CN104221069B - Virtual welding system - Google Patents

Abstract

This printed instructions uses examples to the open present invention, including best mode, and those of ordinary skill in the art is carried out the present invention, including makes and use any device or system and any method being incorporated to of execution.The scope that the present invention can patent is defined by the claims, and the other embodiment that can be expected including those skilled in the art.Such other embodiment is intended in the range of claims, if they have the structural element of the written language for being not different from claim, or if they are included with the written language of claims without substantive different equivalent structural elements.

Description

Virtual welding system

Cross-Reference to Related Applications：The application is that the U.S. patent application serial number submitted on July 10th, 2009 is The part continuation application of No.12/501,257.

Background

Technical field

This disclosure relates to virtual reality emulation, and more particularly, to for the reality environment in emulation or increasing The system and method that arc welding training is provided under strong actual environment.

Technical discussion

How study carries out arc-welding traditionally needs guidance, training and the exercise of many hours.In the presence of can be learnt Many different types of arc-welding and arc welding process.Student is usually using real welding system and in real metal works It is upper to perform welding operation to learn welding.The training of such real world can take rare welding resource and exhaust limited Welding material.However, having become more popular using the training idea of welding simulation recently.Some welding simulations are via individual Computer and/or via internet canbe used on line.But, currently known welding simulation is often limited to its training emphasis (focus)。

For example, emphasis to be put in some welding simulations the training only for " muscle memory ", this only trains weldering Connect how student grips and positioning welding instrument.Other welding simulations are come in limited and usually from unpractiaca mode Emphasis is put in the visual effect and audio frequency effect for showing welding procedure, it is real world welding that the mode is not provided to student Height characterize expectation feedback.Exactly this actual feedback guiding student carries out welding of the necessary regulation to complete. By check electric arc and/or molten bath (puddle) rather than only learnt by muscle memory welding.

By by such approach with such as the embodiment of the present invention for being illustrated in the application remaining content referring to the drawings It is compared, those skilled in the art will be clear that other limitations and the shortcoming of approach that is conventional, traditional and having pointed out.

The content of the invention

In one aspect of the invention, virtual welding system includes that subsystem and quilt based on programmable processor can be grasped It is connected to the spatial pursuit device of the subsystem based on programmable processor with making.Simulation soldering appliance is used, the simulation weldering Bonding tool can spatially be followed the trail of by spatial pursuit device.Simulation soldering appliance includes one or more adapters, wherein often Individual adapter emulates the real world outward appearance of a specific weld type (weld type).Pedestal is removably coupled to one Or more each in adapter.

In another aspect of the present invention, simulation soldering appliance is used in virtual welding system.It is one or more Individual adapter is used, and wherein each adapter emulates the physical features of a specific weld type.Pedestal is removedly coupled To each in one or more adapters, real-time space bit of the pedestal identification simulation soldering appliance relative to reference position Put.

Further, simulation soldering appliance is used in virtual welding system using a kind of method.First adapter quilt Pedestal is removably attached to, the first adapter is associated with the first welds types.First adapter is removed from pedestal, wherein Second adapter is removably connectable to pedestal, and the second adapter is associated with the second welds types.Various type of adapters With the use of the easy-to-use portable virtual welding system of common base, the portable virtual welding system can be basic (mobile) position of upper any movement is used.

This brief description is provided to introduce in simplified form the selection of design, and the design is further retouched in this paper State.This brief description is not intended to limit the key feature or essential feature of theme required for protection, is also not intended to be used to limit Make the scope of theme required for protection.In addition, theme required for protection is not limited to solve any portion for being documented in the disclosure The implementation of any or all shortcoming in point.A further embodiment of the present invention, aspect and advantage are from specification, accompanying drawing Be educible in claims.

Brief Description Of Drawings

Refer to the attached drawing, wherein as in greater detail, specific embodiment and the present invention enter one in specification below The advantage of step is illustrated, in the accompanying drawings：

Fig. 1 is the block diagram of the virtual welding system for including the interchangeable simulation soldering appliance with pedestal, the base Seat may be coupled to each in multiple adapters；

Fig. 2 is an implementation of system set forth in fig. 1；

Fig. 3 is the exemplary lateral plane figure of the GMAW adapters for being removably coupled to pedestal；

Fig. 4 is the exemplary perspective view of the manual welding tool adapter for being removably coupled to pedestal；

Fig. 5 is the exemplary perspective view of combustible gas (oxyfuel) adapter for being removably coupled to pedestal；

Fig. 6 can be the perspective view of the pedestal being connected with Fig. 3, Fig. 4 and adapter set forth in fig. 5；

Fig. 7 is the broken-open perspective view of the pedestal described in Fig. 6；

Fig. 8 A are the perspective views of the simulation soldering appliance for assembling for including pedestal and manual welding tool adapter；

Fig. 8 B are the perspective views for including the simulation soldering appliance of the decomposition of pedestal and manual welding tool adapter；

Fig. 9 is the perspective view of support for being used to be maintained at welded specimen and magnet in known locus；

Figure 10 is to illustrate that welded specimen and magnet are maintained at into known space with interchangeable, compact position The perspective view of the support of the Fig. 9 in position；

Figure 11 is illustrated including being regarded the component of suite of part that transports and operate mobile virtual welding system Figure；

Figure 12 is the preceding elevational view for illustrating the user interface communicated with virtual welding system；

Figure 13 is the preceding elevational view for illustrating the interchangeable user interface communicated with virtual welding system；

Figure 14 can be the perspective view of the helmet used in virtual welding system by user；

Figure 15 is mounted in the backward perspective view of the FMDD in the welding helmet, and the welding helmet is in virtual welding system Used；

Figure 16 is the example of the subsystem block diagram of the subsystem (PPS) based on programmable processor shown in Fig. 1 The flow chart of property embodiment；

Figure 17 is the flow chart of the exemplary of the block diagram of the GPU of the PPS of Figure 16；

Figure 18 is the flow chart of the exemplary of the functional-block diagram of the system of Fig. 1；

Figure 19 is the flow chart of the embodiment of the training method of the Virtual Reality Training System for using Fig. 1；

Figure 20 is that embodiment of the invention shows that welding pixel (welding pixel) (weldering is first (wexel)) is moved Put the front view of figure (displacement map)；

Figure 21 is the sample space (coupon space) of the flat welded specimen for emulating in the system of fig. 1 and corresponding The perspective view in x-y weld seams space (weld space)；

Figure 22 is the turning and corresponding T-S weld seams sky of turning (T connector) welded specimen for emulating in the system of fig. 1 Between perspective view；

Figure 23 is the pipe sample of the pipe welded specimen for emulating in the system of fig. 1 and the perspective in corresponding T-S weld seams space Figure；And

Figure 24 A-24C be the system for illustrating Fig. 1 two-track put molten bath concept front view.

Describe in detail

Referring now to accompanying drawing, some embodiments of the invention or implementation are described below in association with accompanying drawing, its In similar reference number in the whole text in be used to refer to similar element.The present embodiment refers to virtual welding system, institute Virtual welding system is stated using simulation soldering appliance, the simulation soldering appliance has pedestal to receive multiple adapters, wherein Each adapter emulates different welds types.Adapter can have common size, be allowed and pedestal with when being expected to Seamless removable coupling.Although being hereinafter illustrated and retouching under the background of various example virtual welding systems State, the invention is not restricted to the embodiment of illustrated explanation.

More specifically, the embodiment of this theme is related to virtual reality welding system, the virtual reality welding system bag Include the subsystem based on programmable processor, be operably connected to the spatial pursuit of the subsystem based on programmable processor Device, at least one for can spatially being followed the trail of by spatial pursuit device simulation soldering appliance, and it is operably connected to base In at least one display device of the subsystem of programmable processor.In order to provide additional flexibility, soldering appliance bag is simulated Pedestal and multiple adapters are included, wherein each adapter is used to the different welds types of emulation.For example, the first adapter can be with Emulation GMAW welding, the second adapter can emulate SMAW welding, and the 3rd adapter can emulate combustible gas welding etc..Can replace Change ground or additionally, instrument can be used to simulation slicing device, such as combustible gas or other cutting torches.Adapter can all have Standardized size provides portable use, and compact support is used to keep welded specimen in space, to be welded with simulation Bonding tool is used together.By this way, system can emulate various welds types in virtual reality space, wherein welding is molten Pond has the flowing of motlten metal in real time property corresponding with every kind of welds types and heat dissipation characteristics.

When displayed, the real-time motlten metal flowing property and heat dissipation characteristics offer Real time visible in the molten bath of the emulation are anti- Fed the user for simulating soldering appliance, it is allowed to which the user is adjusted in real time in response to the real-time visual feedback Or keep welding skill and technique.Shown molten bath be welding skill and technique and selected welding procedure and parameter based on user and incite somebody to action The sign in the molten bath that can be formed in real world.By watching molten bath (such as shape, color, slag, size), user Its skill and technique can be corrected to carry out good welding and determine the welds types being done.The shape in the molten bath is in response to simulation The motion of soldering appliance.As it is used herein, term " real-time " mean with user under the welding scene of real world The identical mode that will be perceived and experience, perceives and experiences in time in the environment of emulation.Additionally, the molten bath is in response to bag Include the effect of the physical environment of gravity, it is allowed to which user is with various positions (including level, vertical and overhead welding (overhead Welding)) and various pipe soldering angles realistically practise welding.

Referring now to accompanying drawing, the content shown in it is that, in order to illustrate the purpose of exemplary, Fig. 1 is The system block diagram of system 100, system 100 provides arc welding training under real-time virtual actual environment.Virtual welding system 100 is wrapped Include the subsystem (PPS) 110 based on programmable processor.Virtual welding system 100 further includes to be operably connected to PPS 110 spatial pursuit device (ST) 120.Virtual welding system 100 also includes that the physical weld for being operably connected to PPS 110 makes User interface (WUI) 130, and it is operably connected to the display device for being placed on face of PPS 110 and ST 120 (FMDD)140.Virtual welding system 100 also includes being operably connected to observer's display device (ODD) 150 of PPS 110. Virtual welding system 100 also includes being operably connected at least one simulation soldering appliance (MWT) of ST 120 and PPS 110 160.Virtual welding system 100 also includes support 170, and at least one welded specimen that can be attached to support 170 (WC)180.MWT 160 can include being coupled to the pedestal (not shown) of one or more adapter (not shown), to emulate Various different welds types.

Fig. 2 illustrates system 200, and the system 200 illustrates a kind of realization side of system set forth in fig. 1 Formula.FMDD 140 is utilized for user and shows the virtual environment for emulating visually to experience welding.In order to provide this emulation The accurate presentation (rendering) of environment, FMDD 140 communicates with receiving and send in system 200 with PPS 110 The data of the locus of FMDD 140.Can be using known wiredly and/or wirelessly technology (including bluetooth, wireless ethernet Etc.) facilitate communication.Be to obtain spatial position data, one or more sensors 142 be arranged in FMDD 140 and/ Or neighbouring FMDD 140.In turn, sensor 142 is assessed relative to the specific benchmark (such as magnet 172) in system 200 Locus.Magnet 172 may be located at known datum mark and be arranged to it is predetermined relative to the one of welded specimen 180 away from From 178.This predetermined distance 178 can be by using the shape factor, template that are associated with support 170 or pre-configured knot Structure keeps.Therefore, sensor 142 can inherently provide FMDD 140 relative to support 170 relative to the movement of magnet 172 The position data of interior welded specimen 180.Sensor 142 can wirelessly communicate with recognizing the position relative to magnet, utilize Known communication protocol is kept strokes with user updating FMDD 140 in real time.

System 200 also includes that MWT 160, the MWT 160 include being coupled to the adapter 162 of pedestal 166.It will be understood that , adapter 162 is only to represent in multiple adapters, and each adapter emulates specific welds types.Adapter 162 are removably coupled to pedestal 166, to allow an adapter as the removal and displacement of another replacement.It is removable The coupling for removing can be completed using lug, recess, sliding block, button etc., to allow user to press, reverse or with its other party Formula mechanically changes adapter 162 and/or pedestal 166.In order to accurately emulate specific welds types, each adapter 162 It is sized to characterize the equality unit of real world, the equality unit will be used to carry out actual welding operation.One The specific adapter of denier is coupled to pedestal, user can input adapter in use type, to allow PPS to load simultaneously And perform appropriate instruction set associated there.By this way, accurately present corresponding with each type of adapter is shown Show on FMDD 140.

One or more sensors 168 can be arranged in pedestal 166 or neighbouring pedestal 166.With FMDD 140 1 Sample, sensor 168 can wirelessly determine the locus on the magnet 172 on support 170.By this way, with The adapter 162 and pedestal 166 of combination are inherently associated with known position and space relative to magnet 172, because adaptation The size of both device 162 and pedestal 166 is predetermined.It is properly calibrated to receive each to fit in order to ensure system 200 Orchestration 162, user can be connected with (such as via WUI 130) with the interfaces of PPS 110, to indicate a specific adapter current In use.Once forming such instruction, PPS 110 can be wrapped from the retrieval table of memory 112, the memory 112 Containing rule set, so that the environment of emulation to be correctly presented when user is experienced by FMDD 140.

In embodiments, PPS 110 is the computer for being operable to the architecture disclosed in execution.In order to this hair Bright various aspects provide additional background, succinct, the general description that the computing environment for being intended to provide suitable is discussed below, Various aspects of the invention can be implemented in the suitable computing environment.The finger that PPS 110 can be can perform using computer Order, the instruction can run on one or more platform computer, the instruction combine other program modules and/or as hardware with The combination of software is realized.Usually, program module including routine, program, part and data structure etc., hold by described program module The specific task of row realizes specific abstract data type.For example, the executable instruction of such program and computer can be with Processed using various apparatus control examples via robot.

And, it will be appreciated by persons skilled in the art that inventive method can be implemented with other computer system configurations, bag Include uniprocessor or multiprocessor computer system, microcomputer, mainframe computer and personal computer, hand-held calculate dress Put, based on microprocessor or programmable consumption electronic products etc., each of which can be operatively coupled To one or more associated devices.The aspect for illustrating of the invention can also be in distributed computing environment by reality Apply, in the distributed computing environment, specific task is performed by the remote processing device being linked by communication network. In distributed computing environment, program module may be located at both local and remote memorizer memory devices.

PPS 110 can realize including the various aspects of the invention of computer using exemplary environments, wherein in order to logical The letter purpose computer includes processor 114, memory 112 and system bus.System bus (including but does not limit system unit In memory 112) it is coupled to processor 114.Processor 114 can be any various commercially available processors.It is double micro- Processor and other multiprocessor architectures can also be used as processor 114.

System bus can be any one of some types of bus structure, including be obtained using any species is commercial The memory bus or storage control, peripheral bus and local bus of the bus architecture for obtaining.Memory 112 can include Read-only storage (ROM) and random access memory (RAM).Basic input/output (BIOS) is stored in ROM, the base This input/output (BIOS) includes basic routine, and letter is transmitted between the element that the basic routine contributes in PPS 110 Breath, such as in startup stage.

PPS 110 can also include hard disk drive, disc driver and CD drive, and the disc driver is for example From moveable magnetic disc read or write-in moveable magnetic disc, the CD drive for example be used for read CO-ROM disks or from other Optical medium reads or writes other optical mediums.PPS 110 can include at least certain form of computer-readable medium.Computer Computer-readable recording medium can be any obtainable medium that can be accessed by a computer.Rather than limitation by way of embodiment, meter Calculation machine computer-readable recording medium can include computer storage media and communication media.Computer storage media is included in any method or skill Art is realized coming for the volatile of information (for example, computer-readable instruction, data structure, program module or other data) storage With non-volatile, moveable and non-moveable medium.Computer storage media include, but not limited to RAM, ROM, EEPROM, flash memory or other memory technologies, CD-ROM, digital versatile disc (DVD) or other magnetic storages, Huo Zheke With the other media for being used to store information needed and can be accessed by PPS 110.

Communication media typically comprises computer-readable instruction, data structure, program module or believes in the data modulated Other data (such as carrier wave or other transmission mechanisms) in number, and including any information delivery media.Term " is modulated Data-signal " is meant with its characteristic being set or changed for coding information in the signal in this way The signal of individual or more.Rather than limitation by way of embodiment, communication media include wire medium such as wired network or Direct wired connection, and (acoustic) of wireless medium such as sound, RF, infrared medium and other wireless mediums.Appoint Combination above what should also be included within the scope of computer readable media.

A large amount of program modules can be stored in driver and RAM, including operating system, one or more application journeys Sequence, other program modules and routine data.Can be any a large amount of commercially available operations in the operating system of PPS 110 System.

Additionally, user can will be ordered and information input computer by keyboard and indicator device (such as mouse).Its His input unit can include microphone, IR remote controls, trace ball, pen-based input device, control-rod, cribbage-board, digitizing tablet, Satellite disk and scanner etc..These or other input unit is generally connected by the serial port interface for being coupled to system bus To processor, but can be to be connected by other interfaces, such as parallel port, game port, USB (" USB "), IR Interface and/or various wireless technologys.The other types of monitor (not shown) or display device (can also for example be regarded via interface Frequency adapter) it is connected to system bus.Visualization output can also by remotely show procotol (such as RDP, VNC and X-window system etc.) complete.Except visualization is exported, computer typically comprises other peripheral output devices, for example, raises Sound device and printer etc..

Display (such as ODD 150 and WUI 130) can be used together to present electronically from processor with PPS 110 The data of reception.For example, display can be the monitor of LCD, plasma and CRT etc., the monitor is electronically presented number According to.Alternatively or additionally, display can be presented with hard Format Painter (such as printer, facsimile machine and plotter etc.) and received Data.Display can be presented data and can be via any wireless or hardwire protocol and/or standard with any color Data are received from PPS 110.In embodiments, WUI 130 is touch-screen, and the touch-screen allows user and PPS 110 Interface connects, for example, check the welding data from one or more emulation before.User can also be by various data Example manipulates to recognize the information on particular analysis (such as welding quality), wherein such data are for one or more Benchmark be evaluated, for store or other compare.

Computer can use one or more remote computers (such as remote computer (one or more)) The network environment for logically and/or physically connecting in operate.Remote computer (one or more) can be work station, server Computer, router, personal computer, the microprocessor based on converter tools, equity (peer) device or common network node, And typically comprise relative to computer describe part in it is many or all.The logic connection of description includes LAN And wide area network (WAN) (LAN).Such networked environment office, the computer network of enterprise-wide, intranet and Internet is common.

When LAN networking environment is used in, computer is connected to local network by network interface or adapter.When by with In WAN network environment, computer typically comprises modem, or is connected to the communication server on LAN, or Person has other devices for setting up communication on WAN (such as internet).In a network environment, on computer description Program module or part therein can be stored in remote memory storage device.It will be appreciated that networking described herein Connection is exemplary and can be used in other devices that intercomputer sets up communication linkage.

Fig. 3-Fig. 5 illustrates the nonrestrictive exemplary of adapter 162, and wherein Fig. 3 is shown as The adapter 162 of GMAW welding guns 300；Fig. 4 is shown as the adapter 162 of manual welding instrument 400；And Fig. 5 is shown as The adapter 162 of flammable gas torch 500.Although being described as having multiple different parts in this paper adapters, it will be appreciated that, The single and multipart embodiment of adapter is considered within the scope of the invention.It is tuning firstly to Fig. 3, GMAW welding guns 300 Including mouth 310, the mouth 310 is connected to interface (interface) 318 via pipe 312.Welding gun 300 can have with such as true GMAW welding guns used in the application of the real world substantially the same weight and size.The size of each part in welding gun 300 Can be known value, the size can be used to calibrate weldering in the case of in view of welded specimen 180 and magnet 172 Rifle.Interface 318 can include one or more mechanical features to allow adapter 300 to the removable coupling of pedestal.

Fig. 4 illustrates the manual welding instrument 400 welded for plate weld and pipe, and including clamper 422 and imitates Genuine stick electrode 410.In embodiments, the stick electrode 410 of emulation can include haptic type (tactilely) resistance end End, occurs during root run (root pass) welding process during the pipe of such as real world is welded or welds to emulate Connect resistance feedback during flat board.If excessively away from the stick electrode 162 of root of weld movable simulation, user is possible to user Relatively low resistance is felt or perceives, so as to obtain the feedback for adjusting or keeping current welding procedure.Interface 418 allows hand Removable coupling of the work soldering appliance 400 to pedestal.

Fig. 5 illustrates the flammable airway adaptor 500 including mouth 510 and interface 518, and the interface 518 allows combustible gas Removable coupling of the adapter 500 to pedestal.In this embodiment, interface 518 includes neck ring 522, the neck ring 522 Can be fixed around the diameter of pedestal.Button 520 can include that protuberance or other features are come and the complementary characteristic on pedestal (such as recess) is mechanically connected.By this way, whether adapter 500 can be pressed according to button or otherwise grasp It is vertical and " lock " to pedestal.In other embodiments, flammable airway adaptor can be used to characterize cutting torch, the cutting torch quilt For cutting metal object.In this embodiment, cutting torch is displayed in virtual welding system as it is in true generation Operated in the application on boundary the same.For example, PPS 110 can load and perform code, the code representative cutting torch application, without It is welding torch.

According to a further embodiment of the present invention, other simulation soldering appliances are also possible, including are for example emulated hand-held The MWT of semi-automatic gun, the MWT have be sent to by the welding wire welding rod of the rifle.In addition, other spies of the invention Determine embodiment, even if instrument is not used in and actually creates real electric arc in virtual welding system 100, real welding Instrument can serve as MWT 160 preferably to emulate the actual sensation of the instrument in user's hand.Furthermore, can provide imitative Genuine milling tools (grinding tool) is used for being used under the polishing pattern of the emulation of virtual welding system 100.It is similar Ground, can provide the cutting tool of emulation, for being used under the cut mode of the emulation of virtual welding system 100.In addition, can To provide gas-tungsten arc welding (GTAW) welding torch or filler material of emulation, for making in virtual welding system 100 With.

Fig. 6 illustrates pedestal 600, and the pedestal 600 is used to interface and connects one or more adapters, for example GMAW welding guns 300, manual welding instrument 400 and flammable airway adaptor 500.Pedestal 600 includes body 620, and the body 620 can To accommodate one or more electronic units, such as sensor 168 described herein.In embodiments, body 620 is by two Individual half portion is grouped into, and described two half parts are maintained at one via fastener 640 (e.g., such as screw, bolt, rivet etc.) Rise.Rigid line cable 630 extends so as to the communication of niche seat 600 and PPS 110 from body 620.

Abutment (landing) 614 and be arranged on described being abutted against that interface 610 is included on the opposite side of interface 610 Recess 616 in portion.Abutment and recess combination can be used as complementary portion in the interface of example adaptor 300,400,500 The removable interlocking structure of part.However, substantially any mechanical interface is considered to facilitate adapter having to pedestal 600 Effect is removed and replaced.The button 618 being arranged in protuberance 636 may be used to indicate that and be used when button 618 is pressed Person is in effective bond pattern.At least with reference to adapter 400, complementary shape factor can be included in adapter to coordinate Used as the set on button 618, wherein user can press button via the shape factor feature on adapter.For this Purpose, adapter shape factor can give user for weldering with the triggering device in the simulating realistic world or similar device Connect the look and feel of the real world of operation.

Fig. 7 is the broken-open perspective view of pedestal 600, to represent the sensor 652 being arranged in pedestal 600.Sensor 652 is passed through Communicated from one or more different parts (such as PPS 110) by cable 654, and pedestal is arranged on predetermined position In 600 and it is maintained at appropriate location via fastener 658.Impeller 672 is that pedestal 600 provides structure branch through body 620 Support.In embodiments, sensor 652 is using known non-contact technology, such as capacitance sensor, piezoelectric transducer, vortex Sensor, inductance sensor, sonac, hall effect sensor and/or infrared proximity sensor technology.Such skill Art can be used for other sensors described herein, including the sensor for being used in the helmet 146 and pedestal 166 respectively 142 and 168.Fig. 8 illustrates simulation soldering appliance 800, and wherein adapter 400 is removably coupled to pedestal 600, is used for Used in virtual welding system 100.

Fig. 9 illustrates support 700, and the support 700 is used in space be disposed relative to welded specimen 758 One known location of magnet 710.Support 700 includes the arm 714 and base 724 that are coupled via column 722.In embodiment party In case, column 722 is removably coupled base 724, to allow support 700 to resolve into single part for packing and transporting Send.Additionally, base 724 and column 722 can have one or more architectural features (such as impeller), the architectural feature is Such part increases structural support and keeps relatively low weight simultaneously.Plunger 732 can be opened from arm 714, to allow Removal and displacement of the sample on support 700 on repeatable locus.

The size and welded specimen 758 of arm 714 are all relative to the position of the magnet 710 being arranged in abutment 738 Know, the simulation soldering appliance of neighbouring welded specimen 758 there will be known and repeatable output, so that for user carries For appropriate real-time virtual welding surroundings.Pin 762,764 can remove to allow arm 714 as described in Figure 10 from support 700 Pivoted around pin 764.In this embodiment, pin 762 is removed, so as to allow arm 714 around pin 764 from hole 766 in 768 Rotate to the second place.By this way, user can weld in substantial amounts of plane (such as horizontal and vertical) emulation To know from experience the nuance being associated with each.It is worth noting that, the design of support 700 ensures magnet 710 relative to welding The locus of sample 758 is maintained at any one position in two positions, is used for providing accurate repeatable result The establishment and display of real-time welding surroundings emulation.

Figure 11 illustrates Portable welding suite, and the Portable welding suite can be from a position to another Easily transported individual position.Suite can be fabricated in any position substantially adjacent to power supply, and the power supply can With including battery, A/C or other power supplys.Container 810 can be essentially formed to welding robot housing, wherein internal including many Individual shell, platform and other storage areas come accommodate WUI 130, support 700, simulation soldering appliance 800 and the helmet 900.Container can To further include wheel, to facilitate effective transport of container 810.

Figure 12 illustrates exemplary user interface 830, and the user interface 830 shows multiple with typical welding The associated module of system.Interface 830 includes selector 832, to recognize the adapter for the welding system for emulating Type.Temperature measuring equipment 836, current measuring device 838 and voltage measuring apparatus 842 can be to use during welding operation Person provides Real-time Feedback.Similarly, 854 and 856 display additional informations and allow the user to be input into change described information. Figure 13 shows the interchangeable user interface 860 at simulating realistic world hardware welding system interface.In embodiments, use Person can provide input using Touch Screen or other peripheral input methods described herein for display 860.

Figure 14 and Figure 15 illustrate the helmet 900 worn by user when virtual welding system is operated.Figure 14 shows The forward perspective view of the helmet 900, the helmet 900 can be in real-world application also, as described above, quilt It is adapted as including the actual welding helmet of FMDD.By this way, user can wear the welding helmet, as they are true The same under the scene in the world, wherein virtual environment is shown to user in real time via FMDD 140.Figure 15 is illustrated and collected Into the exemplary of the FMDD 140 to the welding helmet 900.FMDD 140 is via non-wireless means or wirelessly It is operably connected to PPS 110 and ST 120.Various embodiments of the invention, the sensor 142 of ST 120 can be with It is attached to FMD 140 or is attached to the welding helmet 900, it is allowed to which FMDD 140 and/or the welding helmet 900 is relative to by ST The reference of the 120 3d space frameworks for creating is tracked.

Figure 16 illustrates the subsystem (PPS) 110 based on programmable processor of the virtual welding system 100 of Fig. 1 The exemplary of subsystem block diagram.Embodiment of the invention, PPS 110 includes CPU (CPU) 111 and one or more GPUs (GPU) 115.In one embodiment, a GPU 115 is used to Monoscopic vision is provided on FMDD 140.In another embodiment, two GPU115 are programmed to above be carried in FMDD 140 For stereoscopic vision.In any case, embodiment of the invention, user is checked with the flowing of real-time motlten metal Property and heat absorption and the molten bath (being called weldpool (weld pool)) of heat dissipation characteristics virtual reality emulation.

Figure 17 illustrates the exemplary embodiment party of the block diagram of the GPU (GPU) 115 of the PPS 110 of Figure 10 Case.Each GPU 115 supports the realization of data parallel algorithm.Embodiment of the invention, each GPU 115 is provided can Two the two of virtual reality view video frequency outputs 118 and 119 are provided.Two in video frequency output can be transferred into FMDD 140, the visual field of welder is given, and the 3rd video frequency output can for example be routed to ODD 150, provide the visual field of welder Or some other visuals field.Remaining 4th video frequency output can for example be routed to projecting apparatus.Two GPU 115 perform phase Same weld physics are calculated, but reality environment can be presented from the identical or different visual field.GPU 115 includes unified calculation Equipment framework (CUDA) 116 and tinter 117.CUDA 116 is that software developer can be used by professional standard programming language The computing engines of GPU 115.CUDA 116 includes parallel core and be used to run the thing of molten bath emulation described herein Reason model.CPU 111 provides the CUDA 116 in welding input data to GPU 115 in real time.Tinter 117 is responsible for drawing and is answered With whole emulated interfaces.Welding bead and molten bath picture are driven by the state of the first dislocation figure of weldering described later herein.According to this The embodiment of invention, physical model is run and is updated with the speed of about 30 times per second.

Figure 18 illustrates the exemplary of the functional-block diagram of the virtual welding system 100 of Fig. 1.Such as Figure 12 institutes The various functions block of the virtual welding system 100 for showing is most of to be realized via the software instruction and module that operate on PPS 110. The various functions block of virtual welding system 100 include physical interface 1201, welding torch and fixture model 1202, environmental model 1203, Sound-content function 1204, welding sound 1205, support/tables' model 1206, inside structure function 1207, calibration function 1208th, welded specimen model 1210, weld physics 1211, internal physical adjust instrument (adjusting apparatus (tweaker)) 1212, figure Shape user interface function 1213, drawing function 1214, student's function of reporting 1215, present device 1216, welding bead present 1217, 3D textures 1218, visual cues function 1219, scoring and tolerance function 1220, tolerance editing machine 1221 and special-effect 1222。

Inside structure function 1207 provides the software computing of the greater degree of the treatment of virtual welding system 100, including example As load document, holding information, manage thread, enable physical model and triggering menu.Embodiment of the invention, it is interior Portion's form and function 1207 is operated on CPU 111.For PPS 110 it is specific real-time input include arc position, welding torch position, FMDD or helmet position, welding gun enable/state (Yes/No) that produces of closed mode and contact.

Graphical user interface function 1213 allows user to use the behaviour of physics user interface 130 by ODD 150 Vertical pole 132 sets welding scene.Embodiment of the invention, welding the setting of scene includes selection language, and input is used Person's name, selection practice plate (i.e. welded specimen), selection welding procedure (such as FCAW, GMAW, SMAW) and associated axial direction Injection, pulse or short arc method, select gas type and flow rate, select the type (such as 6010 or 7018) of stick electrode, with And the type (such as self-shield, gas shield) of selection flux-cored wires.The setting for welding scene also includes selection support 170 tables' height, arm height, arm position and arm are rotated.The setting for welding scene further includes that Environment is (such as empty Intend realistic space in background environment), set feed rate of welding wire, set voltage level, set amperage, selection polarity and Enable or close particular visual prompting.

During the welding scene of emulation, drawing function 1214 collects user's performance parameter and shows the user Parameter is provided to graphical user interface function 1213, to be shown in a graphic format (such as on ODD 150).From ST 120 tracked information feed-in drawing function 1214.Drawing function 1214 include simple analysis module (SAM) and shake (whip)/ Swing (weave) analysis module (WWAM).SAM is used by the data analysis for comparing welding parameter He be stored in welding bead form Person's welding parameter, user's welding parameter includes welding travel angle, gait of march, soldering angle, position and end To workpiece gap distance.WWAM analyzes user's jitter parameter, including coin shape body interval, shaky time and molten bath time. WWAM also analyzes user and swings parameter, including swing width, swing interval and swing timing.Be input into for original by SAM and WWAM Data (such as position and directional data) are construed to the data that functionally can be used, for being drawn.For by SAM and Each parameter of WWAM analyses, tolerance window is by parameter limitation (parameter limits) around use tolerance editing machine 1221 The optimal or ideal set value of welding bead form is input into limit, and scoring and tolerance function 1220 are performed.

Tolerance editing machine 1221 includes estimating that meter is measured in materials'use, electrically use and the welding of weld interval (weldometer).Additionally, when special parameter exceeds tolerance, it may occur however that weld discontinuous (i.e. weld defect).Any weldering Incoherent state is connect to be processed by drawing function 1214 and presented in a graphic format via graphical user interface function 1213.This The discontinuous welding bead arrangement including unsuitable weld seam size, not good of welding of sample, excessively recessed welding bead, evagination, undercut, many Hole, excessively lack of penetration, slag inclusion (slag entrapment), filling, burn-through and excessively splashing.Embodiment party of the invention Case, incoherent grade or amount is optimal depending on specific user's parameter drift-out or degree of preferable set point.

Different parameter limitations can be directed to different classes of user (for example weld beginner, welding expert and People in transaction exhibition) it is pre-defined.Scoring and tolerance function 1220 are approached for special parameter most according to user The degree of good (ideal) value and according to appear in welding in discontinuous or defect grade provide digit score.It is described optimal Value is obtained from real world data.Can be by from scoring and tolerance function 1220 and information from drawing function 1214 Student's function of reporting 1215 is used, to be reported to instruct personnel and/or student to create performance.

The result of virtual welding activity can be analyzed and shown to virtual welding system 100.By analyzing the result, meaning Virtual welding system 100 and can determine during the welding stroke be when and be where along solder joint, user is inclined From the acceptable restriction scope of welding procedure.Scoring can be attributed to the performance of user.In one embodiment, scoring can To be the function of the deviation that soldering appliance 160 is simulated in multiple margins of tolerance in position, orientation and speed, this can be from reason The welding stroke thought extends to critical or unacceptable welding activity.According to what is scored for the performance to user Selection, any gradient of multiple scopes can be included in virtual welding system 100.Scoring can by numeral in the way of or Alphanumeric mode shows.Additionally, the performance of user can graphically show, in time and/or edge Show how the simulation soldering appliance closely crosses solder joint on the position of solder joint.Such as travel angle, processing Angle, speed and the parameter with a distance from solder joint can be the example of measured content, but for the mesh of scoring Any parameter can be analyzed.The margin of tolerance of the parameter takes from the welding data of real world, thus provide on The accurate feedback how user will show in real world.In another embodiment, the performance with user is corresponding The analysis of defect can also be included and be displayed on ODD 150.In this embodiment, can describe and show by measuring The various parameters monitored during virtual welding activity and cause it is discontinuous be what type of figure.Although " occlusion (occlusions) may not be " visual on ODD 150, but due to the performance of user, defect may still have occurred and that, The performance results of user still may correspondingly be shown (i.e. graphical).

Visual cues function 1219 by showing the color and cue mark of covering on FMDD 140 and/or ODD 150, To user's offer feedback immediately.Visual cues are provided for each in welding parameter 151, welding parameter 151 includes position Put, end to workpiece gap distance, soldering angle, travel angle, gait of march and arc length (such as manual welding Connect), and if based on the advance limitation for limiting or tolerance user welding skill and technique some in terms of should be conditioned, then exist Visually indicate the user.For example, it is also possible to be directed to shake/swing skill and technique and welding bead " coin shape body " interval offer vision Prompting.Visual cues can be set independently or with any desired combination.

Calibration function 1208 is provided in the part in kind and virtual reality space made in real space (3D reference frames) The ability of visual part matching.It is installed on the arm 173 of support 170 by by WC, and utilization is operably connected to ST The point (for example being indicated by three scrobiculas on WC) that 120 calibration pen (stylus) contact WC is limited in advance, every kind of inhomogeneity The welded specimen (WC) of type is calibrated in the factory.ST 120 reads the magnetic field intensity at the point of the advance restriction, there is provided position Confidence is ceased to PPS 110, and PPS 110 carried out using the positional information calibration (i.e. from real world space to The conversion of virtual reality space).

The WC of any particular type loads the arm of support 170 within very strict tolerance in the repeatable mode of identical 714.In one embodiment, the distance on arm 714 between sample 758 and magnet 710 is as what is illustrated in fig. 2 above Known distance 178.Thus, once specific WC types are calibrated, the WC types are without being repeated calibration (i.e. certain types of WC Calibration be disposable event).The WC of same type is interchangeable.Calibration ensures that user is perceived during welding procedure The physical feedback content that show to the user in virtual reality space of matching so that emulate and look truer. For example, if user slides the end of MWT 160 around the turning of actual WC 180, the user will be in FMDD 140 On see that the end is slided around the turning of virtual WC, the end felt just as the user is around the reality Turning slide it is such.Embodiment of the invention, MWT 160 be placed on pre-aligned shelf (jig) and It is calibrated also based on known rack location.

According to interchangeable embodiment of the invention, there is provided " intelligence " with sensor is tried for example on the turning of sample Sample.ST 120 can follow the trail of the turning of " intelligence " welded specimen, so that virtual welding system 100 continuously knows that " intelligence " is welded Position of the sample in real world 3d space.Another replaceable embodiment of the invention, there is provided license key carrys out " solution Lock " welded specimen.When specific WC is purchased, there is provided license key, it is allowed to which user virtually welds license key input Welding system 100, the software that unblock is associated with the WC.Another embodiment of the invention, the real world based on part CAD charts, and can provide special non-standard welded specimen.User even can part in real world actually by Before generation, welding CAD parts can be trained.

Sound-content function 1204 and welding sound 1205 provide particular type welding sound, the welding sound according to Whether specific weld parameter changes in tolerance or beyond tolerance.Sound is adjusted according to various welding procedures and parameter.Example Such as, in MIG spray arc welding processes, crack sound is provided when user is properly positioned MWT 160, and works as MWT 160 The sound of whooshing is provided when being properly oriented.In short arc welding process, for appropriate welding skill and technique provide stabilization crack Sound or " fry " sound (frying sound), and the sound of whooshing can be provided when there is undercut.These sound are imitated (mimic) sound of the real world of correct and mis-welds skill and technique is corresponded to.

Various embodiments of the invention, high-fidelity sound-content can be taken from using various electronics and mechanical device The real world recording of actual welding.Embodiment of the invention, the volume and directionality of the sound for being perceived are according to making The head (assuming that user is just wearing the FMDD 140 followed the trail of by ST 120) of user is relative between MWT 160 and WC 180 The position of the electric arc of emulation, orientation and distance and change.For example, sound can be via the earplug speakers in the helmet 900 or warp User is provided to by configuring the loudspeaker in console 135 or support 170.

Environmental model 1203 is provided to provide the various background scenes in virtual reality space (static and motion).This The background environment of sample can include, such as indoor welding shop, outdoor runway, garage etc., and can include mobile vehicle, People, bird, cloud and various ambient sounds.Embodiment of the invention, background environment can be interaction.For example, using Person can be welded, it is necessary to examine (survey) background area closely before welding is started with ensuring that environment is suitable to (such as safely) Connect.Welding torch and fixture model 1202 are provided to be modeled in virtual reality space various MWT 160 (including such as rifle, to be had Bracket of stick electrode etc.).

Sample model 1210 is provided to model various WC 180 in virtual reality space, and WC 180 includes such as flat board Sample, T- joint samples, docking-joint samples, groove welding bead sample and tubulose sample (such as pipe of 2 inch diameters and 6 English The pipe of very little diameter).Alternatively or additionally, welded specimen model can include miscellaneous editions, and wherein sample is included in single One or more of welded specimen types in shape factor.For example, exemplary various welded specimens can be in single part Including T- joints, docking-joint and groove welding bead.Support/tables' model 1206 is provided to be built in virtual reality space The various parts of mould holder 170, the various parts of T/S 170 are included such as the adjustable arm used in virtual reality space 714th, base 724 and it is used to be coupled on adjustable arm the column 174 of base.Physical interface model 1201 is provided to The various parts of welding user interface 130, console 135 and ODD 150 are modeled in virtual reality space.

Embodiment of the invention, realizes the emulation in the molten bath or weldpool in virtual reality space, wherein described The molten bath of emulation has real-time motlten metal flowing property and heat dissipation characteristics.Embodiment of the invention, positioned at molten bath emulation Center be operate in the weld physics function 1211 (being called physical model) on GPU 115.Weld physics function is using double Dislocation layer technology come model exactly dynamic flow characteristics/viscosity (viscosity), coagulability, thermal gradient (heat absorption with radiating), Molten bath vestige (wake) and weld bead shape, and this is described in more detail herein in conjunction with Figure 14 A-14C.

Weld physics function 1211 and welding bead are presented function 1217 and connect to show welding bead from motlten metal state to cooling Whole states between solid state.Welding bead present function 1217 using from weld physics function 1211 information (such as it is hot, Mobility, dislocation, coin shape body interval), to be realistically presented exactly and in virtual reality space welding bead in real time. 3D texture functions 1218 provide to welding bead presentation function 1217 texture maps (texture maps) to make additional texture (example Such as burnt trace (scorching), slag, particle (grain)) cover on the welding bead of emulation.For example, in welding process or welding Process just terminates, and slag can be illustrated to come across on welding bead and then be moved to expose following welding bead.Dress is presented Put function 1216 for using the various non-molten baths of Informational Expression from special effects module 1222 specific features, including Mars (sparks), splash (spatter), flue dust, arclight, smoke and gas body and specific incoherence (such as undercut and porous).

Internal physical regulation instrument 1212 is to allow various weld physics parameters to be defined, update for various welding procedures With the adjusting apparatus of modification.Embodiment of the invention, internal physical regulation instrument 1212 operate on CPU 111 and Regulation or renewal parameter is downloaded in GPU 115.The parameter that can be conditioned via internal physical regulation instrument 1212 Type includes the parameter being associated with welded specimen, permission technique is changed and need not reset welded specimen (allows to form second Welding bead (pass)) technological parameter, be changed without resetting various global parameters of whole emulation and various other Parameter.

Figure 19 is the flow chart of the embodiment of the training method 1300 using the virtual welding system 100 of Fig. 1.In step In 1310, according to welding skill and technique relative to welded specimen movement simulation soldering appliance.In step 1320, virtual reality system is used The system position of tracing simulation soldering appliance and orientation in three dimensions.In step 1330, the virtual reality welding is watched The display picture of system, soldering appliance is simulated by the emulation projected from the simulation soldering appliance of the emulation in emulation Immediate vicinity forms the molten bath of emulation, and at least one of the welded specimen of the welding bead material stacking of emulation to the emulation is imitated When on genuine surface, the display picture shows the simulation soldering appliance and the welded specimen in virtual reality space Real-time virtual reality emulation.In step 1340, the real-time melting gold in the molten bath of the emulation is watched in the display picture Category mobility and heat dissipation characteristics.In step 1350, the described real-time motlten metal stream in the molten bath in response to watching the emulation Move property and heat dissipation characteristics and change at least one aspect for welding skill and technique in real time.

Method 1300 illustrates how user watches the molten bath in virtual reality space and imitated in response to viewing The various features (including real-time motlten metal flowing property (such as viscosity) and radiating) in genuine molten bath and change its welding skill and technique. User can also watch and in response to other features, including real-time molten bath vestige and coin shape body interval.Watch and in response to molten Pond is characterized in how most welding operation is actually performed in real world.Weld physics function 1211 Two-track is put layer model and is operated on GPU 115, it is allowed to which such real-time motlten metal flowing property and heat dissipation characteristics are built exactly Mould simultaneously shows to user.For example, radiating determines hardening time (welding unit needs how long thoroughly to solidify).

In addition, user can simulate soldering appliance and/or welding procedure using identical or different (such as second), The second welding bead is completed on welding bead material.In such second welding bead scene, emulation simulation soldering appliance by from imitative The immediate vicinity for really simulating the emulation of soldering appliance injection forms the molten bath of the second emulation, piles up the welding bead material with the first emulation During the welding bead material of the second emulation that material is combined, the emulation shows the simulation Welder of the emulation in virtual reality space Tool, welded specimen and original emulation welding bead material.Can be formed in a similar way using identical or different Welder The additional subsequent passes of tool or technique.Particular of the invention, when by previous welding bead material, new welding bead material When expecting and be possible to any combinations in following sample material and forming new molten bath in virtual reality world, any Two or subsequent passes in, previous welding bead material is combined with stacked new welding bead material.Such subsequent passes may be needed To form big filler weld or groove weld, for example, can be executed to repair the welding bead formed by previous welding bead, or One or more fillings and capping after high temperature welding bead (hot pass) can be included and root run is completed in pipe welding (cap) welding bead.Various embodiments of the invention, welding bead and base material can include mild steel, stainless steel, aluminium, be based on The alloy or other materials of nickel.

Figure 20 A-20B embodiments of the invention illustrate the concept of welding unit (weldering unit) dislocation Figure 142 0.Figure 20A shows the side view of the flat welded specimen (WC) 1400 with flat top surface 1410.Welded specimen 1400 is with for example The form of plastic components is present in real world, and also can be present in virtual reality in the form of the welded specimen for emulating In space.Figure 20 B show the sign of the top surface 1410 of the WC 1400 of emulation, and the top surface 1410 is broken down into shape Into the grid or array of the welding unit (welding unit) of weldering unit Figure 142 0.Each weldering unit (for example, weldering unit 1421) limits welded specimen Surface 1410 sub-fraction.The first figure of weldering defines surface resolution.Changeable passage (channel) parameter value is allocated Give each weldering unit, it is allowed to which each welds the value of unit during the welding procedure of emulation, with real-time in virtual reality weld seam space Mode is dynamically changed.The changeable channel parameters value corresponds to passage molten bath, and (motlten metal flowing property/viscosity is moved Put), heat (heat absorption/radiating), dislocation (solid dislocation) and extra content (various additional states, such as slag, particle, Jiao Trace, original metal (virgin metal)).These changeable passages are referred to as PHED herein, PHED correspond to respectively molten bath, Heat, extra content and dislocation.

Figure 20 illustrates the flat welded specimen (WC) 1400 for emulating the Figure 14 in the virtual welding system 100 of Fig. 1 Welded specimen space and weld seam space exemplary.Point O, X, Y and Z limit part 3D welded specimens space.Always For ground, per sample (p.s.) type is limited from 3D sample spaces to the mapping in 2D virtual reality weld seams space.The weldering unit figure of Figure 20 1420 is the two-dimensional matrix of the value for being mapped to virtual reality weld seam space.As shown in Figure 20, user will be from point B to point E is welded.In fig. 20, the trajectory from point B to point E is shown in both 3D welded specimens space and 2D weld seams space.

Direction of each type of welded specimen for each the position restriction dislocation in the first figure of weldering.It is flat for Figure 21 Welded specimen, the dislocation direction of the whole positions in welding unit's figure (i.e., in z-direction) is identical.To illustrate the mapping, The texture coordinate that first figure will be welded in both 3D welded specimens space and 2D weld seams space is shown as S, T (sometimes referred to as U, V).Weldering unit figure It is mapped to and characterizes the square surface 1410 of welded specimen 1400.

Figure 22 illustrates turning (T connector) welded specimen (WC) 1600 emulated in the virtual welding system 100 of Fig. 1 Welded specimen space and weld seam space exemplary.Turning WC 1600 has in 3D welded specimens space Two surfaces 1610 and 1620, described two surfaces 1610 and 1620 are mapped to 2D weld seams space as shown in Figure 22.Together Sample, point O, X, Y and Z limit part 3D welded specimens space.It is empty in 3D welded specimens space and 2D weld seams to illustrate the mapping Between the texture coordinate of first figure will be welded in the two be shown as S, T.As shown in Figure 22, user will be welded from point B to point E Connect.In fig. 22, the trajectory from point B to point E is shown in both 3D welded specimens space and 2D weld seams space.However, moving The direction put is directed towards the lines X'-O' as shown in in 3D welded specimens space, as illustrated in fig. 22 towards relative turning.

Figure 23 illustrates the welding for emulating the tubular weldment sample (WC) 1700 in the virtual welding system 100 of Fig. 1 Sample space and the exemplary in weld seam space.Tubulose WC 1700 has the table of bending in 3D welded specimens space Face 1710, the surface 1710 is mapped to 2D weld seams space as illustrated in fig. 23.Equally, point O, X, Y and Z limits part 3D welderings Connect sample space.To illustrate the mapping, the texture that first figure will be welded in both 3D welded specimens space and 2D weld seams space is sat It is denoted as S, T.As shown in Figure 23, user will be welded from point B to point E along the track of bending.In fig 23, divide Not the geometric locus and line from point B to point E are shown in 3D welded specimens space and 2D weld seams space.The direction of dislocation is away from lines Y-O (i.e. away from the center of pipe).

Can be mapped to the similar fashion of the rectangular surface area of geometry with texture maps, solderable weldering unit figure can To be mapped to the square surface of welded specimen.In each unit with image referred to as pixel (abbreviation of image primitive) identical meaning In justice, each unit of solderable map interlinking is referred to as weldering unit.Pixel includes the information for limiting color (such as red, green, blueness etc.) Passage.Weldering unit includes the information channel (such as P, H, E, D) for being limited to solderable surface in virtual reality space.

Embodiment of the invention, weld unit form be summed up as comprising four passage PHED of floating number (molten bath, Heat, extra content, dislocation).Extra passage is used as logical message of the storage on weldering unit (for example, in the first position of the weldering With the presence or absence of any slag) one group of binary number.Any liquefied metal of the molten bath passage storage for the first position of the weldering Dislocation value.Dislocation value of the dislocation passage storage for the metal of the solidification of the first position of the weldering.Passage of heat storage is given at institute State the value of the heat level of the first position of weldering.By this way, the weld-enabled portion of welded specimen can show the welding bead because being soldered And the dislocation for producing, the surface " molten bath " of flicker, Yin Re and color for producing etc. for being produced by liquid metal.All these effects Fruit is realized by being applied to the vertex shader and pixel tinter on welding surface.

Embodiment of the invention, using dislocation figure and particIe system, wherein particle can be interacted with each other simultaneously Collision dislocation figure.The particle is virtual dynamic fluid particle and provides the liquid behavior in molten bath, but is not to be in directly Existing (not being directly visible).Conversely, the particle effect only on the dislocation figure is visually visible.It is input to Weld the motion of the heat affecting proximate particle of unit.Be related to emulation molten bath has two kinds of dislocation, the dislocation bag of both types IncludeMolten bathWithDislocation。Molten bathIt is " interim " and only to continue at when there is particle and heat occur.DislocationIt is " permanent ".Molten bathDislocation is the weld seam liquid metal of quick change (for example flashing) and can be considered to be atDislocation" top ".Particle A part for covering virtual surface dislocation figure (welding unit's figure).Dislocation characterizes permanent solid metal, the permanent solid gold Category includes both initial base metal and cured welding beads.

Embodiment of the invention, the welding procedure emulated in virtual reality space works in the following manner：Grain Son is from transmitter (transmitter of the MWT 160 of the emulation) outflow in slim taper part.Particle contact emulation for the first time Welded specimen surface, wherein the surface by weldering unit figure limit.The particle is interacted with each other and schemed with weldering unit mutual Effect, and accumulation is got up in real time.Weldering unit is closer to transmitter, then the heat for adding is more.Heat basis and electric arc point Distance and heat are modeled from the time quantum of electric arc input.Special pattern part (such as color etc.) is by thermal drivers.For foot The weldering unit of enough high temperature, draws or presentation molten bath in virtual reality space.As long as anywhere hot enough, the figure liquefaction of weldering unit is led Cause for the first position of these welderingsMolten bathDislocation " rise ".Determined by welding first position sampling " highest " particle at eachMolten bath Dislocation.When transmitter advances along seam track, the weldering unit position cooling for leaving.Heat is moved with special speed from the first position of weldering Remove.When cooling threshold value is reached, the figure solidification of weldering unit.So,Molten bathDislocation is gradually converted intoDislocation(welding bead for solidifying).Increase Plus dislocation be equal to removal molten bath so that whole height does not change.The life-span of adjustment or regulation particle completes with solidification Retained before.Be modeled specified particle characteristic in virtual welding system 100 and include attracting/repel, speed (relative to Heat), wetting (relative to radiating), direction (relative to gravity).

The general of (dislocation and particle) molten bath model is put in the two-track that Figure 24 A-24C illustrate the virtual welding system 100 of Fig. 1 The exemplary of thought.Welded specimen of the emulation with least one surface in virtual reality space.In virtual reality The surface of welded specimen is emulated in space, formation includes that layer is put in the two-track of solid dislocation layer and molten bath dislocation layer.Molten bath dislocation layer Solid dislocation layer can be changed.

As described herein, " molten bath " is limited by a region of the first figure of weldering, wherein molten bath value depositing due to particle And improve.Sampling process is characterized in Figure 24 A-24C.Showing weld first figure one has seven sections of neighbouring weldering unit.Currently 'sDislocationValue is characterized by the unblanketed rectangular strip 1910 with assigned altitute.In Figure 24 A, particle 1920 be illustrated as with currently Dislocation horizontal plane collision circular unblanketed point and heaped.In Figure 24 B, " highest " particle height 1930 is at each The first position of weldering is sampled.In Figure 24 C, the rectangle 1940 with shade shows the reason due to particle,DislocationTop on increased Add fewMolten bath.Due toMolten bathIt is increased with the specific liquefied fraction based on heat, weld seam melt pool height will not immediately be set to sampling Value.Although not shown in Figure 24 A-24C, make solidification process visualization be it is possible, such asMolten bath(the square with shade Shape) be gradually reduced andDislocation(unblanketed rectangle) gradually increases described just to replace from followingMolten bath.By this way, it is real When motlten metal flowing property feature emulated exactly.When user practises specific weld technique, user can be real-time The motlten metal flowing property feature and heat dissipation characteristics in molten bath are observed in virtual reality space, and is used the information to adjust or is protected Hold its welding skill and technique.

It is fixed to characterize the number of the weldering unit on the surface of welded specimen.In addition, as described herein, being generated by emulation Molten bath particle to model mobility is interim.Thus, once using virtual welding system 100 in the welding procedure phase for emulating Between in original bath is generated in virtual reality space, weldering unit is often to maintain relative constancy plus the number of molten bath particle.This Because during welding procedure, the number of processed weldering unit is fixed, and because molten bath particle is with similar Speed (i.e. molten bath particle is interim) is just being created and " destruction ", and the number of molten bath particle exist and processed becomes In holding relative constancy.Therefore, during the welding stage of emulation, the treatment load of PPS 110 keeps relative constancy.

According to interchangeable embodiment of the invention, molten bath particle can be created in the surface of welded specimen or in weldering Connect the lower face of sample.In such embodiments, dislocation can be tried with relative to initial (not being soldered) welding The initial surface dislocation of sample is that mode positively or negatively is modeled.By this way, molten bath particle can be tried not only in welding Set up on the surface of sample, can be with penetration welded specimen.However, the number of weldering unit is still fixed, and it is created and destroys Molten bath particle be still relative constancy.

According to interchangeable embodiment of the invention, the unit's dislocation figure of the weldering with more multichannel can be provided to model molten bath Mobility rather than modeling particle.Or, dense volume elements figure (voxel map) can be modeled rather than modeling particle.Such as Used herein, volume elements (such as volume pixel) is volume element, the value in sign three dimensions on regular grid.Or, can Only to model the particle for being sampled and never disappearing, rather than modeling weldering unit figure.However, such replaceable embodiment party Case may not provide the treatment load of relative constancy for system.

Additionally, embodiment of the invention, is emulated by the way that material is removed and penetrates (blowthrough) or open-work (keyhole).For example, if electric arc is maintained at same position by user in real world crossing for a long time, material will fire Fall to cause hole.Such real world penetrate through the first decimation technique (decimation techniques) of weldering be simulated in Virtual welding system 100.If being defined as by virtual welding system 100 by the heat that a weldering unit absorbs too high, the weldering unit can be with It is labeled or be designated as being burned off and presented (be for example rendered as hole) with this.However, next, being directed to Specific weld technique (such as pipe welding) can weld first reconstruction, wherein after being initially burned off, material is added back.Always It, emulation weldering unit's selection of virtual welding system 100 (removing material) and weldering unit rebuild (will material add go back).In addition, The operation that material is removed in root run welding is suitably emulated in virtual welding system 100.

In addition, the operation that material is removed in root run welding is suitably emulated in virtual welding system 100.Example Such as, in real world, before subsequently stroke is welded, the polishing of root run can be performed.Similarly, virtual welding System 100 can emulate the polishing stroke operation that material is removed from virtual solder joint.It is to be understood that removed material The negative sense dislocation on first figure can be modeled as welding.That is, the polishing welding bead for removing material is operated by virtual welding system 100 modelings, cause the welding bead profile for changing.The emulation of polishing stroke operation can be automatic, and this is that is, virtual welding System 100 removes a material for predefining thickness, and the material of the predetermined thickness can be the weldering of correspondence root run Road surface.

In interchangeable embodiment, actual milling tools or grinding machine (grinder) can be simulated as by simulation The activation of soldering appliance 160 or another input unit and enable or close.It is noted that milling tools can be simulated to imitate (resemble) grinding machine of real world.In this embodiment, user manipulates (maneuver) polishing work along root run Tool removes material to respond the motion of the milling tools.It is to be understood that user can be allowed to remove excessive material Material.In a similar way as described above, hole or other (above-mentioned) may be caused if user polishes off excessive material Defect.Further, can realize (be programmed) forcing spacing or stop preventing user from removing excessive material or excessive Material just be removed when pointed out.

Embodiment of the invention, in addition to not visible " molten bath " particle described herein, virtual welding system 100 are also characterized using the visual particle of other three typesElectric arcEffect,FlameEffect andMarsEffect.These types Particle with any kind of other particle interactions, and can will not only interact with dislocation figure.Although these particles are certain Face of weld with emulation is collided, but they will not interact each other.Embodiment of the invention, onlyMolten bathParticle Can interact with each other.Mars particlePhysical features be arranged such, so as to Mars particle is everywhere in virtual reality space Jump is altered and is rendered as luminous point (glowing dots).

Arc particelsPhysical features be arranged such so thatArc particelsClash into the specimen surface or weldering of (hit) emulation Road and stay for some time.Arc particelsLarger dark bluish white color dot is rendered as in virtual reality space.Using many Such point of superposition forms any one visual image.Final result is the white luminous ring of light with blue edge (nimbus)。

Flame particlePhysical features be modeled lentamente to be raised above.Flame particleIt is rendered as medium sized dark Reddish yellow color dot.Any one visual image is formed using such point of many superpositions.Final result is to be raised above and fade out (fading out) have red edge orange red flame group.According to a further embodiment of the present invention, it is other kinds of Non- molten bath particle can be implemented in virtual welding system 100.For example, can be with the modeling of flame particle similar mode simultaneously Emulation smoke particle.

Last step is provided by the tinter 117 of GPU 115 in the visualization process of emulation vertex shader and Pixel tinter is processed.Vertex shader and pixel tinter are providedMolten bathWithDislocationAnd the surface face changed due to heat Color and emissivity etc..Extra (E) passage in the first form of PHED welderings as described earlier in this article is used comprising the first place of each weldering All extraneous informations.Embodiment of the invention, extraneous information includes non-initial position (true=welding bead, vacation=initial steel Iron), slag position, undercut value (at the weldering unit amount of undercut, wherein zero equal to without undercut), porous value it is (porous at the weldering unit Amount, wherein zero be equal to without porous), and coding the solidifying weld beads time welding bead vestige (wake) value.In the presence of one group with The associated image mapping of different welded specimen pictures, including initial steel, slag, welding bead and porous.These images map quilt For in both bump mapping and texture mapping.The amount of these images mapping fusion (blending) is by described herein various Mark and value are controlled.

Mapped using 1D images and the first welding bead vestige value of each weldering realizes welding bead vestige effect, the first welding bead of each weldering The time that the given part (a given bit) of vestige value coding welding bead is cured.Once high temperature molten-bath arc welding unit position is no longer It is referred to as the sufficiently high temperature in " molten bath ", the time is stored in the position and is referred to as " welding bead vestige ".Final result is coloring Device code can be drawn " ripple mark (ripples) " using 1D texture mappings, and " ripple mark " is given and portrayed described in (portray) Unique outward appearance in the direction that welding bead is laid.According to interchangeable embodiment of the invention, virtual welding system 100 can be Emulation simultaneously shows welding bead in virtual reality space, the welding bead have when the molten bath of the emulation is moved along seam track by The real-time welding bead indication character that the real-time mobility in the molten bath of the emulation is caused to solidification transition.

According to interchangeable embodiment of the invention, virtual welding system 100 can instruct user how butt welding machine Device carries out failure and mediates (troubleshoot).For example, the failure of system mediates pattern the user can be trained to ensure that its is correct Ground (such as correct specific gas flow rate, the correct power line of connection etc.) sets the system.It is another interchangeable according to the present invention Embodiment, virtual welding system 100 is able to record that and welding process of a resetting (or at least part for welding process, such as N Frame).Trace ball (track ball) can be provided to roll the frame of video, it is allowed to which user instructs individuals review to weld Journey.Playback can also be provided with selectable speed (such as full speed, Half Speed, a quarter speed).Implementation of the invention Scheme, can provide split screen (split-screen) playback, for example, allow abreast (side-by-side) sight on ODD 150 See two welding processes.For example for comparison purpose, " good " welding process can be close to " difference " welding process and be watched.

Sum it up, disclosing a kind of real-time virtual reality welding system, the system includes being based on Programmable Logic Controller Subsystem, spatial pursuit device, at least one simulation soldering appliance and at least one display device, the spatial pursuit device can The subsystem based on Programmable Logic Controller is operatively coupled to, at least one simulation soldering appliance can be by the sky Between tracker spatially follow the trail of, at least one display device is operably connected to described based on Programmable Logic Controller Subsystem.Virtual reality welding system is designed to provide portable use, wherein compact support is used to protect welded specimen Hold in space, be used together with simulation soldering appliance.Simulation soldering appliance includes maying be coupled to being total to for multiple adapters Same pedestal, wherein each adapter emulate a specific welds types.By this way, the system can be empty in virtual reality Between it is middle emulation with real-time motlten metal flowing property and heat dissipation characteristics molten bath.The system can also be on said display means The molten bath of the emulation is shown in real time.

Above example is several possible embodiment for illustrating various aspects of the present invention, wherein this area skill Art personnel are according to reading and understand that the specification and drawings will recognize that equivalent change and/or modification.Especially, relative to upper The various functions that the part (component, equipment/device, system and circuit etc.) of face description is performed, for describing such part Term (including being related to " device (means) ") be intended to be described with execution the tool of part (be for example functionally be equal to part) Any part (such as hardware, software or combination therein) of body function is corresponding, unless be otherwise noted, even if knot It is not equal to perform the open structure of the function in the implementation that the present invention is illustrated on structure.Although additionally, of the invention Special characteristic may be disclosed relative in simply several implementations, when for it is any being given or it is specific should During with being desired and favourable, such feature can be combined with one or more other features of other implementations.Also Have, to a certain degree, term " including (including) ", " including (includes) ", " having (having) ", " have (has) ", " carry (with) " or deformation therein is used in detailed description and/or claim, such term Inclusive is intended that in the way of similar in appearance to term " including (comprising) ".As employed herein, term " benchmark " " datum mark " refers to the reference measured from it.

This printed instructions uses examples to the open present invention, including best mode, and also makes this area general Logical technical staff can carry out the present invention, including make and use any device or system and any method being incorporated to of execution. The scope that the present invention can patent is defined by the claims, and can expect including those skilled in the art other Embodiment.Such other embodiment is intended in the range of claims, if they are wanted with right is not different from The structural element of the written language asked, or if they include being equal to without substantially different with the written language of claims Structural element.

Reference number：

The interface of 100 virtual welding system 318

The 110 manual welding instruments of subsystem 400 based on programmable processor

The stick electrode of the emulation of 111 CPU 410

The clamper of 112 memory 422

The flammable oxyfuel gas welding torch of 114 processor 500

The mouth of 115 GPU 510

The interface of 116 unified calculation equipment framework 518

The button of 117 tinter 520

The neck ring of 118 video frequency output 522

The pedestal of 119 video frequency output 600

The interface of 120 spatial pursuit device 610

The 130 welding abutments of user interface 614

The recess of 132 control stick 616

140 buttons of display device 618 for being placed on face

The body of 142 sensor 620

The rigid line cable of 146 helmet 630

The fastener of 150 display device 640

The 160 simulation sensors of soldering appliance 652

The cable of 162 adapter 654

The fastener of 166 pedestal 658

The impeller of 168 sensor 672

The support of 170 support 700

The magnet of 172 magnet 710

The arm of 178 preset distance 714

The column of 180 welded specimen 722

The base of 200 system 724

The plunger of 300 welding gun 732

The abutment of 310 mouth 738

The welded specimen of 312 pipe 758

The welding bead of 762 pin 1217 is presented

The 3D textures of 764 pin 1218

The visual cues function of 766 hole 1219

Score/tolerance function in 768 holes 1220

The 800 simulation tolerance editing machines of soldering appliance 1221

The special-effect of 810 container 1222

The method of 830 user interface 1300

The step of 832 selector 1310

The step of 836 temperature measuring equipment 1320

The step of 838 current measuring device 1330

The step of 842 voltage measuring apparatus 1340

854 step 1350 steps

The flat welded specimen of 856 steps 1400

The flat top surface of 860 interchangeable user interface 1410

The dislocation figure of 900 helmet 1420

1201 physical interfaces 1421 weld unit

The welded specimen of 1202 welding torches/fixture model 1600

The surface of 1203 environmental model 1610

The surface of 1204 sound-content function 1620

The 1205 welding pipe welded specimens of sound 1700

1206 supports/the curved surface of tables' model 1710

The rectangular strip of 1207 inside structure function 1910

The particle of 1208 calibration function 1920

The particle of 1210 welded specimen model 1930 is highly

1211 rectangles of the weld physics 1940 with shade

1212 internal physicals adjust the stick electrode of instrument 6010

The stick electrode of 1213 user interface function 7018

1214 drawing functions

1215 student's function of reporting B points

1216 are presented device D information channels

E points/information channel

H information channels

O points

O' lines

P information channels

S texture coordinates

T texture coordinates

U texture coordinates

V texture coordinates

X points

X' lines

Y points

Z points

Claims (22)

1. a kind of virtual welding system, the virtual welding system includes：

Subsystem based on programmable processor；

Spatial pursuit device, the spatial pursuit device is operably connected to the subsystem based on programmable processor；

Simulation soldering appliance, the simulation soldering appliance can spatially be followed the trail of by the spatial pursuit device, the simulation weldering Bonding tool includes,

Two or more adapters, wherein each adapter emulate the real world outward appearance of a specific weld type；And

Pedestal, the pedestal is removably coupled to each in described two or more adapters, and the pedestal includes One or more sensors, to determine the locus relative to the spatial pursuit device；And wherein

Each in described two or more adapters is connected with the pedestal, and

The subsystem based on programmable processor performs the appropriate instruction set being associated with each adapter, to mount In being presented in the display device of face and each the corresponding display in described two or more adapters.

2. virtual welding system as claimed in claim 1, also includes：

It is arranged on one or more sensors in the pedestal；And

Magnet with locus, the magnet is followed the trail of to recognize the simulation welding by one or more sensor Relative position of the instrument to the magnet.

3. virtual welding system as claimed in claim 2, also includes：

Welded specimen, the welded specimen has at least one surface and emulates the real world part to be soldered, described Welded specimen is arranged to from the known distance of the magnet one, wherein at least one surface of the welded specimen is virtual It is simulated as including that layer is put in the two-track of solid dislocation layer and molten bath dislocation layer in realistic space, wherein molten bath dislocation layer can Change the solid dislocation layer.

4. virtual welding system as claimed in claim 3, also includes：

Support, the support is utilized to support the magnet and the welded specimen with predetermined spatial relationship.

5. virtual welding system as claimed in claim 2, also includes：

The helmet worn by user；And

It is arranged on the display device for being placed on face in the helmet, the display device display emulation for being placed on face Welding pool real-time motlten metal flowing property and heat dissipation characteristics, to be displayed on the display device for being placed on face For the user of the simulation soldering appliance provides real-time visual feedback when upper, it is allowed to which the user in real time may be used in response to described Adjust oneself in real time depending on feedback or keep welding skill and technique.

6. system as claimed in claim 5, wherein

The helmet position is determined by the spatial pursuit device and is sent to the subsystem based on programmable processor.

7. system as claimed in claim 6, also includes：

One or more sensors in the helmet are arranged on, to follow the trail of space of the helmet relative to the magnet Position.

8. system as claimed in claim 7, wherein

The sensor is capacitance sensor, piezoelectric transducer, infrared proximity sensor, hall effect sensor, vortex biography It is one or more in sensor, inductance sensor and sonac.

9. a kind of simulation soldering appliance used in virtual welding system, wherein the virtual welding system is included based on can compile The subsystem and spatial pursuit device of thread processor, the simulation soldering appliance include：

Two or more adapters, each adapter emulates the physical features of a specific weld type；And

Pedestal, the pedestal is removably coupled to each in described two or more adapters, the pedestal identification Described to simulate real-time spatial position of the soldering appliance relative to reference position, the pedestal includes one or more sensors, To determine the locus relative to the spatial pursuit device；And wherein

Each in described two or more adapters is connected with the pedestal, and

The subsystem based on programmable processor performs the appropriate instruction set being associated with each adapter, to mount In being presented in the display device of face and each the corresponding display in described two or more adapters.

10. the simulation soldering appliance for being used in virtual welding system as claimed in claim 9, wherein

Datum mark is welded specimen, and the welded specimen has at least one table when the real world part to be soldered is emulated Face, the welded specimen has at least one surface and emulates the real world part to be soldered, wherein the welding examination At least one surface of sample is simulated as including the two-track of solid dislocation layer and molten bath dislocation layer in virtual reality space Layer is put, wherein molten bath dislocation layer can change the solid dislocation layer.

The 11. simulation soldering appliances used in virtual welding system as claimed in claim 10, also include：

Magnet, the magnet is set relative to the welded specimen with predetermined position.

The 12. simulation soldering appliances used in virtual welding system as claimed in claim 11, also include：

Support, the support fixes locus of the magnet relative to the welded specimen.

The 13. simulation soldering appliances used in virtual welding system as claimed in claim 12, also include：

One or more sensors, one or more sensor is arranged in the pedestal, one or more Multiple sensors determine position of the pedestal relative to the magnet.

The 14. simulation soldering appliances used in virtual welding system as claimed in claim 13, wherein the sensor will Their position is sent to the subsystem based on programmable processor.

The 15. simulation soldering appliances used in virtual welding system as claimed in claim 14, also include：

It is arranged on the interface of the first end of the pedestal, in the interface facility and described two an or more adapter one Individual removable mechanical couplings.

The 16. simulation soldering appliances used in virtual welding system as claimed in claim 15, wherein

The interface is included at least one first mechanical features, described at least one first mechanical features and the adapter At least one second mechanical features are complementary, with the removable mechanical couplings of convenient each adapter to the pedestal.

The 17. simulation soldering appliances used in virtual welding system as claimed in claim 9, wherein

The pedestal also includes triggering device, and the triggering device is used to indicate effective weld seam shape in virtual welding system State.

The 18. simulation soldering appliances used in virtual welding system as claimed in claim 17, wherein

The triggering device is bonded in each adapter via set, it is described set by user via the adapter mechanically Manipulate to start effective weld seam state.

A kind of 19. methods that simulation soldering appliance is used in virtual welding system, methods described includes：

The first adapter is removedly connected to pedestal, first adapter is associated with the first welds types；

First adapter is recognized for the subsystem based on programmable processor, to allow the subsystem to load and hold The appropriate instruction set that row is associated with first adapter, and the instruction set is rendered as being placed on the display of face Display on device；

First adapter is removed from the pedestal；And

The second adapter is removedly connected to identical pedestal, second adapter is associated with the second welds types；

Second adapter is recognized for the subsystem based on programmable processor, to allow the subsystem loading simultaneously And the appropriate instruction set being associated with second adapter is performed, and the instruction set is rendered as to be placed on face Display in display device；

Wherein described pedestal includes sensor, and the sensor determines space of the simulation soldering appliance relative to welded specimen Position, wherein the position of the pedestal is updated in real time display.

20. methods as claimed in claim 19, also include：

Magnet, the magnet is arranged on a known position relative to the welded specimen, wherein the sensor determines institute State the position of magnet and at least the position based on the magnet calculates the position of the welded specimen.

21. methods as claimed in claim 19, also include：

According to the first welding skill and technique relative to the welded specimen simulation soldering appliance of the movement with first adapter；

The simulation soldering appliance with first adapter is followed the trail of in three dimensions using the virtual welding system；

The display of the virtual welding system is watched, in the simulation soldering appliance with first adapter of emulation Emulation is formed by the immediate vicinity in the emulation launched from the simulation soldering appliance with first adapter Welding pool and by first emulation welding bead material deposition to emulation welded specimen at least one emulation surface on when, institute State display and show that the simulation soldering appliance and the welded specimen with first adapter are empty in virtual reality Between in real-time virtual reality emulation；

The first real-time motlten metal of the welding pool of the emulation of viewing first flows property and heat dissipation characteristics on the display；With And

In response to watching the described first real-time motlten metal flowing property and heat dissipation characteristics of the welding pool of first emulation Change at least one aspect of the first welding skill and technique in real time.

22. methods as claimed in claim 19, also include：

According to the second welding skill and technique relative to the welded specimen simulation soldering appliance of the movement with second adapter；

The simulation soldering appliance with second adapter is followed the trail of in three dimensions using the virtual welding system；

The display of the virtual welding system is watched, in the simulation soldering appliance with second adapter of emulation Formed by the immediate vicinity of the emulation launched from the simulation soldering appliance with second adapter of emulation The welding pool of emulation and by second emulation welding bead material deposition to emulation welded specimen at least one emulate surface When upper, the display is shown with the simulation soldering appliance of second adapter and the welded specimen virtual Real-time virtual reality emulation in realistic space；

The second real-time motlten metal of the welding pool of the emulation of viewing second flows property and heat dissipation characteristics on the display；With And

In response to watching the described second real-time motlten metal flowing property and heat dissipation characteristics of the welding pool of second emulation Change at least one aspect of the second welding skill and technique in real time.