supply system <NUM>, and a welding torch <NUM>. The welding power supply <NUM> generally supplies power to the welding system <NUM> and/or other devices (e.g., hand tools). For welding, the welding power supply <NUM> is coupled to the welding wire feeder <NUM> via a weld cable <NUM>, and is coupled to a workpiece <NUM> using a lead cable <NUM> having a clamp <NUM>. In the illustrated example, the welding wire feeder <NUM> is coupled to the welding torch <NUM> via a weld cable <NUM> to supply welding wire and power to the welding torch <NUM> during operation of the welding system <NUM>. In other examples, the welding power supply <NUM> may couple and directly supply power to the welding torch <NUM>.

In the example of <FIG>, the welding power supply <NUM> includes power conversion circuitry that receives input power from an alternating current power source <NUM> (e.g., the AC power grid, an engine/generator set, or a combination thereof), conditions the input power, and provides DC or AC output power via the weld cable <NUM>. As such, the welding power supply <NUM> may power the welding wire feeder <NUM> that, in turn, powers the welding torch <NUM>, in accordance with demands of the welding system <NUM>. The lead cable <NUM> terminating in the clamp <NUM> couples the welding power supply <NUM> to the workpiece <NUM> to close the circuit between the welding power supply <NUM>, the workpiece <NUM>, and the welding torch <NUM>. The welding power supply <NUM> may include circuit elements (e.g., transformers, rectifiers, switches, and so forth) capable of converting the AC input power to a direct current electrode positive (DCEP) output, direct current electrode negative (DCEN) output, variable polarity, or a variable balance (e.g., balanced or unbalanced) AC output, as dictated by the demands of the welding system <NUM> (e.g., based on the type of welding process performed by the welding system <NUM>, and so forth).

In some examples, an automation system <NUM> may be used in the welding system <NUM>. The automation system <NUM> may include controllers and actuators to automatically control at least a portion of the welding system <NUM> without additional user input. In some embodiments, the automation system <NUM> is connected to the power source <NUM>, the wire feeder <NUM>, the torch <NUM>, or and/or the workpiece <NUM>. The automation system <NUM> may be a robotic welding system that may control the relative movement between the torch <NUM> and the workpiece <NUM> according to instructions loaded to the automation system <NUM>. In some examples, the automation system <NUM> may control the power supply <NUM> and/or the wire feeder <NUM> to control the weld process and the weld variables for a desired welding application.

An operator <NUM> may intend to perform welding-type activities using the welding system <NUM> and/or perform maintenance on one or more components of the welding system <NUM>. However, in some circumstances, the operator <NUM> may be inexperienced with the particular task that the operator <NUM> wishes to perform. This may occur, for example, when the operator <NUM> has little or no welding experience, when the operator has little or no familiarity with the equipment in the system <NUM>, when the operator has not recently performed the task and does not remember one or more aspects of the task, the task is particularly complex, and/or for any other reason.

To assist the operator <NUM>, the operator <NUM> uses a portable computing device <NUM>. The portable computing device <NUM> may be a smartphone, a tablet computer, a laptop computer, and/or any other type of computing device. As discussed in more detail below, the example portable computing device <NUM> presents one or more interfaces to interactively provide information related to one or more of the device(s) <NUM>, <NUM> in the welding system <NUM>. In some examples, providing information via the portable computing device <NUM> may include overlaying graphical information on images captured by the portable computing device <NUM> for display to the operator <NUM>, providing an operating manual, and/or providing an interactive menu for tasks. According to the present invention, information includes equipment configuration instructions corresponding to one or more devices <NUM>, <NUM>, and can further include weld training instructions to be performed using one or more of the devices <NUM>, <NUM>, instructions for a user to manipulate the device(s) <NUM>, <NUM> before the operator <NUM> commences a welding type operation, instructions for the operator <NUM> to manipulate the device(s) after completing the welding type operation, equipment servicing information (e.g., diagnostic techniques, repair instructions, component replacement instructions, etc.), maintenance information (e.g., cleaning information) consumable replacement instructions, and/or any other information or instructions that may be useful to the operator <NUM>.

The portable computing device <NUM> includes one or more cameras to capture image data. The portable computing device <NUM> is configured to recognize specific models of welding equipment from image data captured by the camera when, for example, the operator <NUM> points the camera at the equipment.

In some examples, the welding equipment (for example the power supply <NUM> and the wire feeder <NUM>) includes wireless communication antennas <NUM>, <NUM>. The portable computing device <NUM> may establish wireless communications with nearby welding equipment (e.g., the power supply <NUM>, the wire feeder <NUM>) via wireless communication links <NUM>, <NUM> with the respective antennas <NUM>, <NUM>. The portable computing device <NUM> may identify the welding equipment based on prior recognition and/or communications (e.g., prior pairing between the portable computing device <NUM> and the welding equipment) and/or based on exchanging identifying data with the portable computing device <NUM>.

Additionally or alternatively, the portable computing device <NUM> may establish communications with one or more server(s) <NUM> via wireless communication link(s) <NUM>. The welding equipment (e.g., the power supply <NUM>, the wire feeder <NUM>) may also be in communication with the same server <NUM> or a different server via another communication link <NUM>, which may be wireless or wired. The communication links <NUM>, <NUM>, <NUM>, <NUM> may be any combination of wired and/or wireless communication protocols, including WiFi, Bluetooth, Bluetooth Low Energy, Z-Wave, Zigbee, UDP, TFTP, lwIP, HTTP, and/or the like. The server <NUM> may be, for example, a local or remote/cloud workstation(s) or one or more server(s) in a data center.

In some examples, the wire feeder <NUM> has a wire feeder interface <NUM> that includes information for an operator <NUM> and provides controls to set weld parameters (e.g., graphical user interfaces (GUIs), one or more controls, etc.). In some examples, the power supply <NUM> has a power supply interface <NUM> that includes information for an operator <NUM> and provides controls to set weld parameters (e.g., GUIs, one or more controls, etc.).

<FIG> is a block diagram of an example implementation of the portable computing device <NUM> of <FIG>. The portable computing device <NUM> includes a central processing unit ("CPU") <NUM>. The portable computing device <NUM> also includes one or more cameras <NUM> which may be connected to a graphics processing unit <NUM>. The example camera <NUM> includes an optical sensor and associated data processing circuitry. The portable computing device <NUM> also includes a display <NUM>, a memory <NUM>, a communications interface and an antenna <NUM>. In some examples, the display <NUM> is a touchscreen display that generates electric signals in response to user input, and can be used as a user interface. The user input can be either a touch or a gesture. In some examples, the portable computing device <NUM> contains a display driver <NUM>. In some examples, the CPU <NUM> drives the display <NUM> directly. In some examples, the CPU <NUM> interacts directly with the camera <NUM>, and in some examples, a graphics processing unit <NUM> receives input from the camera <NUM>.

Some example cameras <NUM> include a high dynamic range imager or image sensor array (e.g., at least <NUM> dB of dynamic range) and/or native wide dynamic range imager (e.g., at least <NUM> dB of dynamic range). In other examples, the camera <NUM> includes a medium dynamic range (MDR) imager with at least <NUM> dB of dynamic range.

The portable computing device <NUM> may be capable of communicating wirelessly via multiple communication protocols. The portable computing device <NUM> may send and receive signals via the comm. interface <NUM> and the antenna <NUM>. Example protocols include WiFi, Bluetooth, Bluetooth Low Energy, Z-Wave, Zigbee, UDP, TFTP, lwIP, HTTP, RFID and/or the like. The portable computing device <NUM> may also communicate via a wired connection.

The example portable computing device <NUM> contains additional sensors, including a microphone <NUM>, an accelerometer <NUM>, and/or other sensors <NUM>. In some examples, the camera <NUM> faces the opposite direction of the display <NUM>. The display <NUM> may show the view of the camera <NUM> in real time (e.g., with little or no perceptible lag between movement of the camera and corresponding changes shown on the display <NUM>). Real-time display may be accomplished by sending images captured by the camera <NUM> to the CPU <NUM>. The CPU <NUM> then commands the display <NUM> to display the images captured by the camera <NUM> substantially instantaneously.

While example implementations of the portable computing device <NUM> are described with reference to <FIG>, other implementations may be used. For example, the GPU <NUM>, the display driver <NUM>, the comm. interface <NUM>, and the memory <NUM> may be implemented using hardware, software, firmware, and/or any combination of hardware, software, and/or firmware. For example, components may be added, removed, replaced, combined, divided, and/or otherwise modified from the illustrated example. The CPU <NUM>, the GPU <NUM>, the speaker <NUM>, the microphone <NUM>, the accelerometer <NUM>, the display driver <NUM>, the sensors <NUM>, the memory <NUM>, the comm. interface <NUM> and the antenna <NUM> may be implemented using one or more integrated circuits and/or discrete circuits, such as general purpose processors, special purpose processors (e.g., digital signal processors), programmable logic devices, application specific integrated circuits (ASICs), systems-on-chip (SoCs), and/or any other type and/or combination of types of integrated and/or discrete circuits. Furthermore, implementations may include combinations of components and/or functions into single integrated circuit packages and/or divisions of components and/or functions into multiple integrated circuit packages.

<FIG> shows an example of the portable computing device <NUM> identifying the power supply <NUM> via an image processing method. The portable computing device <NUM> may identify the power supply <NUM> (or other welding-type devices) in various ways. The portable computing device <NUM> may identify the exact model or model family of the power supply <NUM>, or other type of welding equipment. For example, when the power supply <NUM> is in the field of view <NUM> of the camera <NUM>, the CPU <NUM> may perform image processing to identify the model of the power supply <NUM>. In some examples, the CPU <NUM> compares identifiable features of the power supply <NUM> captured by the camera <NUM> to characteristic features stored in memory <NUM> of different types of welding equipment, or to images of different types of welding equipment received from a server <NUM> via communications link <NUM>. In some examples, the welding device is not identified unless the CPU <NUM> or GPU <NUM> determines there is a match in a predetermined number of images captured by the camera <NUM>. This threshold may be required to limit false positives, and ensure that the welding device is only identified when the operator <NUM> focuses the camera <NUM> on the welding device that the operator <NUM> desires to identify for a reasonable amount of time (e.g., <NUM> second).

In some examples, the portable computing device <NUM> transmits live video, representative images, and/or extracted image features captured by the camera <NUM> and/or the GPU <NUM> to a server <NUM> via the communications link <NUM>. The server <NUM> then completes the image processing and sends back information regarding the identified welding device to the portable computing device <NUM> via the communications link <NUM>.

In order to command the portable computing device <NUM> to identify the welding device, the operator <NUM> may put the portable computing device <NUM> into an identification mode. During the identification mode, the camera <NUM> may turn on and begin capturing images. During the identification mode, the display <NUM> displays the field of view <NUM> of the camera <NUM> so that the operator <NUM> can see the field of view <NUM> of the camera <NUM> (e.g., as feedback to the operator <NUM> to point the camera <NUM> at the desired device). The CPU <NUM> or GPU <NUM> receives and processes the images captured by the camera <NUM>, and substantially in real time sends the images to the display <NUM>, which then displays the images captured by the camera <NUM>.

If the display <NUM> is a touchscreen, in order to command the portable computing device <NUM> to identify the welding equipment, the operator <NUM> may press on or give some other indication to the touchscreen display <NUM>. In some examples, the operator <NUM> may press on the image of the welding equipment that the operator wishes to identify. The CPU <NUM> may then conduct the image processing to identify the welding equipment. If more than one welding device is in the field of view <NUM>, for example, if the power supply <NUM> and the wire feeder <NUM> are both in the field of view <NUM>, the operator <NUM> may select which device the operator <NUM> would like the portable computing device <NUM> to identify. For example, the operator may indicate which welding device to identify by pressing on the image of the device on the touchscreen display <NUM>.

During identification mode, the portable computing device <NUM> may automatically identify any welding equipment in the field of view <NUM>. After identifying the welding equipment, the display <NUM> may show the model number or name of the welding device or some other simulated graphic indicating the identity of the welding device. The model number or name of the identified device may be overlaid on the live camera feed displayed on the display <NUM>. The display <NUM> may also provide the operator <NUM> the option to see more information about the identified welding equipment. In some examples, after identifying a welding device, the portable computing device <NUM> may establish wireless communications with the identified welding device via wireless communication link <NUM> if the identified welding device is capable of such wireless communications.

During the identification mode, a search bar <NUM> may be shown on the display <NUM>. The operator <NUM> may input, for example, a model number or name into the search bar <NUM> to attempt to identify the welding equipment. Further, a menu bar <NUM> may be shown on the display <NUM>. When the operator <NUM> selects the menu bar <NUM>, the display <NUM> shows more options to the operator <NUM>.

Some equipment (e.g., the power supply <NUM>) may have a barcode, or a QR code, a graphic logo, a sticker with a model ID number, or the like. The camera <NUM> may scan the barcode, QR code, etc. and thereby identify the power supply <NUM>. Additionally or alternatively, the power supply <NUM> may include a radio frequency identification tag, which the portable computing device <NUM> can identify via RFID communications. In some examples, the welding equipment is be equipped with antennas (<NUM>, <NUM>) and connects to a local wireless area network. The portable computing device <NUM> may be connected on the same local wireless area network. The portable computing device <NUM> may display to the operator <NUM> via the display <NUM> all of the devices on the local wireless area network, and the operator may select any device on the local wireless area network, thereby identifying the welding device. In such examples, the portable computing device <NUM> may show an image of the identified welding device retrieved from memory <NUM> to the display <NUM> so that the operator <NUM> may confirm that the identified welding device matches the real world welding device.

During the identification mode, the operator may speak the name of the welding equipment to be identified or speak the model number of the welding equipment to be identified. Based on the spoken information (e.g., received via the microphone <NUM> of the portable computing device <NUM>), the portable computing device <NUM> detects the model number or model name of the welding equipment to be identified, and compares the detected name or model number to the names or model numbers stored in memory <NUM> or received from a server <NUM> via the communications link <NUM>. The portable computing device <NUM> may thereby identify the welding equipment.

In some examples, the operator <NUM> may point the camera <NUM> so that the field of view <NUM> is looking at the welding consumables such as gas <NUM> and wire. The CPU <NUM> or GPU <NUM> may perform image processing to identify the consumables for the weld job and/or check the identified consumables against a selected weld procedure specification (WPS) for inconsistencies that could lead to weld defects. If such inconsistencies are identified, the portable computing device <NUM> alerts the operator <NUM> (e.g., via the display <NUM> and/or the speaker <NUM>) and/or other people (e.g., via the communications interface <NUM>), and/or disable the trigger on the weld torch <NUM>.

Turning to <FIG>, the example CPU <NUM> may perform image processing to identify the model of the power supply <NUM>, or other welding equipment, by comparing images of the interface <NUM> of the power supply <NUM> to images of welding equipment interfaces (e.g., images stored in memory <NUM> and/or received from a server <NUM> via the communications link <NUM>). The operator <NUM> may be able to zoom in the field of view <NUM> to focus on the interface <NUM>, by interacting with the display <NUM>. and/or by moving the portable computing device <NUM> closer to the interface <NUM>. In some examples, the CPU <NUM> may first automatically detect an interface <NUM> in the field of view <NUM> using first image features, and then automatically focus the image processing on the interface <NUM> of the power supply <NUM> (or any other welding equipment to be identified) to identify the particular interface using second image features. The camera <NUM> also may have optics providing a large depth of field so that the camera <NUM> easily achieves focus on the desired area(s).

In some examples, the portable computing device <NUM> transmits live video captured by the camera <NUM> to a server <NUM> via the communications link <NUM>, which completes the image processing, and sends back information regarding the identified welding equipment to the portable computing device <NUM> via the communications link <NUM>.

In some examples, the CPU <NUM> or the GPU <NUM> can perform image processing based on images received from the camera <NUM> to detect the welding device based on: a number of input devices; a type of at least one input device in the image of the welding device; a number of display devices in the image of the welding device; a display device type in the image of the welding device; model number text; a graphic logo; input device indicator text; an input device indicator graphic; a graphical arrangement; an arrangement of user input devices, output devices, or user input devices and output devices; a communication connector type; a communication connector location; a positive power stud terminal location; a negative power stud terminal location; an air vent location; a housing size; and/or a housing shape.

<FIG> illustrates the portable computing device <NUM> providing information regarding the identified welding device (e.g., power supply <NUM>) to an operator <NUM> via the display <NUM>. In some examples, after identifying the power supply <NUM>, the display <NUM> may display various options to the operator <NUM>. These options may be overlaid on a live feed from the camera <NUM>, or the display <NUM> may show a new screen and cease displaying the live feed from the camera <NUM>. For example, the display <NUM> may indicate to the operator <NUM> the types of weld processes (e.g., MIG, GMAW, TIG, GTAW, Arc, SMAW, Flux core, plasma cutting, etc.) the identified welding equipment is capable of performing. After indicating to the operator <NUM> the types of weld processes the identified device is capable of performing, the portable computing device <NUM> may provide the operator <NUM> with information regarding how to adjust the settings of the identified welding device to conduct each process. In some examples, the operator <NUM> may select which process the operator <NUM> wishes to perform, and the portable computing device <NUM> will then communicate to the operator <NUM> the information regarding how to adjust the settings of the identified welding device. Such information may be communicated to the operator <NUM> via displayed text on the display <NUM>, displayed images on the display <NUM>, displayed video on the display <NUM>, audio instructions played through the speaker <NUM>, or any combination thereof. In some examples, such instructions may be indicated via simulated graphics overlaid on an image of the identified device. In some examples, the simulated graphics corresponding to instructions may be overlaid on a live feed sent from the camera <NUM> to the display <NUM> in order to instruct the operator <NUM> how to adjust the settings of the identified welding device in the real world welding environment.

In some examples, if the identified welding device (power supply <NUM>) and the portable computing device <NUM> have established a wireless communication link <NUM>, the portable computing device <NUM> may send configuration commands corresponding to the operator selected process to the identified welding device (power supply <NUM>).

The display <NUM> may also provide the operator <NUM> the option to see more technical information including: the compatible input power, compatible shielding gases to be used compatible consumable filler/wire, compatible conduits, compatible welding torches, etc. The display <NUM> may also provide a link to view the user manual for the identified device. The display <NUM> may also provide instruction regarding how to properly connect welding components. For example, the display <NUM> may provide instructions to the operator <NUM> regarding how to connect an identified power supply <NUM> to a wire feeder <NUM>. Instructions may include displayed text, displayed images, displayed video, audio instructions played through the speaker <NUM>, or any combination thereof. In some examples, the display <NUM> may list the types of wire feeders compatible with the identified power supply <NUM>. The operator <NUM> may select which of the listed wire feeders will be connected to the power supply <NUM>. The display <NUM> may then provide information regarding how to properly connect the identified power supply <NUM> to the selected wire feeder. Such information may be communicated to the operator <NUM> via displayed text on the display <NUM>, displayed images on the display <NUM>, displayed video on the display <NUM>, audio instructions played through the speaker <NUM>, or any combination thereof. In some examples, such instructions may be indicated via simulated graphics overlaid on an image of the identified device. In some examples, the simulated graphics corresponding to instructions may be overlaid on a live feed sent from the camera <NUM> to the display <NUM> in order to instruct the operator <NUM> how to adjust the settings of the identified welding device in the real world welding environment.

In some examples, the operator <NUM> may enter in a part number, for example the model number of a wire feeder, and the portable computing device <NUM> will inform the operator <NUM> via the display whether that wire feeder is compatible with the identified power supply <NUM>. If they are compatible, the portable computing device <NUM> may instruct the operator <NUM> how to connect the power supply <NUM> to the wire feeder. Such instructions may be communicated to the operator <NUM> via one or more of displayed text on the display <NUM>, displayed images on the display <NUM>, displayed video on the display <NUM>, audio instructions played through the speaker <NUM>, and/or any other presentation technique. In some examples, such instructions may be indicated via simulated graphics overlaid on an image of the identified device. In some examples, the simulated graphics corresponding to instructions may be overlaid on a live feed sent from the camera <NUM> to the display <NUM> in order to instruct the operator <NUM> how to adjust the settings of the identified welding device in the real world welding environment.

The portable computing device <NUM> may identify both a wire feeder <NUM> and a power supply <NUM> via any of the methods described above. For example, the CPU <NUM> may use image processing to identify both the wire feeder <NUM> and the power supply <NUM>. The CPU <NUM> may identify the wire feeder <NUM> and the power supply <NUM> either sequentially, or in some examples, if both the wire feeder <NUM> and the power supply <NUM> are in the same field of view <NUM>, the CPU <NUM> may identify the wire feeder <NUM> and the power supply <NUM> substantially simultaneously while both are displayed on the display <NUM>. The portable computing device <NUM> then may display to the operator <NUM> whether the identified power supply <NUM> and wire feeder <NUM> are compatible, and provide instructions regarding how to connect the power supply <NUM> to the wire feeder <NUM>. Such instructions may be communicated to the operator <NUM> via displayed text on the display <NUM>, displayed images on the display <NUM>, displayed video on the display <NUM>, audio instructions played through the speaker <NUM>, or any combination thereof. In some examples, such instructions may be indicated via simulated graphics overlaid on an image of the identified device. In some examples, the simulated graphics corresponding to instructions may be overlaid on a live feed sent from the camera <NUM> to the display <NUM> in order to instruct the operator <NUM> how to adjust the settings of the identified welding device in the real world welding environment.

The display <NUM> may also provide programming instructions for the identified device based on a selected WPS. Instructions may include displayed text, displayed images, displayed video, audio instructions played through the speaker <NUM>, or any combination thereof. The display <NUM> may also show information about the interface <NUM> controls, for example which knobs or buttons or other input devices control the power supply output voltage, current, pulse length, etc. The portable computing device <NUM> may also provide any other useful information to the operator <NUM> via the display <NUM>, such as information regarding where the device may be serviced, warranty information, etc..

<FIG> illustrates an example where the operator <NUM> has selected the option that the portable computing device <NUM> provides more information regarding the interface <NUM> of the identified power supply <NUM> via the display <NUM>. The user interface <NUM> has a display <NUM> which displays welding-related variables (e.g., "Voltage," "Wire Feed Speed," and "Program") and values of the corresponding welding-related variables. Example displays <NUM> may include liquid crystal displays (LCDs), seven-segment light emitting diodes (LEDs), organic LED (OLED) displays, and/or display devices using any other display technologies. The interface <NUM> also has input controls <NUM>, <NUM>, <NUM>, and <NUM> (buttons, knobs, switches, etc.) that are used to adjust the welding-related variables (e.g., "Voltage," "Wire Feed Speed," "Pulses Per Second," and "Program") of the power supply <NUM>. The identified power supply <NUM> may have a controller that uses information received via the interface <NUM> to modify welding-type variables that are controllable in the welding-type device <NUM>. For example, GMAW-capable welding power supplies may have controllable variables that include output voltage, wire feed speed, wire preheating, output inductance, and/or transfer mode (e.g., spray, short circuit, etc.). As another example, SMAW-capable welding power supplies may have controllable variables that include output current and/or hot start current. The interface <NUM> of the identified power supply <NUM> (or the interface of any other identified welding device) may be used to manually control the welding-type variables of the power supply <NUM>.

In some examples, a display area <NUM> of the display <NUM> may provide more information about the interface <NUM>. The operator <NUM> may select certain features of the interface <NUM>, for example the first input control <NUM> by pressing the area of the touchscreen display <NUM> corresponding to the first input control <NUM>. The display <NUM> may then highlight that selected feature of the interface <NUM> (e.g., first control input <NUM>) and the display area <NUM> may provide information about the operation of that selected feature (e.g., first control input <NUM>). For example, input control <NUM> may control the output voltage of the power supply <NUM>. The display area <NUM> may provide information to the operator <NUM> regarding proper welding voltages for various welding operations, and how to manually adjust the input control <NUM> to ensure that the power supply <NUM> operates at the proper output voltage.

In some examples, as described above, the operator <NUM> may have already selected a weld procedure or WPS the operator will perform. In such examples, the display area <NUM> may instruct the operator <NUM> how to manually adjust each input control (<NUM>, <NUM>, <NUM>, and <NUM>) to ensure that the welding parameters are properly configured for the selected welding process. The display <NUM> may also show to the operator <NUM> how the interface display <NUM> should appear after the operator <NUM> has manually configured the welding device. In some examples, the display area <NUM> may also instruct the operator <NUM> how to manually adjust each input control (<NUM>, <NUM>, <NUM>, and <NUM>) to ensure that the welding parameters are properly configured after the welding process is complete. The display area <NUM> may also provide other instructions for the operator <NUM> to complete after the welding process is complete in order to ensure proper shutdown of the identified welding device. Is some examples, such shutdown instructions may be communicated to the operator <NUM> via displayed text on the display <NUM>, displayed images on the display <NUM>, displayed video on the display <NUM>, audio instructions played through the speaker <NUM>, or any combination thereof. In some examples, such instructions may be indicated via simulated graphics overlaid on an image of the identified device. In some examples, the simulated graphics corresponding to instructions may be overlaid on a live feed sent from the camera <NUM> to the display <NUM> in order to instruct the operator <NUM> how to adjust the settings of the identified welding device in the real world welding environment.

In some examples, if the identified welding device (power supply <NUM>) and the portable computing device <NUM> have established a wireless communication link <NUM>, the portable computing device <NUM> may send configuration commands corresponding to the operator selected process to the identified welding device (e.g. power supply <NUM>) via the wireless communication link <NUM>. A controller within the welding device (e.g. power supply <NUM>) receives and processes the configuration commands, and then configures the parameters of the welding device such that the welding device is correctly configured to perform the selected welding operation. For example, the welding device may be configured according a WPS selected by the operator <NUM> via the portable computing device <NUM>. The welding device may send a confirmation signal via the wireless communication link <NUM> to the portable computing device <NUM> confirming that the welding device has been successfully configured to perform the selected welding operation. The portable computing device <NUM> may indicate the confirmation that the welding device has been properly configured for the selected welding process to the operator <NUM> via the display <NUM>. The display <NUM> may also indicate to the operator <NUM> how the interface display <NUM> should appear after the welding device has been configured to perform the selected welding process. The display <NUM> may also indicate to the operator <NUM> how the interface display <NUM> should appear after the welding device has been ended in order to ensure that the welding device has been properly shutdown.

<FIG> and <FIG> illustrate an example of a welding device within the field of view <NUM> of the camera <NUM>. In some examples, the portable computing device <NUM> may provide service or maintenance information to the operator <NUM> regarding the identified welding device (e.g., power supply <NUM> or wire feeder <NUM>). As <FIG> shows, in some examples, an operator <NUM> may request that portable computing device <NUM> provide images of the interior of the housing of the welding device. For example, in <FIG> the display <NUM> shows the internal wire feed assembly <NUM> which comprises a wire spool, a mounting structure, and a wire driver assembly. Other internal images may be displayed as well. Internal images may be helpful for an operator <NUM> or a service technician. The portable computing device <NUM> may retrieve the internal images from memory <NUM>, or may receive the internal images from a server <NUM> via wireless link <NUM>. The portable computing device <NUM> may then display the internal images of the identified welding device.

In some examples, the identified welding device (e.g., power supply <NUM> or wire feeder <NUM>) is equipped with a controller capable of performing diagnostic tests or keeping an error log. If the identified welding device (e.g., wire feeder <NUM> or power supply <NUM>) and the portable computing device <NUM> have established a wireless communication link (<NUM>, <NUM>), the portable computing device <NUM> may send a request that the identified welding device run diagnostic tests via the wireless communication link (<NUM>, <NUM>). The welding device then runs the diagnostic tests, and transmits the results of the diagnostic test to the portable computing device <NUM>. The portable computing device <NUM> may communicate the results of the diagnostic to the operator <NUM> via the display <NUM>. The portable computing device <NUM> may also communicate to the operator <NUM> service instructions regarding fixing any issue diagnosed with the welding device during the diagnostic test. Service instructions may be communicated to the operator <NUM> via displayed text on the display <NUM>, displayed images on the display <NUM>, displayed video on the display <NUM>, audio instructions played through the speaker <NUM>, or any combination thereof. In some examples, the portable computing device <NUM> may retrieve service instructions from memory <NUM>. In some examples, the portable computing device <NUM> may receive service instructions from a server <NUM> via a wireless link <NUM>.

In some examples, the portable computing device <NUM> sends a request to the identified welding device for an error log via the wireless communication link (<NUM>, <NUM>). The identified welding device then sends the error log to the portable computing device <NUM> via the wireless communication link (<NUM>, <NUM>). The portable computing device <NUM> may display the error log to the operator <NUM> via the display. In some examples, the portable computing device <NUM> may run a diagnostic test based on the received error log, and then display to the operator <NUM> service instructions regarding fixing any issue diagnosed with the welding device during the diagnostic test. In some examples, the portable computing device <NUM> may retrieve service instructions from memory <NUM>. In some examples, the portable computing device <NUM> may receive service instructions from a server <NUM> via a wireless communication link <NUM>. In some examples, the portable computing device <NUM> may transmit the received error log to a server <NUM> via wireless communication link <NUM>. The server <NUM> then may run a diagnostic test based on the received error log. The server <NUM> may then transmit to the portable computing device <NUM> service instructions regarding fixing any issue diagnosed with the welding device during the diagnostic test. The portable computing device <NUM> may then communicate the service instructions to the operator <NUM>. Service instructions may be communicated to the operator <NUM> via displayed text on the display <NUM>, displayed images on the display <NUM>, displayed video on the display <NUM>, audio instructions played through the speaker <NUM>, or any combination thereof. In some examples, the simulated graphics corresponding to instructions may be overlaid on a live feed sent from the camera <NUM> to the display <NUM> in order to instruct the operator <NUM> how to adjust the settings of the identified welding device in the real world welding environment.

In some examples, the welding device may be in direct communication with the server <NUM> via a wireless communication link <NUM>. The welding device may upload any error or diagnostic information to a server <NUM> via the wireless communication link <NUM>. The portable computing device <NUM> may request that the server <NUM> send any diagnostic or error information regarding the identified welding device to the portable computing device <NUM> via communications link <NUM>. The server <NUM> in response to the request then sends any diagnostic or error information regarding the identified welding device as well as service instructions regarding fixing any issue diagnosed with the welding device to the portable computing device <NUM> via data link <NUM>. The portable computing device <NUM> may then communicate the service instructions to the operator <NUM>. Service instructions may be communicated to the operator <NUM> via displayed text on the display <NUM>, displayed images on the display <NUM>, displayed video on the display <NUM>, audio instructions played through the speaker <NUM>, or any combination thereof. In some examples, the simulated graphics corresponding to instructions may be overlaid on a live feed sent from the camera <NUM> to the display <NUM> in order to instruct the operator <NUM> how to adjust the settings of the identified welding device in the real world welding environment.

In some examples, the portable computing device <NUM> may receive from a server <NUM> other information regarding maintenance or service of the identified welding device. For example, the server <NUM> may provide a troubleshooting guide for the identified welding device. The portable computing device <NUM> may then display the troubleshooting guide to the operator <NUM> via the display <NUM>. In some examples, the server <NUM> may provide a list of known or common issues for the identified welding device. The portable computing device <NUM> may then display the list to the operator <NUM> via the display <NUM>. In some examples, the operator <NUM> may select an issue from the displayed list of known issues. The portable computing device <NUM> may then communicate to the operator <NUM> service instructions regarding how to correct that known issue. The service instructions may be communicated to the operator <NUM> via displayed text on the display <NUM>, displayed images on the display <NUM>, displayed video on the display <NUM>, audio instructions played through the speaker <NUM>, or any combination thereof. In some examples, the simulated graphics corresponding to instructions may be overlaid on a live feed sent from the camera <NUM> to the display <NUM> in order to instruct the operator <NUM> how to adjust the settings of the identified welding device in the real world welding environment.

In some examples, the operator <NUM> may type in an issue regarding the identified welding device into a search bar <NUM>. The portable computing device <NUM> may then request information regarding that searched issue from a server <NUM>. The server <NUM> may then transmit service instructions to resolve that searched issue regarding the identified welding device. The portable computing device <NUM> may then communicate to the operator <NUM> service instructions regarding how to correct that known issue. The service instructions may be communicated to the operator <NUM> via displayed text on the display <NUM>, displayed images on the display <NUM>, displayed video on the display <NUM>, audio instructions played through the speaker <NUM>, or any combination thereof. In some examples, the simulated graphics corresponding to instructions may be overlaid on a live feed sent from the camera <NUM> to the display <NUM> in order to instruct the operator <NUM> how to adjust the settings of the identified welding device in the real world welding environment.

<FIG> shows a flow chart of an exemplary method <NUM> for identifying a welding type device using a portable computing device <NUM>, connecting the portable computing device <NUM> to the identified welding device, and displaying information regarding the identified welding device. At block <NUM>, an operator <NUM> commands the portable computing device <NUM> to enter an identification mode. This may include opening an application on a smartphone or tablet computer, or indicating within an application to enter an identification mode. Then at block <NUM>, the portable computing device <NUM> identifies a welding device.

As explained in detail above, a welding device may be identified in various ways. For example, an operator <NUM> may type a model number, model name, vin number, or other identification information into a search bar. In some examples, the operator <NUM> may speak the identifying information and a microphone <NUM> on the portable computing device <NUM> can detect the operator <NUM>'s voice and thereby identify the welding device. In some examples, the portable computing device <NUM> may be connected to a wireless network, and the welding device(s) may also be connected to the wireless network. In such examples, the portable computing device <NUM> may identify and display all welding devices on the wireless network. In other examples, the power supply <NUM> may include a radio frequency identification tag, which the portable computing device <NUM><NUM> can identify.

The portable computing device <NUM> is equipped with a camera <NUM> When the operator <NUM> enters identification mode at block <NUM>, the camera <NUM> may turn on, and the portable computing device <NUM> may display the camera's field of view to a display <NUM> on the portable computing device <NUM>. The portable computing device <NUM> may then identify any welding equipment in the camera's field of view via various methods. For example, the welding device may have a barcode, or a QR code, a graphic logo, a sticker with a model ID number, or the like. The camera <NUM> may scan the barcode, QR code, etc. and thereby identify the welding device.

In some examples, the portable computing device <NUM> may identify the welding device via image processing. <FIG> shows an exemplary method <NUM> for identifying a welding device via image processing. At block <NUM>, the portable computing device <NUM> retrieves stored images of welding devices. These images can be stored in memory locally on the portable computing device <NUM>, or they may be retrieved from a server <NUM>. At block <NUM>, the portable computing device <NUM> captures images of the welding device via the camera <NUM>. At block <NUM>, the portable computing device <NUM> displays the captured images to the display of the portable computing device <NUM>. The portable computing device <NUM> may display the captured images substantially in real time as the images are captured. At block <NUM>, the portable computing device <NUM> compares the images to the retrieved stored images in order to identify the welding device. In some examples, the portable computing device <NUM> compares pixel positions of the retrieved images to pixel positions of the captured images in order to identify the welding device. At block <NUM>, the portable computing device <NUM> identifies the welding device. In some examples, text or other simulated graphics may be displayed over or along with the captured images, indicating information such as the model number, model name, or other useful information regarding the identified welding device to an operator <NUM>. The text or other simulated graphics may be overlaid onto the captured images substantially in real time so that it appears to the operator <NUM> that the text or other simulated graphics are overlaid on a live feed from the camera <NUM>.

Returning to <FIG>, at block <NUM>, the portable computing device <NUM> informs the operator <NUM> that the welding device has been identified. For example, the display may overlay text or other simulated graphics onto the captured images of the welding device identifying the welding device. In other examples, the display may transition to a new screen with retrieved images or information regarding the identified welding device. At block <NUM>, the portable computing device <NUM> receives confirmation from the operator <NUM> that the welding device was correctly identified. The operator <NUM> may for example type into an interface that the identification is correct. In some examples, the display is a touchscreen and the operator <NUM> may perform a gesture on the touchscreen indicating that the identification was correct. In some examples, the operator <NUM> may speak a command that the identification was correct which the microphone <NUM> can detect. The operator <NUM> may also inform the portable computing device <NUM> that the identification is incorrect via any of the methods described above. In such cases, the process may go back to the identification process at block <NUM>.

After receiving confirmation from the operator <NUM> that the identification is correct, at block <NUM> the portable computing device <NUM> displays options to the operator <NUM> regarding the identified welding device. For example, the operator <NUM> may request more information, for example control information; welding parameters; welding processes the welding device is capable of performing; a list of WPSs the welding device can be configured to perform; configuration information; service and maintenance information; or other technical information. In some examples where the welding device is connected to a wireless network, the portable computing device <NUM> may also provide the option to wirelessly connect with the welding device.

If the welding device is capable of wirelessly communicating, then at block <NUM> the portable computing device <NUM> may attempt to establish wireless communications with the welding device. In some examples this process may occur automatically, and in some examples this process occurs after the operator <NUM> requests that the portable computing device <NUM> connects with the identified welding device.

At block <NUM> the portable computing device <NUM> receives the operator <NUM> selection from the operator <NUM>. If the operator <NUM> selected to perform a certain WPS, at block <NUM>, the portable computing device <NUM> may retrieve the certain WPS instructions. Then at block <NUM>, the portable computing device <NUM> may display those retrieved WPS instructions to the operator <NUM>. The instructions may include configuration information for the identified welding device for the selected WPS. The retrieved instructions may also include step by step instructions for performing the selected WPS. Such instructions may include text, video, images, audio instructions, simulated graphics overlaid on a live camera feed, or some combination thereof. In some examples, if the portable computing device <NUM> and the identified welding device are wirelessly connected, at block <NUM> the portable computing device <NUM> may command the welding device to adjust its parameters to achieve the selected WPS. After receiving this information regarding the selected WPS, the operator <NUM> may choose to go back to block <NUM> to see the other options.

At block <NUM>, if the operator <NUM> selected to see service information, the portable computing device <NUM> retrieves service and/or maintenance information regarding the identified welding device. The information may be retrieved for example from a local memory, from a server <NUM>, or from the welding device via a wireless connection. In some examples, the welding device may have a memory with its service history stored on the memory. The welding device may send its service history to the portable computing device. At block <NUM>, the portable computing device <NUM> displays the service information to the operator <NUM>. The service information may include text, a link to the user manual, internal images of the welding device, audio commands, videos, or other simulated graphics. After receiving this information, the operator <NUM> may choose to go back to block <NUM> to see the other options.

If the operator <NUM> requested more information about a certain parameter of the identified welding device, then at block <NUM> the portable computing device <NUM> retrieves and displays the requested information. Such information may include, for example descriptions of the welding interface, for example the effect that adjusting a certain knob/button on the interface of the identified welding device. Other information, may include other welding devices the identified welding device is compatible with, the required input power, compatible welding consumables, etc. After receiving this information, the operator <NUM> may choose to go back to block <NUM> to see the other options.

If the operator <NUM> requested a list of capabilities of the identified welding device, at block <NUM>, the portable computing device <NUM> displays a list of capabilities. This may include a list of WPSs the identified welding device may perform, or more generally the welding operations the welding device is capable of performing, for example, MIG, GMAW, TIG, GTAW, Arc, SMAW, Flux core, plasma cutting, etc. After displaying the capabilities list, in some examples, at block <NUM> the operator <NUM> may select a displayed capability. For example, the operator <NUM> may select to configure the identified device for MIG welding. The portable computing device <NUM> may then provide instructions for configuring the identified device for MIG welding as described above. In some examples, the portable computing device <NUM> may command the welding device to be configured for the selected capability via a wireless communication link. After receiving this information, and/or selecting a welding capability, the operator <NUM> may choose to see the other options at block <NUM>.

At block <NUM>, the operator <NUM> may also choose to go back to identification mode at block <NUM>, or to exit the welding information application.

The present methods and/or systems may be realized in hardware, software, or a combination of hardware and software. A typical combination of hardware and software may be a general-purpose computing system with a program or other code that, when being loaded and executed, controls the computing system such that it carries out the methods described herein.

Claim 1:
A portable computing device (<NUM>), comprising:
a camera (<NUM>); and
a display device (<NUM>);
the portable computing device being characterized by comprising
a processor (<NUM>) configured to:
access one or more images captured by the camera;
identify a welding-type device (<NUM>, <NUM>) based on the one or more images, wherein the welding-type device is a power supply (<NUM>) or a wire feeder (<NUM>); and
based on the identified welding-type device, present an interface on the display device (<NUM>) configured to interactively provide information related to the identified welding-type device; wherein the interface is configured to provide equipment configuration instructions corresponding to the identified welding-type device (<NUM>, <NUM>).