Patent ID: 12205489

The figures are not necessarily to scale. Where appropriate, the same or similar reference numerals are used in the figures to refer to similar or identical elements.

DETAILED DESCRIPTION

Some examples of the present disclosure relate to weld training systems that show (e.g., transparent and/or translucent) “ghost” images of a welding tool (e.g., torch) on a display screen of a welding headgear to help guide a trainee through a welding operation. In some examples, the “ghost” images of the welding tool may indicate target positions and/or orientations for the actual welding tool being used by the trainee. As the “ghost” images indicate target positions/orientations of the welding tool, the images are referred to herein as target tool images.

In some examples, the target tool images may serve as a guide to help new welding operators understand proper welding technique (e.g., travel speed, contact tip to work distance, work angle, travel angle, aim, etc.) for a particular welding operation. In some examples, the target tool images may be shown on a display screen of a welding helmet and/or other headgear. By displaying the target tool image on a display screen of the helmet/headgear, a user wearing the helmet/headgear will be able to easily see the target tool image in relation to the actual welding tool, without having to look away from the welding operation.

In some examples, the weld training systems may additionally “reset” (or provide an option to reset) the target tool image to an earlier and/or prior position if the target tool image gets too far from the welding tool. This may help in situations where the travel speed of the target tool image substantially outpaces the travel speed of the actual welding tool (or vice versa). In such situations, the relative orientations of the target tool image and actual welding tool may be difficult to compare due to their distance, making the target tool image less helpful as a training guide. Additionally, resetting the target tool image to a position closer to the welding tool may minimize the possibility that the trainee will be tempted to overcompensate their travel speed (up or down) in order to catch up with the target tool image; a practice which may be highly detrimental to the quality of the weld.

Some examples of the present disclosure relate to a non-transitory machine readable medium comprising machine readable instructions which, when executed by a processor, cause the processor to: determine a first target position and a first target orientation for a target tool image based on one or more target welding technique parameters; identify an actual position and an actual orientation of a welding tool based on sensor data received from a sensor of a welding headgear; compare the actual position of the welding tool with the first target position of the target tool image; and in response to determining the first target position of the target tool image is more than a threshold distance from the actual position of the welding tool: reset, or provide an option to reset, the first target position of the target tool image to a second target position that is closer to the actual position of the welding tool.

In some examples, the non-transitory machine readable medium further comprises machine readable instructions which, when executed by a processor, cause the processor to display the target tool image on a display screen of the welding headgear based on the first target position or the second target position. In some examples, the non-transitory machine readable medium further comprises machine readable instructions which, when executed by a processor, cause the processor to display a movement of the target tool image on the display screen at a travel speed that corresponds to an actual travel speed of the welding tool. In some examples, the non-transitory machine readable medium further comprises machine readable instructions which, when executed by a processor, cause the processor to negatively adjust a welding score in response to the first target position being reset.

In some examples, the welding score is determined based on a difference between the first target orientation of the target tool image and the actual orientation of the welding tool, as well as a number of times the first target position of the target tool image was reset. In some examples, the one or more target welding technique parameters were recorded during a previous welding operation. In some examples, the second target position of the target tool image corresponds to a position that was recorded during the previous welding operation.

Some examples of the present disclosure relate to a welding headgear, comprising: a display screen; a sensor configured to detect sensor data relating to a welding tool; and processing circuitry configured to: determine a first target position and a first target orientation for a target tool image based on one or more target welding technique parameters, identify an actual position and an actual orientation of the welding tool based on the sensor data, compare the actual position of the welding tool with the first target position of the target tool image, and in response to determining the first target position of the target tool image is more than a threshold distance from the actual position of the welding tool: reset, or provide an option to reset, the first target position of the target tool image to a second target position that is closer to the actual position of the welding tool.

In some examples, the processing circuitry is further configured to: identify an activation time of the welding tool or a length of a weld bead, determine the first target position and first target orientation for the target tool image based on the one or more target welding technique parameters as well as: the activation time of the welding tool, or the length of the weld bead. In some examples, the one or more target welding technique parameters were recorded during a previous welding operation, and the second target position of the target tool image corresponds to a position of a previous welding tool that was recorded during the previous welding operation when a previous weld bead was of a same length as the length of the weld bead. In some examples the welding headgear further comprises a helmet shell, the display screen, sensor, and processing circuitry being retained by the helmet shell.

In some examples, the one or more target welding technique parameters comprise one or more of a torch position, torch orientation, torch travel speed, torch travel direction, torch travel angle, work angle, contact tip to work distance, torch aim, or weld path characteristic, and the sensor comprises a camera sensor, optical sensor, infra-red (IR) sensor, thermal sensor, acoustic sensor, ultrasonic sensor, or electromagnetic sensor. In some examples, the target tool image comprises an outline, transparent depiction, translucent depiction, or semi-transparent depiction of the welding tool, a different welding tool, or a welding consumable. In some examples, the processing circuitry is further configured to: compare the actual position and actual orientation of the welding tool with the first target position and first target orientation of the target tool image, and in response to determining the actual position and actual orientation of the welding tool match the first target position and first target orientation of the target tool image, providing an effect that affirms that the welding tool is properly positioned and oriented.

Some examples of the present disclosure relate to a method of guiding a welding operator, comprising: determining, via processing circuitry of a welding headgear, a first target position and a first target orientation for a target tool image based on one or more target welding technique parameters; identifying an actual position and an actual orientation of a welding tool based on sensor data received from a sensor of the welding headgear; comparing the actual position of the welding tool with the first target position of the target tool image; and in response to determining the first target position of the target tool image is more than a threshold distance from the actual position of the welding tool: resetting, or providing an option to reset, the first target position of the target tool image to a second target position that is closer to the actual position of the welding tool.

In some examples, the method further comprises displaying the target tool image on a display screen of the welding headgear based on the first target position or second target position. In some examples, the method further comprises negatively adjusting a welding score in response to the first target tool position being reset, and displaying the welding score on the display screen. In some examples, the method further comprises displaying a movement of the target tool image on the display screen at a travel speed that corresponds to an actual travel speed of the welding tool.

In some examples, the one or more target welding technique parameters comprise one or more of a torch position, torch orientation, torch travel speed, torch travel direction, torch travel angle, work angle, contact tip to work distance, torch aim, or weld path characteristic, the sensor comprises a camera sensor, optical sensor, infra-red (IR) sensor, thermal sensor, acoustic sensor, ultrasonic sensor, or electromagnetic sensor, and the target tool image comprises an outline, transparent depiction, translucent depiction, or semi-transparent depiction of the welding tool, a different welding tool, or a welding consumable. In some examples, the method further comprises comparing the actual position and actual orientation of the welding tool with the first target position and first target orientation of the target tool image; and in response to determining the actual position and actual orientation of the welding tool match the first target position and first target orientation of the target tool image, providing an effect, via a user interface of the welding headgear, that affirms that the welding tool is properly positioned and oriented.

FIG.1ashows an example of a weld training system100. As shown, the weld training system100includes welding-type equipment102connected (e.g., electrically) with a welding-type tool104. In the example ofFIG.1, an operator106wearing a welding helmet200is using the welding-type tool104to perform a welding-type operation on a workpiece108sitting on a welding bench110. An observer112holding an observation device150is shown watching the operator106perform the welding-type operation.

While not shown in the example ofFIG.1for the sake of simplicity, in some examples, the welding-type equipment102may also be (e.g., electrically) connected to the welding bench110and/or workpiece108. Though only one observer112is shown in the example ofFIG.1for the sake of simplicity, in some examples there may be several observers112with several different observation devices150. While shown as a handheld mobile device (e.g., smartphone, tablet, etc.) in the example ofFIG.1, in some examples, the observation device150may instead be a welding helmet200or other device.

In some examples, the welding helmet200worn by the operator106inFIG.1may implement a weld training simulator configured to conduct a weld training simulation. In some examples, the welding helmet200may be configured to conduct a weld training simulation that is a virtual, augmented, or mixed reality weld training simulation. In some examples, the welding helmet200may conduct the weld training simulation by outputting simulation stimuli (e.g., visual effects, audio effects, haptic effects, and/or other sensory stimulations perceptible to the operator106) while still allowing the operator106to perceive some or all of the real world. The stimuli output by the welding helmet200may overlap with (and/or augment) real world stimuli, resulting in an augmented, mixed, mediated, or simulated reality.

In some examples, the welding helmet200may simulate various stimuli that occur during live, real world, welding-type operations, such as, for example the sight, sound, and/or feel of a welding arc, a molten weld puddle, a weld bead, welding fumes, spatter, sparks, a welding-type tool, a workpiece material, and/or an auto-darkening filter (ADF). In this way, the welding helmet200can provide the operator106with a simulated version of a live welding-type operation. In some examples, the welding helmet200may instead be used during an actual live welding-type operation. Whether used during live, real world, welding-type operations, or simulated welding-type operations, the welding helmet200may provide various stimuli to help guide the operator106through the welding-type operation.

In some examples, the welding helmet200may provide stimuli in the form of real time feedback. For example, the welding helmet200may provide feedback to the operator106with respect to a welding technique of the operator106, welding parameters set by the operator106, and/or other aspects of the weld training system100. In some examples, the feedback may help to guide a new and/or less experienced operator106in understanding how to perform the welding operation.

In order to conduct the weld training simulation convincingly, the welding helmet200may track the position and/or orientation of certain items. For example, the welding helmet200may track the position and/or orientation of the workpiece108, the welding bench110, the welding-type tool104, and/or certain portions of the welding-type tool104(e.g., the nozzle, contact tip, etc.). In examples where live welding occurs, the welding helmet200may track the position and/or orientation of a welding arc. In some examples, the welding helmet200may track the position and/or orientation of itself, which may, in some situations, help the welding helmet200to distinguish between movement of the welding helmet200and movement of items tracked by the welding helmet200. In some examples, the welding helmet200may track positions and/or orientations using helmet sensors202, discussed further below with respect toFIGS.2-3.

In some examples, markers114may assist the welding helmet200and/or weld training system100in tracking the position and/or orientation of the welding-type tool104. For example, the markers114may be easily recognizable by the welding helmet200in (e.g., image) data captured by the helmet sensors202, and thus assist in recognition of the welding-type tool104. In some examples, the markers114may assist in identifying and/or recognizing particular portions of the welding-type tool104.

For example, the markers114may define (and/or may be calibrated to define) a recognizable and/or unique geometric configuration (and/or rigid body). In some examples, this geometric configuration (and/or rigid body) can be correlated (e.g., in memory) with a known (e.g., stored in memory) structural configuration and/or model of the welding-type tool104. Thus, by identifying and/or tracking the particular geometric configuration of markers114, the weld training system100may be able to identify and/or track the structural configuration of the welding-type tool104; including particular portions (e.g., nozzle, neck, handle, etc.) of the structural configuration.

In some examples, the welding-type tool104may include at least three markers114fixed to the welding-type tool104relative to one another in a single plane, and a fourth marker114fixed to the welding-type tool104in a different (e.g., adjacent) plane, to define a rigid body. While a certain number of markers114are shown in the example ofFIG.1attached to the handle, neck, and nozzle of the welding-type tool104for the purposes of illustration, in some examples more or fewer markers114may be attached to the handle, neck, nozzle, and/or other portions of the welding-type tool104.

In some examples, the welding-type tool104may include no markers114. In such examples, the weld training system100may instead use object recognition, computer vision, and/or other image processing techniques to identify, recognize, and/or track the welding-type tool104.

While depicted inFIG.1as a welding torch or gun configured for gas metal arc welding (GMAW), in some examples, the welding-type tool104may instead be a different welding-type tool104. For example, the welding-type tool104may be an electrode holder (i.e., stinger) configured for shielded metal arc welding (SMAW), a torch and/or filler rod configured for gas tungsten arc welding (GTAW), a welding gun configured for flux-cored arc welding (FCAW), and/or a plasma cutter. In some examples, the welding-type tool104may be a mock welding-type tool, and/or be configured for mock (as opposed to live) welding-type operations.

In the example ofFIG.1, the welding-type tool104is connected to welding-type equipment102. In examples where live welding-type operations are conducted, the welding-type equipment102may provide welding-type power and/or consumables to the welding-type tool104, and/or information to the welding helmet200. In some examples where live welding-type operations are conducted, the welding-type tool104may transmit one or more signals to the welding-type equipment102(and/or welding helmet200and/or observation device150) when activated (e.g., via trigger pull, foot pedal press, etc.). In response to the activation signal(s), the welding-type equipment102may output welding-type power and/or consumables (e.g., wire and gas) to the welding-type tool104.

In some examples where simulated welding-type operations are conducted, the welding-type tool104may still transmit one or more signals to the welding-type equipment102(and/or welding helmet200and/or observation device150) when activated. However, the welding-type equipment102may just provide activation information to the welding helmet200(and/or observation device150) in response to the activation signals, rather than outputting power or consumables. In some examples where simulated welding-type operations are conducted, the welding-type equipment102may comprise mock welding-type equipment and/or a computational system (e.g., desktop, laptop, etc.). In some examples where simulated welding-type operations are conducted, the welding-type equipment102may be omitted altogether.

In the example ofFIG.1, the welding-type equipment106comprises a welding-type power supply118, wire feeder120, and gas supply122. In some live welding examples, the wire feeder120may be configured to feed wire to the welding-type tool104. In some live welding examples, the gas supply122may be configured to route shielding gas to the welding-type tool104.

In the example ofFIG.1, the power supply118includes power communication circuitry124, power control circuitry126, and power conversion circuitry128interconnected with one another. In some examples, the power conversion circuitry128may be configured to receive input power (e.g., from a generator, a battery, mains power, etc.) and convert the input power to welding-type output power, such as might be suitable for use by the welding-type tool104for welding-type operations. In some examples, the power control circuitry126may be configured to control operation of the communication circuitry124, power conversion circuitry128, wire feeder120, and/or gas supply122(e.g. via one or more control signals) in accordance with one or more welding parameters.

In the example ofFIG.1, the welding-type equipment102further includes an operator interface130. In some examples, the operator interface130may comprise one or more display screens, touch screens, knobs, buttons, levers, switches, microphones, speakers, lights, and/or other mechanisms through which an operator106may provide input to, and/or receive output from, the welding-type equipment. For example, an operator106may use the operator interface130to input one or more welding parameters (e.g., target voltage, current, wire feed speed, wire/filler type, wire/filler diameter, gas type, gas flow rate, welding-type process, material type of workpiece108, position of welding-type process, joint position, joint type, joint geometry/thickness, etc.). As another example, the operator106may use the operator interface130to view and/or otherwise understand the current welding parameters of the welding-type equipment102.

While shown as part of the power supply118inFIG.1, in some examples, the operator interface130, power control circuitry126, and/or power communication circuitry124(and/or some other control/communication circuitry) may be part of the wire feeder120and/or gas supply122. In some examples, the power communication circuitry124may be configured to facilitate communication with the welding-type tool104, welding helmet200, observation device150, and/or welding helmet200.

FIGS.2a-2bshow example enlarged front and side view of the welding helmet200. While shown as a welding helmet200in the examples ofFIGS.2a-2b, in some examples, the welding helmet200may be a different sort of headgear. For example, the welding helmet200may instead be implemented via goggles, a non-welding helmet, a visor, and/or other appropriate wearables.

In the example ofFIGS.2a-2b, the welding helmet200comprises a helmet shell201attached to a suspension204. As shown, the suspension204comprises several straps and/or bands configured to wrap around the head of an operator106. The straps are connected to one another and to the helmet shell201at least at two side attachment points on either side of the head of the operator106. In some examples, the helmet200may be configured to rotate and/or pivot about the side attachment points to transition between raised and lowered positions.

In the examples ofFIGS.2a-2b, the welding helmet200also includes a lens assembly206fixed to (and/or integrated into) a front portion of the helmet shell201at approximately eye level. In some examples, the lens assembly206may comprise a mobile device (e.g., smartphone, tablet, etc.). In some examples, the lens assembly206may include a cover lens, an auto-darkening filter (ADF), and/or one or more display screens602(see, e.g.,FIGS.6a-6d). In some examples, the cover lens may be (e.g., partially or fully) transparent and/or configured to allow an operator106to see through the cover lens and/or view the surrounding environment.

In some examples, the display screen(s)602of the lens assembly206may comprise one or more near-eye displays. In some examples, the display screen(s)602may be semi-transparent and/or configured to overlay information (e.g., virtual/simulated/holographic objects, guidance, technique feedback, technique parameters, welding parameters, messages, etc.) onto at least part of cover lens (and/or lens assembly206). In some examples, the display screen(s)602may be integrated into safety glasses attached to (and/or in communication with) the welding helmet200.

In some examples, a display screen(s)602may cover the entire cover lens (and/or lens assembly206). In some examples where the display screen(s)602covers the entire cover lens (and/or lens assembly206), the ADF may be omitted. In some examples, a display screen602may cover only a portion of the cover lens (and/or lens assembly206), so as to be visible on only one side (e.g., to only one eye). In some examples, providing the display screen(s)602over both sides of the lens assembly206(and/or eyes) may make stereoscopic display possible, which may make it possible to display images that appear to have more depth. In some examples, a display screen may be positioned at and/or over a periphery of the lens assembly206, so as to be less distracting.

In some examples, the display screen(s)602may be configured to display simulation stimuli and/or feedback. For example, the display screen(s)602may display stimuli simulating effects of the ADF, information regarding welding parameters of the welding equipment102, and/or feedback regarding welding technique parameters (e.g., contact tip to work distance, travel speed, travel angle, work angle, aim, etc.). In some examples, the display screen(s)602may display feedback regarding welding parameters as compared to expected welding parameters. In some examples, the display screen(s)602may display feedback regarding target welding technique parameters in the form of one or more (e.g., transparent and/or translucent) target tool images, depicting target positions and/or orientations of the welding-type tool104. In some examples, feedback may be instead (or additionally) output via other helmet I/O devices208.

In the examples ofFIGS.2a-2b, the welding helmet200includes helmet input/output (I/O) devices208. In some examples, the helmet I/O devices208are devices through which an operator106may provide input to, and/or receive output from, the welding helmet200. In some examples, the I/O devices208may include knobs, buttons, levers, switches, touch screens, microphones, speakers, haptic devices, lights (e.g., LEDs), and/or other appropriate I/O devices208. In some examples, the display screen(s)602may be considered part of the helmet I/O devices208. In some examples, settings of the weld training simulation may be controlled and/or presented to the operator106via the helmet I/O devices208. While shown as being retained on an external surface of the helmet shell201in the examples ofFIGS.2a-2bfor the purposes of illustration, in some examples, some I/O devices208may also be retained on an internal surface of the helmet shell201.

In the examples ofFIGS.2a-2b, the welding helmet200also includes helmet sensors202. Four helmet sensors202are shown as part of the lens assembly206, while a fifth helmet sensor202is shown attached to a rear of the helmet shell201, separate from the lens assembly206. In some examples, the welding helmet200may include more or fewer helmet sensors202. In some examples, the four helmet sensors202of the lens assembly206may be used to track the six degree of freedom (DOF) position and/or orientation of items for the weld training simulation, while the fifth helmet sensor202may be used to track the position and/or orientation of the welding helmet200itself.

In some examples, the helmet sensors202of the welding helmet200may be fixed relative to each other, the helmet shell201, and/or the display screen(s). In some examples, the relative positions of the helmet sensors202of the welding helmet200may be known, stored, entered manually, and/or automatically detected during a calibration procedure. In some examples, each helmet sensor202may comprise one or more camera sensors, optical sensors, infra-red (IR) sensors, thermal sensors, acoustic sensors, ultrasonic sensors, electromagnetic sensors, inertial measurement sensors, accelerometers, gyroscopes, magnetometers, and/or other appropriate types of sensors.

In the examples ofFIGS.2a-2b, the welding helmet200further includes helmet circuitry218and a helmet power source216. In some examples, the helmet circuitry218and helmet power source216may be internal to the helmet shell202. In some examples, the helmet power source216may provide electrical power to the components of the welding helmet200. In some examples, the power source216may comprise one or more batteries, solar panels, and/or energy harvesting devices. In some examples, one or more components of the welding helmet200may have a separate power source from which to draw power. In some examples, the helmet circuitry218may support, drive, and/or facilitate operation of the welding helmet200. In some examples, the power source216and/or helmet circuitry218may be part of the lens assembly206.

FIG.3is a block diagram showing components and interconnections of the weld training system100. In particular,FIG.3shows more detailed components and interconnections of the welding helmet200and helmet circuitry218. While not shown for the sake of simplicity, the welding helmet200may further include power source216connected with (and/or providing electrical power to) some or all of the components of the welding helmet200.

In the example ofFIG.3, the welding helmet200is in communication with the welding-type tool104, the welding equipment102, one or more other welding helmets200, and one or more observation devices150. In some examples, each observation device150may have components similar to that of the welding helmet200(e.g., sensors, I/O devices, circuitry, power, etc.). In some examples, each observation device150may have a structure similar (or identical) to that which is disclosed in U.S. patent application Ser. No. 17/209,755, filed Mar. 23, 2021, entitled “Welding Simulation Systems with Observation Devices,” which is hereby incorporated by reference in its entirety.

In the example ofFIG.3, the welding helmet200includes one or more helmet sensors202, helmet I/O devices208, and helmet circuitry218. As shown, the helmet circuitry218includes helmet memory circuitry302, helmet processing circuitry304, helmet communication circuitry306, and helmet I/O circuitry308interconnected with one another via a common electrical bus.

In some examples, the helmet I/O circuitry308may comprise one or more drivers for the helmet I/O devices208. In some examples, the helmet I/O circuitry308may be configured to generate one or more signals representative of input received via the helmet I/O device(s)208, and provide the signal(s) to the bus. In some examples, the helmet I/O circuitry308may also be configured to control the helmet I/O device(s)208to generate one or more outputs in response to one or more signals (e.g., received via the bus).

In some examples, the helmet communication circuitry306may include one or more wireless adapters, wireless cards, cable adapters, wire adapters, dongles, radio frequency (RF) devices, wireless communication devices, Bluetooth devices, IEEE 802.11-compliant devices, WiFi devices, cellular devices, GPS devices, Ethernet ports, network ports, lightning cable ports, cable ports, etc. In some examples, the helmet communication circuitry306may be configured to facilitate communication via one or more wired media and/or protocols (e.g., Ethernet cable(s), universal serial bus cable(s), etc.) and/or wireless mediums and/or protocols (e.g., cellular communication, general packet radio service (GPRS), near field communication (NFC), ultra high frequency radio waves (commonly known as Bluetooth), IEEE 802.11x, Zigbee, HART, LTE, Z-Wave, WirelessHD, WiGig, etc.). In some examples, the helmet communication circuitry306may be coupled to one or more antennas to facilitate wireless communication.

In some examples, the helmet communication circuitry306may be configured to facilitate communications of the welding helmet200. In some examples, the helmet communication circuitry306may receive one or more signals (e.g., from the welding-type tool104, welding-type equipment102, etc.) decode the signal(s), and provide the decoded data to the electrical bus. As another example, the helmet communication circuitry306may receive one or more signals from the electrical bus (e.g., representative of one or more inputs received via the helmet I/O circuitry308) encode the signal(s), and transmit the encoded signal(s) to an external device (e.g., welding-type tool104, welding-type equipment102, etc.).

In some examples, the helmet processing circuitry304may comprise one or more processors, controllers, and/or graphical processing units (GPUs). In some examples, the helmet processing circuitry304may comprise one or more drivers for the helmet sensors202. In some examples, the helmet processing circuitry304may be configured to execute machine readable instructions stored in the helmet memory circuitry302.

In the example ofFIG.3, the helmet memory circuitry302includes (and/or stores) a weld training simulation process400. As shown, the weld training simulation process400includes a target tool image process500. In some examples, the weld training simulation process400and/or target tool image process500may comprise machine readable instructions configured for execution by the helmet processing circuitry304.

In some examples, the weld training simulation process400may process sensor data captured by helmet sensors202and track the 6 DOF position and/or orientation of the welding-type tool104, workpiece(s)108, welding helmet200, and/or other relevant items using the captured sensor data. In some examples, the weld training simulation process400may use the 6 DOF position(s) and/or orientation(s) (e.g., in conjunction with other information) to simulate a welding-type operation, workpiece material, etc. In some examples, the weld training simulation process400may use the 6 DOF position(s) and/or orientation(s) (e.g., in conjunction with other information) to determine what simulation stimuli to output, as well as how and/or where to output, in order to effectively guide the operator106through the welding-type operation.

In some examples, the weld training simulation process400may execute the target tool image (e.g., sub) process500to help guide the operator106through the welding-type operation. In some examples, the target tool image process500may show a “ghost” (e.g., transparent and/or translucent) image of a welding-type tool on the display screen(s)602of the welding helmet200to indicate target positions and/or orientations for the actual welding-type tool104. In some examples, the target tool image process500may use the 6 DOF position(s) and/or orientation(s) (e.g., in conjunction with other information) to determine how and/or where to output the target tool image, so as to effectively guide the operator106through the welding-type operation.

FIG.4is a flowchart illustrating example operation of the weld training simulation process400of the welding helmet200. In some examples, an observation device150may operate a modified form of the weld training simulation process400and/or coordinate with the weld training simulation process (e.g., as described in U.S. patent application Ser. No. 17/209,755, filed Mar. 23, 2021, entitled “Welding Simulation Systems with Observation Devices”).

In the example ofFIG.4, the weld training simulation process400begins at block402, where the weld training simulation process400configures a weld training session. In some examples, configuring the weld training session may comprise configuring the welding helmet200so it can communicate with the welding-type equipment102, the welding-type tool104, other welding helmets200, and/or one or more observation devices150.

In some examples, configuring the weld training session may comprise configuring welding parameters. In some examples, configuring the weld training session may comprise the welding helmet200receiving the welding parameters from the welding-type equipment102. In some examples, configuring the weld training session may comprise calibrating the welding helmet200, such as, for example, calibrating the spatial relationship between the helmet sensors202, and/or between the helmet sensors202and the display screen(s)602of the welding helmet200.

In some examples, configuring the weld training session may comprise one or more selections. For example, selecting a (e.g., type of) weld training exercise, a (e.g., type of) welding-type operation, a (e.g., type of) welding-type tool104, a (e.g., type of) the welding-type equipment102, one or more (e.g., types of) markers114, one or more weld training session parameters, desired feedback, and/or desired stimuli. In some examples, configuring the weld training session may comprise selecting whether live or mock welding-type operations will be conducted.

In some examples, an operator106may provide one or more inputs (e.g., via the helmet I/O device(s)208) to configure the weld training simulation process400. In some examples, the welding helmet200may synchronize and/or communicate with one or more observation devices150and/or other welding helmets200to configure the weld training simulation process400at block402. In some examples, the weld training simulation process400may store the configuration data in helmet memory circuitry302.

After the configurations are complete, the weld training simulation process400may begin a weld training session. In some examples, the weld training session may begin in response to an input from an operator106(e.g., via the helmet I/O device(s)208). In some examples, the weld training session may begin in response to one or more signals received from the welding-type tool104, welding-type equipment102, observation device(s)150, and/or one or more other welding simulators300. In some examples, the weld training simulation process400may send one or more signals to other welding helmets200and/or observation devices150indicating when the weld training session has started.

In the example ofFIG.4, the weld training simulation process400proceeds to block404after block402. At block404, the weld training simulation process400obtains sensor data from the perspective of the welding helmet200via the helmet sensor(s)202of the welding helmet200. Using the sensor data, the weld training simulation process400determines the position(s) and/or orientation(s) of items tracked by the weld training simulation process400(e.g., the welding-type tool104, workpiece(s)108, arc, etc.) in 6 DOF (e.g., x, y, z coordinates and yaw, pitch, roll angles). In some examples, the weld training simulation process400may also obtain sensor data from the perspective of an observation device150and/or another welding helmet200in order to appropriately provide renderings from those perspectives (e.g., as further described in U.S. patent application Ser. No. 17/209,755, filed Mar. 23, 2021, entitled “Welding Simulation Systems with Observation Devices”).

In the example ofFIG.4, the weld training simulation process400proceeds to block406after block404. At block406, the weld training simulation process400identifies an activation state of the welding-type tool104. In some examples, the weld training simulation process400may determine the activation state based on sensor data. For example, one or more markers114on the welding-type tool104may change state (e.g., from invisible to visible, lit to unlit, static to blinking, blinking at a first frequency to blinking at a second frequency, etc.) when the welding-type tool104is activated.

In some examples, the weld training simulation process400may determine the activation state based on position/orientation information. For example, the weld training simulation process400may conclude that the welding-type tool104is activated if the welding-type tool104(and/or a nozzle, contact tip, etc. of the welding-type tool104) is within a threshold distance of a workpiece108. In some examples, the weld training simulation process400may determine the activation state of the welding-type tool104based on one or more signals received from the welding-type tool104, the welding-type equipment102, and/or another welding helmet200. For example, the welding-type tool104may send one or more signals to the welding-type equipment102when the welding-type tool is activated (and/or deactivated), and the welding-type equipment102may send one or more (identical or different) signals to the welding helmet200. As another example, the welding-type tool104may send the one or more signals directly to the welding helmet200. As another example, another welding helmet200that has determined the activation state may send one or more signals representative of the activation state.

In some examples, the weld training simulation process400may use configuration information from block402(e.g., type(s) of welding-type tool104and/or marker(s)114) to determine the activation state. For examples, the weld training simulation process400may expect to receive an activation signal from the welding-type tool104for certain configurations, and expect to receive an activation signal from the welding-type equipment102for other configurations. In some examples, the weld training simulation process400may expect to determine activation state purely from position/orientation information in certain other configurations.

In the example ofFIG.4, the weld training simulation process400proceeds to block408after block406. At block408, the weld training simulation process400determines (and/or outputs) one or more welding technique parameters. In some examples, the weld training simulation process400may determine the welding technique parameters based on configuration data, sensor data, position and/or orientation information, and/or the activation state of the welding-type tool104. In some examples, welding technique parameters may be further determined based on sensor data, and/or position/orientation data relating to other objects tracked by the weld training simulation process400. In some examples, the weld training simulation process400may determine a weld training score for the operator106based on how closely one or more of the welding technique parameters (and/or other welding parameters) match one or more expected welding technique parameters (and/or other welding parameters).

In some examples, the welding technique parameters may include one or more weld bead/path characteristics, such as, for example, a length, straightness, weave, whip, and/or position of the weld bead/path, and/or a distance between weld beads/paths. In some examples, data relating to the movement (and/or activation) of the welding-type tool104along the weld path and/or joint may be evaluated to determine the weld bead/path characteristics.

In the example ofFIG.4, the weld training simulation process400proceeds to block410after block408. At block410, the weld training simulation process400generates simulation stimuli. In some examples, the simulation stimuli may include visual, audio, and/or haptic stimuli. For example, the simulation stimuli may simulate the sight, sound, and/or feel of an ADF, a welding-type tool104, workpiece108(e.g., material), welding arc, weld puddle, weld bead, and/or welding fumes. In some examples, simulation stimuli may indicate welding parameter information, welding technique parameter information, score information, and/or feedback as to how to adjust and/or improve welding parameters and/or welding technique parameters. In some examples, simulation stimuli may be output via the helmet I/O devices208.

In the example ofFIG.4, the target tool image process500is shown as part of block410of the weld training simulation process400. In some examples, the target tool image process500may execute as part of block410. In some examples, the target tool image process500may provide a specific form of stimuli and/or feedback as part of block410. In particular, the target tool image process500may show target tool images604on the display screen(s)602of the welding helmet200to indicate target positions and/or orientations for the actual welding-type tool104and help the operator106(see, e.g.,FIGS.6a-6d). The target tool image process500executed at block410is discussed in detail further below.

In the example ofFIG.4, the weld training simulation process400proceeds to block412after block410. At block412, the weld training simulation process400records details (e.g., technique parameters, welding parameters, 6 DOF position/orientation data) of the weld training session so far. In some examples, the details may be saved in helmet memory circuitry302, and/or stored in cache until the end of the welding-type operation then saved in helmet memory circuitry302. In some examples, these details may be used at a later date by the target tool image process500to create and/or control the target tool images604.

In the example ofFIG.4, the weld training simulation process400proceeds to block414after block412. At block414, the weld training simulation process400determines whether the present welding-type operation (and/or training session) is over. In some examples, the determination may be made based on one or more inputs received (or not received) via the helmet I/O devices208and/or helmet communication circuitry306. As shown, the weld training simulation process400returns to block404if the weld training simulation process400determines that the present welding-type operation (and/or training simulation) is not over. The weld training simulation process400ends after block414if the weld training simulation process400determines that the present welding-type operation (and/or training session) is over (though, in some examples, the weld training simulation process400may instead return to block402). In some examples, the weld training simulation process400may communicate the determination at block414to synched observation devices150and/or welding helmets200.

FIG.5is a flowchart illustrating example operation of the target tool image process500. In some examples, the target tool image process500may provide a specific form of stimuli and/or feedback to help guide an operator106. In particular, the target tool image process500may show a (e.g., transparent and/or translucent) target tool image604to indicate target positions and/or orientations for the actual welding-type tool104(see, e.g.,FIGS.6a-6d). In some examples, the target tool images604may be shown on the display screen(s)602of the welding helmet200and/or other headgear, so that a user wearing the helmet/headgear can easily see the target tool image604in relation to the actual welding-type tool104they are holding. In this way, a new welding operator106may be trained on proper welding technique without requiring an experienced operator to be present for live instruction.

In some examples, the target tool image process500may additionally “reset” (or provide an option to reset) the target tool image604to an earlier/later (and/or prior/subsequent) position if it gets too far away from the actual position of the welding-type tool104. This may help in situations where the travel speed of the target tool image604substantially outpaces the travel speed of the actual welding-type tool104(or vice versa), and the resulting distance makes differences between the relative orientations more difficult to discern. Additionally, resetting the target tool image604to a position closer to the welding-type tool104may lessen the possibility that the operators106will be tempted to drastically increase/decrease their travel speed in order to catch up with the target tool image604; a practice which may be highly detrimental to the quality of the weld.

In the example ofFIG.5, the target tool image process500begins at block502, where the target tool image process500obtains target welding technique parameters (e.g., contact tip to work distance, travel speed, travel angle, work angle, aim, position, orientation, etc.). In some examples, the target welding technique parameters may have been recorded during a prior weld training simulation process400(e.g., at block412). In some examples, the target welding technique parameters may be determined by the target tool image process500based on data recorded during a prior weld training simulation process400. In some examples, the target welding technique parameters may be manually entered (e.g., by an administrator).

In some examples, particular target welding technique parameters may be tied to a particular time (e.g., of a welding-type operation and/or clock) and/or position (e.g., relative to workpiece, weld path, world coordinates, etc.). This might allow the target tool image process500to determine, for example, particular target welding technique parameters for x seconds into the welding operation, or for y centimeters along the weld bead/path.

In some examples, the target welding technique parameters may be modified and/or customized at block502. For example, the target welding technique parameters may be modified and/or customized to start/end at particular position(s)/time(s), which may be useful if the operator106only wants guidance for one or more particular portions of the welding operation. As another example, the travel speed may be modified to be slower (e.g., ½ or ¼ speed) or faster (2×, 4×, etc.) than what was originally recorded. In some examples, setting a slower/faster speed may make it easier for a new operator106to stay close to the target tool image604, which has certain advantages, as explained above.

As another example, the target welding technique parameters may be modified and/or customized to have a travel speed that is always equal to the travel speed of the welding-type tool104. In some examples, this may ensure the target tool image604never outpaces the welding-type tool104, which has certain advantages, as explained above. As another example, the target welding technique parameters may be modified and/or customized to be determined by position rather than time. This may ensure that the target tool image604is always shown at the same position along the weld bead/path as the welding-type tool104, effectively eliminating the risk that the target tool image604outpaces the welding-type tool104.

In some examples, other parameters of the target tool image process500may be modified and/or customized at block502as well. For example, the look and/or feel of the target tool image604itself may be customized (e.g., size, shape, color, effects, etc.). In some examples, the type of tool the target tool image604depicts (e.g., in size, shape, etc.) may be customized. In some examples, in the absence of customization, the type of tool the target tool image604depicts may default to be the type of tool used by the operator106, or the type of tool used when the target welding technique parameters were first recorded. While referred to as a target tool image for the sake of simplicity, in some examples, the target tool image604may depict a welding consumable (e.g., electrode, filler rod, etc.) as well as, or instead of, a welding-type tool104. In some examples, the parameters of the target tool image process500may be stored in helmet memory circuitry302.

In the example ofFIG.5, the target tool image process500proceeds to block504after block502. At block504, the target tool image process500identifies a position and/or orientation for the target tool image604. In some examples, the position and/or orientation of the target tool image604may be identified/determined based on the sensor data and/or position/orientation data that was obtained and/or determined in the weld training simulation process400(e.g., at block404). In some examples, the position and/or orientation of the target tool image604may also be based on the target welding technique parameters. In some examples, the position and/or orientation of the target tool image604may be identified/determined relative to the welding helmet200, the workpiece108, the welding-type tool104, and/or some other object.

In some examples, the position and/or orientation of the target tool image604may also be based on timing and/or positional information. For example, the position and/or orientation of the target tool image604may be based on the amount of time the welding-type tool104has been activated (e.g., arc time). As another example, the position and/or orientation of the target tool image604may be based on the most recent position of the welding-type tool104along the weld path when it was activated. As another example, the position and/or orientation of the target tool image604may be based on the length (and/or other profile information) of the weld bead/path that has been produced during the welding operation so far.

In the example ofFIG.5, the target tool image process500proceeds to block506after block504. At block506, the target tool image process500determines whether the position of the actual welding-type tool104is more than a threshold distance from the position of the target tool image604. This check may be helpful to make sure that the target tool image604does not get too far away from the actual welding-type tool104, so as to minimize the detrimental impact associated with such a situation. In some examples, the precise value of the threshold distance may be stored in helmet memory circuitry and/or be editable as part of the custom configurations at block502.

In the example ofFIG.5, the target tool image process500proceeds to block508after block506if the position of the actual welding-type tool104is more than a threshold distance from the position of the target tool image604. At block508, the target tool image process500determines whether to reset the target tool image604to an earlier/later time and/or position that is closer to the position of the actual welding-type tool104. In some examples, this determination may involve notifying the operator106(or an administrator) of the disparity in positions and/or prompting for a decision whether to reset. In some examples, the target tool image process500may be configured (e.g., at block502) to default to reset (or not reset) in the absence of response to the reset prompt.

In the example ofFIG.5, the target tool image process500proceeds to block510after block508if the target tool image process500determines to reset (e.g., based on a received input or default) the target tool image604to an earlier time and/or position closer to the welding-type tool104. In some examples, the target tool image process500may provide an output (e.g., via the helmet I/O device(s)208) notifying the operator106of the reset before and/or after the reset occurs. At block510, the target tool image process500adjusts the score(s) of the weld training simulation based on the reset. In some examples, this may serve as a way to account for the negative scoring impact of failing to match the target position of the target tool image604if no reset were available. In some examples, the score(s) may be negatively impacted each time there is a reset, such as by a decrease of a portion (e.g., one third/half/full) of a letter grade or a portion (e.g., 5%, 10%, 15%, etc.) of a numerical score. In some examples, the negative impact may increase (e.g., from −5% to −15%) each reset, every other reset, or after a certain number of resets.

In the example ofFIG.5, the target tool image process500proceeds to block512after block510. At block512, the target tool image process500modifies its configuration (and/or the target welding technique parameters) to reset the target tool image604. For example, the target tool image process500may revert the target tool image604to an earlier position along the weld bead/path. As another example, the target tool image process500may revert the target tool image604to a position (and/or other target welding technique parameters) corresponding to an earlier (e.g., arc) time. In some examples, the target tool image process500may revert the target tool image604to a time or position that would place the target tool image604closest to the position of the welding-type tool104. In some examples, the target tool image process500may revert the target tool image604to a time or position that would place the target tool image604closest to a point a threshold distance away from the welding-type tool104.

In some examples, the target tool image process500may further adjust the travel speed of the target tool image604at block512. This may help the operator106better keep up with the target tool image604. In some examples, the target tool image process500may reduce the travel speed of the target tool image604(e.g., by some fraction and/or percentage). In some examples, the target tool image process500may set the travel speed of the target tool image604to match that of the welding-type tool104. In some examples, the target tool image process500may keep track of the number of resets, progressively decrease the travel speed (e.g., from ¾ speed, to ½ speed, to ⅓ speed, etc.) for each reset, up to a threshold number of resets, at which point the travel speed of the target tool image604is set to match that of the welding-type tool104. In some examples, the threshold number of resets, the speed decrease progression, and/or the placement of the target tool image604at reset may be set as part of the configuration of block502.

In the example ofFIG.5, the target tool image process500returns to block504after block502. As shown, the target tool image process500proceeds to block514after block508if the target tool image process500decides not to reset the target tool image604. As shown, the target tool image process500also proceeds to block514after block506if the position of the actual welding-type tool104is not more than a threshold distance from the position of the target tool image604.

At block506, the target tool image process500displays the target tool image604on the display screen(s)602of the welding helmet200(as shown, for example, inFIGS.6a-6d). In some examples, the target tool image process500may determine a display location for the target tool image604on the display(s)602of the welding helmet200prior to display at block514. In some examples, the determination of the display location may involve a translation based on the sensor data and/or position/orientation data relating to the welding helmet200(from block404). For example, the target tool image process500may use the known position and/or orientation of the target tool image604relative to the workpiece108, and the known position and/or orientation of the welding helmet200(and/or its display screen(s)) relative to the workpiece108, and translate this information into an appropriate display location for the target tool image604. In some examples, the target tool image process500may also determine a display location for, and/or display, a target weld bead606(and/or weld path), using the same (or a similar) process (see, e.g.,FIGS.6a-6d).

In the example ofFIG.5, the target tool image process500proceeds to block516after block514. At block516, the target tool image process500outputs one or more additional feedback effects (and/or simulation stimuli) if the actual welding technique parameters (e.g., determined at block408) are the same as (or within a threshold of) the target welding technique parameters. In some examples, the target tool image process500may output a different effect for each congruent actual/target welding technique parameter. In some examples, the target tool image process500may only output an effect if a certain number (or all) of the actual welding technique parameters are the same as (or within a threshold of) the target welding technique parameters. In some examples, one or more additional images may also be output (e.g., a smiling emoji, a check mark, fireworks, etc.).

In some examples, the additional feedback effects may indicate to the operator106that they are properly positioning and/or orienting the welding-type tool104. In some examples, the effects may include a darkening, emboldening, and/or highlighting of the (e.g., outline of the) target tool image604. For example, the (e.g., outline of the) target tool image604may change color (e.g., to green) or become animated (e.g., pulsing). As another example, the target tool image process500may change the (e.g., outline of the) target tool image604to one color (e.g., green) when the actual/target welding technique parameters are the same (or within a threshold), change to a second color (e.g., yellow) when the actual/target welding technique parameters are different (e.g., by more than the threshold), and/or change to a third color (e.g., red) when the actual/target welding technique parameters are very different (e.g., by more than second threshold). In some examples, the target tool image process500may change the transparency and/or darkness of the target tool image604in addition (or as an alternative) to the color, so that the target tool image604appears to fade away as it gets farther (e.g., more than a 1st, 2nd, 3rd, etc. threshold) away from the actual welding-type tool104. In some examples, the thresholds discussed above with respect to block516may be set and/or configured as part of block502.

In the example ofFIG.5, the target tool image process500proceeds to block518after block516. At block518, the target tool image process500determines whether it should end or not. In some examples, this determination may coordinate with the determination at block414of the weld training simulation process400. As shown, the target tool image process500ends if the target tool image process500determines it should end, and otherwise proceeds back to block504if the target tool image process500determines it should not end.

FIGS.6a-6dillustrate example depictions of a target tool image604on a display screen602of the welding helmet200. Also shown are depictions of an actual welding-type tool104, a target weld bead606, an actual weld bead608, a workpiece108, and two examples of scores614. The target weld bead606is shown as a transparent outline along the joint of the workpiece108. The target tool image604is shown as a transparent outline in the same shape as the welding-type tool104.

In some (e.g., live-weld) examples, the workpiece108and/or welding-type tool104seen inFIGS.6a-6dmay be unaltered images of a real live welding-type tool104and/or workpiece108seen through the display screen602, or captured from a helmet (e.g., camera) sensor202and displayed on the display screen602. In some (e.g., simulated weld) examples, the welding-type tool104and/or workpiece108may be enhanced and/or altered when displayed on (or seen through) the display screen602, so as to lend credibility to the simulation.

In the example ofFIG.6a, the welding operation is just beginning. The welding-type tool104is shown just beginning to weld at the start of the target weld bead606. As shown, the target tool image604is at the same position as the actual welding-type tool104(since this is the beginning). However, the target tool image604has a different orientation than the welding-type tool104, which results in different target/actual technique parameters (e.g., travel angle, work angle, aim, contact tip to work distance, etc.). As shown, the scores614have been impacted by the difference in orientation by decreasing slightly from the 100% and/or A+ starting point.

In the example ofFIG.6b, the welding operation has progressed a bit from the beginning shown inFIG.6a. As shown, the welding-type tool104has moved farther along the target weld bead606from the start. However, the target tool image604has moved much farther than the welding-type tool104, to almost the end of the target weld bead606. With the positions of the target tool image604and the actual welding-type tool104so incongruent and/or out of synch, it is difficult to tell whether the orientations are also incongruent and/or out of synch, and thus less useful as a guidance mechanism. As shown, the scores614have also been negatively impacted by the incongruity. Indeed, the positions are so different that the operator106has been presented with a reset option610(e.g., block508), which the operator106may be able to select using voice or a special input on the welding-type tool104itself, to avoid interrupting the welding operation.

In the example ofFIG.6c, the welding operation has progressed a little more fromFIG.6b, and the target tool image604has been reset to the position of the actual welding-type tool104. As shown, the scores614have been negatively impacted from the reset of the target tool image604. Nevertheless, with the two positions closer together, it is easier to tell that the orientation of the actual welding-type tool104is different than that of the target tool image604.

In the example ofFIG.6d, the welding operation has progressed a little more fromFIG.6c, and the operator106has managed to match the position and orientation of the welding-type tool104with the target tool image604. As shown, the outline of the target tool image604has been emboldened via an additional feedback effect (e.g., block516) to let the operator106know that the positions/orientations of the welding-type tool104and target tool image604are congruent and/or synchronized. An additional smiley face emoji612is also shown to emphasize the positivity of the congruency and/or synchronization, and the scores614have been similarly positively impacted. In some examples, there may be a further effect that shows the precise impact on the score (e.g., +10).

The ability of the target tool image process500to reset the position of the target tool image604to a position closer to the actual welding-type tool104may help in minimizing the risk that an operator106will overcompensate to try and catch up with the target tool image604; a practice which may be highly detrimental to the quality of the weld. Additionally, resetting the target tool image604to a position closer to the welding-type tool104may allow an operator106to better perceive and/or understand differences in orientation and/or other technique parameters. While a reset may have a negative impact on score, the reset may also increase the chance the operator106will be able to thereafter synchronize the welding-type tool104with the target tool image604, which may have a positive impact on score.

The present methods and/or systems may be realized in hardware, software, or a combination of hardware and software. The present methods and/or systems may be realized in a centralized fashion in at least one computing system, or in a distributed fashion where different elements are spread across several interconnected computing or cloud systems. Any kind of computing system or other apparatus adapted for carrying out the methods described herein is suited. 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. Another typical implementation may comprise an application specific integrated circuit or chip. Some implementations may comprise a non-transitory machine-readable (e.g., computer readable) medium (e.g., FLASH drive, optical disk, magnetic storage disk, or the like) having stored thereon one or more lines of code executable by a machine, thereby causing the machine to perform processes as described herein.

While the present method and/or system has been described with reference to certain implementations, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present method and/or system. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present method and/or system not be limited to the particular implementations disclosed, but that the present method and/or system will include all implementations falling within the scope of the appended claims.

As used herein, “and/or” means any one or more of the items in the list joined by “and/or”. As an example, “x and/or y” means any element of the three-element set {(x), (y), (x, y)}. In other words, “x and/or y” means “one or both of x and y”. As another example, “x, y, and/or z” means any element of the seven-element set {(x), (y), (z), (x, y), (x, z), (y, z), (x, y, z)}. In other words, “x, y and/or z” means “one or more of x, y and z”.

As utilized herein, the terms “e.g.,” and “for example” set off lists of one or more non-limiting examples, instances, or illustrations.

As used herein, the terms “coupled,” “coupled to,” and “coupled with,” each mean a structural and/or electrical connection, whether attached, affixed, connected, joined, fastened, linked, and/or otherwise secured. As used herein, the term “attach” means to affix, couple, connect, join, fasten, link, and/or otherwise secure. As used herein, the term “connect” means to attach, affix, couple, join, fasten, link, and/or otherwise secure.

As used herein the terms “circuits” and “circuitry” refer to physical electronic components (i.e., hardware) and any software and/or firmware (“code”) which may configure the hardware, be executed by the hardware, and or otherwise be associated with the hardware. As used herein, for example, a particular processor and memory may comprise a first “circuit” when executing a first one or more lines of code and may comprise a second “circuit” when executing a second one or more lines of code. As utilized herein, circuitry is “operable” and/or “configured” to perform a function whenever the circuitry comprises the necessary hardware and/or code (if any is necessary) to perform the function, regardless of whether performance of the function is disabled or enabled (e.g., by a user-configurable setting, factory trim, etc.).

As used herein, a control circuit may include digital and/or analog circuitry, discrete and/or integrated circuitry, microprocessors, DSPs, etc., software, hardware and/or firmware, located on one or more boards, that form part or all of a controller, and/or are used to control a welding process, and/or a device such as a power source or wire feeder.

As used herein, the term “processor” means processing devices, apparatus, programs, circuits, components, systems, and subsystems, whether implemented in hardware, tangibly embodied software, or both, and whether or not it is programmable. The term “processor” as used herein includes, but is not limited to, one or more computing devices, hardwired circuits, signal-modifying devices and systems, devices and machines for controlling systems, central processing units, programmable devices and systems, field-programmable gate arrays, application-specific integrated circuits, systems on a chip, systems comprising discrete elements and/or circuits, state machines, virtual machines, data processors, processing facilities, and combinations of any of the foregoing. The processor may be, for example, any type of general purpose microprocessor or microcontroller, a digital signal processing (DSP) processor, an application-specific integrated circuit (ASIC), a graphic processing unit (GPU), a reduced instruction set computer (RISC) processor with an advanced RISC machine (ARM) core, etc. The processor may be coupled to, and/or integrated with a memory device.

As used, herein, the term “memory” and/or “memory device” means computer hardware or circuitry to store information for use by a processor and/or other digital device. The memory and/or memory device can be any suitable type of computer memory or any other type of electronic storage medium, such as, for example, read-only memory (ROM), random access memory (RAM), cache memory, compact disc read-only memory (CDROM), electro-optical memory, magneto-optical memory, programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically-erasable programmable read-only memory (EEPROM), a computer-readable medium, or the like. Memory can include, for example, a non-transitory memory, a non-transitory processor readable medium, a non-transitory computer readable medium, non-volatile memory, dynamic RAM (DRAM), volatile memory, ferroelectric RAM (FRAM), first-in-first-out (FIFO) memory, last-in-first-out (LIFO) memory, stack memory, non-volatile RAM (NVRAM), static RAM (SRAM), a cache, a buffer, a semiconductor memory, a magnetic memory, an optical memory, a flash memory, a flash card, a compact flash card, memory cards, secure digital memory cards, a microcard, a minicard, an expansion card, a smart card, a memory stick, a multimedia card, a picture card, flash storage, a subscriber identity module (SIM) card, a hard drive (HDD), a solid state drive (SSD), etc. The memory can be configured to store code, instructions, applications, software, firmware and/or data, and may be external, internal, or both with respect to the processor.

The term “power” is used throughout this specification for convenience, but also includes related measures such as energy, current, voltage, and enthalpy. For example, controlling “power” may involve controlling voltage, current, energy, and/or enthalpy, and/or controlling based on “power” may involve controlling based on voltage, current, energy, and/or enthalpy.

As used herein, welding-type power refers to power suitable for welding, cladding, brazing, plasma cutting, induction heating, carbon arc cutting, and/or hot wire welding/preheating (including laser welding and laser cladding), carbon arc cutting or gouging, and/or resistive preheating.

As used herein, a welding-type power supply and/or power source refers to any device capable of, when power is applied thereto, supplying welding, cladding, brazing, plasma cutting, induction heating, laser (including laser welding, laser hybrid, and laser cladding), carbon arc cutting or gouging, and/or resistive preheating, including but not limited to transformer-rectifiers, inverters, converters, resonant power supplies, quasi-resonant power supplies, switch-mode power supplies, etc., as well as control circuitry and other ancillary circuitry associated therewith.