CN110189551A - 一种焊接训练系统的系统和方法 - Google Patents
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Abstract
本发明提供一种焊接训练系统。该焊接训练系统包括被配置成执行焊接作业的焊枪和耦接在焊枪上的移动设备。该移动设备被配置成通过一个或多个传感器探测在焊接作业过程中的焊枪的动态位置或方向信息以确定焊接作业的一个或多个操作参数。该移动设备也被配置成至少部分地基于一个或多个焊接参数显示焊接环境。
Description
本申请为申请日为2014年12月1日、国际申请号为PCT/US2014/067951、国家申请号为201480062863.X、发明名称为“一种焊接训练系统的系统和方法”的发明专利申请的分案申请。
相关专利申请的交叉引用
本申请要求于2013年12月3日提交的美国临时专利申请No.61/911,321,题目为“使用便携式智能设备的训练系统”,本申请参考引用了该专利的全部内容。
背景技术
本公开总体涉及一种焊接系统,更具体地涉及,为了训练和/或招聘的目的,作为焊接训练工具使用的移动设备。
焊接是一种被越来越多地应用到各种工业和应用的工艺。虽然很多的工业应用继续延续着手动的焊接作业,但在某些情况下,这些工艺是可以自动化作业的。在这两种情况中,这些焊接作业依赖各种类型的设备以确保焊接消耗品(例如送丝、保护气等)能够在预定的时间以适当的量提供到焊缝。
为了准备手动焊接作业,焊接作业员可能使用焊接训练系统作训练。该焊接训练系统可被设计为训练焊接作业员掌握适当的技术以便完成多种的焊接作业。很多训练方法和系统被利用到该训练系统中,但是,通常这些方法和系统是大的且笨重的,并且过于昂贵而不能被大规模地制造和使用。因此,提供一种低成本的焊接训练方法和系统将会是有益的,该焊接训练方法和系统比较容易被大规模地制造和使用。
简要说明
在一个实施例中,提供一种焊接训练系统。该焊接训练系统包括:焊枪,被配置成执行焊接程序;以及移动设备,其耦接到所述焊枪上。该移动设备被配置成通过一个或多个传感器探测焊枪在焊接过程中焊枪的动态位置或者定向信息以确定焊接过程的一个或者多个操作参数。该移动设备也被配置成至少部分地基于一个或多个操作参数显示其焊接环境。
在另一实施例中,提供一种焊接训练系统。该焊接训练系统包括焊枪,其被配置成在方向设备上对一个模拟焊缝执行模拟的焊接作业。该焊接训练系统也包括移动设备,其耦接到焊枪上。该移动设备包括照相机,用于探测布置在方向设备上多个标识符中的一个或多个。该移动设备也包括处理器,该处理器至少部分基于该照相机探测到的多个标识符中的一个或多个而生成焊枪的动态位置或定向信息。
在另一实施例中,提供了一种储存计算机指令的永久性计算机可读介质。该计算机指令被配置成控制焊接训练系统中的焊枪相对于方向设备对模拟焊缝执行虚拟的焊接作业。该方向设备是一个模拟的工作表面。该计算机指令通过装在移动设备上的一个或多个传感器接收焊枪的动态位置或者定位信息,该移动设备耦接于焊枪。该计算机指令被配置成:至少部分地基于接收到的位置或定向信息,通过布置在移动设备中的处理电路确定焊枪更新的动态位置或者定向信息。利用这些更新的动态位置或者定向信息确定虚拟焊接过程的一个或者多个操作参数。
附图说明
当参照附图阅读下面的详细描述时,可以更好地理解本公开的这些和其它的特征、方面和优点,贯穿附图中相同的附图标记表示相同的部件,其中:
图1是根据本公开的一些方面利用耦接到焊枪上的移动设备的焊接训练系统的实施例的方框图。
图2是根据本公开的一些方面的图1中的耦接到焊枪的移动设备的实施例。
图3是根据本公开的一些方面的图1中的装配到焊枪的移动设备的实施例,其中该移动设备使用了方向设备。
图4是根据本公开的一些方面的示出对应于模拟的、增强的、或虚拟的真实焊接环境的数据的屏幕的实施例。
发明内容
本文描述的系统和方法的实施例涉及使用移动设备的焊接训练系统。在某些实施例中,该移动设备可耦接到焊接训练系统的焊枪,并且作业员可以接合焊枪和移动设备以执行模拟焊接体验,以达到训练或者招聘的目的。特别是,移动设备可被配置成将与模拟焊接体验相关的传感器反馈信息提供给焊接训练系统和/或作业员。例如,布置在移动设备里的一个或者多个传感器可被配置成在模拟焊接体验过程中探测焊枪的位置或者定向信息。进一步,基于探测到的位置或者定向信息,该移动设备能被配置成将虚拟焊接环境的可视表示形式显示到移动设备或者外部设备的显示器上。另外,该移动设备可被配置成在模拟焊接体验过程中确定模拟焊接的一个或者多个操作参数,并且在某些实施例中,也可将一个或多个操作参数显示到移动设备或者外部设备的显示器上。
在某些实施例中,该焊枪和移动设备可被配置成使用方向设备执行模拟焊接体验。例如,该方向设备可以是带有一系列标识符(例如,多种图案的点、纹理、凸面、条形码、QR条码等等)的预制的二维或三维材料,这些标识符定向焊枪并且引导作业员执行模拟焊接。在某些情况下,该方向设备是针对特殊类型或特殊系列的模拟焊缝配置的。在某些实施例中,该移动设备利用一个或多个照相机或者光学传感器探测方向设备上的标识符来定向焊枪,同时相对于方向设备执行特殊类型或系列的模拟焊接。
某些实施例中,焊接训练系统的移动设备可耦接到焊枪上,该焊枪执行真实的焊接过程(例如,现场焊弧,真弧模形)。在这种情况下,该焊接训练系统能够实现增强的焊接体验,其被配置成允许使用增强的现实模拟的训练。例如,该移动设备可被配置成提供焊接作业员执行增强的真实焊接的视频直播、焊弧的视频直播、焊接溶池的视频直播,和/或焊接作业的模拟视频。此外,在某些实施例中,该移动设备可对增强焊接工艺中的相关增强工艺参数提供实时反馈信息,所述实时反馈信息在增强焊接体验过程中对作业员作出指导。
以这种方式,为了达到训练或招聘的目的,作业员可利用低成本的焊接训练系统从事实时模拟焊接体验或实时增强焊接体验。特别地,本文描述的低成本焊接训练系统能够被大规模地使用和复制。应当指出,该移动设备也可被配置成提供焊后反馈,该焊后反馈提供模拟或增强的焊接体验的相关工艺参数的汇总,包括作业员的动作。
如本文中使用的,该焊接训练系统可包括任一适当的焊接相关系统,包括但不限于,焊接训练系统、实时焊接系统、模拟焊接系统、虚拟现实焊接系统、焊接训练应用(例如,被利用移动设备上)、应用在游戏平台的焊接训练系统,如此等等。在某些实施例中,该焊接训练系统可被配置成执行虚拟的焊接作业、保护金属极电弧焊(SMAW)工艺、气体保护电弧焊(GMAW)工艺、钨极隋性气体(TIG)焊接工艺,等离子切割工艺,或任何其他类型的焊接工艺。
图1是根据本公开的一些方面的焊接训练系统10的实施例的方框图。如上所述,该焊接训练系统10的实施例包括任何适当的焊接相关系统,包括使用焊接训练系统10执行焊接应用的焊接相关系统,该焊接训练系统10实现模拟或增强的焊接体验。在某些实施例中,该焊接训练系统10包括移动设备12,它可以是任何个人移动设备和/或便携式移动设备。例如,该移动设备12可以是蜂窝电话(例如,智能电话、电话,电话,),平板电脑、膝上计算机、个人数字助理(PDA)等等。该移动设备12可具有:多种传感器(例如,加速度计、陀螺仪、照相机、磁力仪、GPS),这些传感器布置在如下所述的传感系统14中;存储器,用于储存数据和指令;以及处理器,被配置成接收来自传感器的反馈和执行移动设备12的指令。在某些实施例中,该移动设备12包括显示屏,其被配置成将信息(例如,图形的模拟焊接体验、增强焊接体验、焊接参数)显示给作业员。
特别地,图示的实施例描述了可通信地耦接至焊枪24的移动设备12。该焊接训练系统10的移动设备12包括一个或多个处理器16(或任何计算元件)、存储设备18、存贮设备20和显示器22。该处理器16可被用于执行软件,例如焊接软件、焊接应用、图像处理软件、传感设备软件等等。此外,该处理器16包括一个或多个微处理器,例如一个或多个“通用”微处理器、一个或多个专用微处理器和/或专用集成电路(ASICS)、或者它们的某些组合。例如,该处理器16可包括一个或多个精简指令集(RISC)处理器。
该存储器18包括易失性存储器,例如随机存取存储器(RAM),和/或非易失性存储器,例如只读存储器(ROM)。该存储设备18可储存各种各样的信息,并可用于各种目的。例如,该存储设备18可储存处理器可执行指令(例如固件或软件)供处理器16执行,例如通过移动设备12允许模拟或者增强焊接体验的指令(例如应用),和/或用于传递反馈信息到移动设备12或从移动设备12传递反馈信息的指令。另外,在模拟或增强焊接作业过程中,各种焊接工艺的各种控制体系,连同相关的设定和参数,可被储存在存贮设备20和/或存储设备18内,再加上被配置成提供一个具体输出的代码(例如开始送丝、启动气流、捕获焊接电流数据、探测短路参数、确定飞溅量等等)。
该储存设备20(例如非易失性存贮器)可包括ROM、闪存、硬驱、或任何其它合适的光学、磁、或固态储存介质,或者它们的组合。该储存器20可储存数据(例如与模拟或者增强焊接作业对应的数据、与模拟或者增强焊接作业对应的视频和/或操作参数的数据等等),指令(例如焊接系统的软件或固件,焊接应用的软件,实现与移动设备12的通信和/或控制的软件等等)和其他任何适当的数据。如将能领会的那样,与模拟或增强的焊接作业对应的数据可包括焊接作业录像,模拟或增强视频,系统10元件的定向和/或位置,焊枪24相对于模拟或真实工件的工作角度,焊枪24相对于模拟或真实工件的行进角度,焊枪24相对于模拟或真实工件的行进速度,系统10的元件之间的距离,电压,电流,横越路径,间断性分析,焊接设备设定等等。
如上所述,该移动设备12包括显示器22,其被配置成显示数据和/或与模拟或增强的焊接工艺相关的屏幕(例如用于显示焊接软件产生的数据),或者其他类似物。该显示器22提供一个图形用户界面给焊接作业员(例如焊接指导员,焊接学生等等)。例如,由显示器22显示的图形用户界面可提供多个屏幕,以使作业员(例如焊接学生、焊接玩家、焊接实习生等等)可以执行模拟或增强的焊接任务,观看模拟或增强焊接参数的实时反馈,查看模拟或增强焊接任务的焊后总结,查看来自以前的模拟或增强的焊接任务的平均值和/或结果,比较和查看一个或者多个焊接作业员的最终焊接分数等等。在某些实施例中,显示器22是一个触屏显示器,其被配置成接收触摸输入并将与触摸输入对应的数据提供给移动设备12。在某些实施例中,显示器22被配置成显示与传感设备软件对应的信息,并提供被执行的焊接的虚拟的和/或模拟图像,如下文中进一步描述的那样。
如上所述,移动设备12包括焊接应用,该焊接应用被布置在存储设备18上并由处理器16执行。此外,作业员可以通过显示器22操作焊接应用。例如,焊接应用可允许作业员从多种类型或序列的焊缝几何图形中进行选择,例如T形,圆角,截头或其他几何图形,也可以选择焊缝的方向(例如平的,水平的,垂直的,高架的)。根据模拟焊缝的选择参数,焊接应用可以开始。在某些实施例中,在作业员启动焊枪24的触发器或者在显示器22上选择焊接工艺之后,并且当焊枪24移动时,移动设备12的传感系统14可收集焊枪24的位置和/或定向信息作为传感器反馈信息。根据传感器反馈信息,显示器可以图形地展示焊枪24进入到模拟焊接环境中相对于模拟焊缝的位置。
在某些实施例中,显示器22可显示菜单,在那里,作业员16能够规定一些设定,例如焊接应用的类型、焊接的模式(例如模拟模式,真弧模式,增强模式,以及其它模式)、焊缝的几何形状、方向、材料厚度、送丝速度和电压。另外一个实施例可允许作业员挑选焊缝、方向、材料厚度,并且移动设备12的焊接应用可暗示送丝速度和电压。作业员可以调整起始点的设定或者接受这些参数。根据传感系统14探测到的行进速度、角度和方向,移动设备12可被配置成模拟焊接。随着技术改进,基于行进速度、角度和方向,作业员的模拟焊接将会在焊缝的期望位置和正确宽度上进行。
在某些实施例中,移动设备12可利用来自传感系统14的传感器反馈来确定类似于行进速度、相对于焊缝的焊丝位置、焊枪角度、接触点或者焊枪到焊缝/工件距离的参数。移动设备12的处理器16可以执行指令(例如软件)以利用传感器反馈来模拟和显示模拟焊接。通过各种来源,包括但不限于,有形的非永久性的储存介质(例如闪存盘、光盘、磁盘)、网络、网站(例如制造商网站、www.Millerwelds.com)等等,软件可供移动设备12使用。在某些实施例中,来自一个或多个作业员执行的模拟焊接的分数和结果也可被储存(例如在存储器18内)或者共享。
特别地,移动设备12的传感系统14可包括多种传感器,用于探测移动设备12(引申开来,移动设备12装配在其上的焊枪24)相对于参考点或参考物的运动、位置和/或方向。例如移动设备12可具有用于角度信息的一个或多个3D陀螺仪,一个或多个3D加速度计,一个或多个接近传感器,一个或多个磁力计,一个或多个GPS接收器,一个或多个Bluetooth传感器,其他无线场传感器或者它们的任意组合。移动设备12可利用一个或多个这些传感器探测移动设备12在一定方向上的速度的改变和/方向的改变。来自一个或多个传感器的反馈(例如信号)可被储存在移动设备12的存储器18内,用于后续检索和/或传送到另一个移动设备、计算机系统或者网络,或者它们的任意组合。移动设备12的处理器16实时地利用来自一个或多个传感器的反馈在显示器22上模拟和显示模拟焊接应用。在某些实施例中,移动设备12可仅仅利用这些传感器中的一个或多个。在某些实施例中,移动设备12上的传感系统14包括一个或多个照相机或者光学传感器。在某些实施例中,这些照相机或者光学传感器可用于识别环境中的多个元件,这些元件对模拟或者增强焊接应用作出指导,如结合图3进一步作说明的那样。
在某些实施例中,至少部分基于移动设备12的加速度(并因此是耦接在移动设备12的焊枪24的加速度),移动设备12的传感系统14里的一个或多个3D加速度计可产生信号,这些由3D加速度计由产生的信号可以G(大约9.81m/s2)为单位。移动设备12的总加速度大约等于重力加速度(例如1G)加上使用者施加到移动设备12上的加速度。移动设备12可以利用来自一个或多个3D陀螺仪的信号将重力加速器和使用者施加的加速器分离开来,所述来自一个或多个3D陀螺仪的信号与来自一个或多个3D加速度计的信号是大约同时到来的。
此外,在某些实施例中,传感系统14包括一个或多个3D陀螺仪,移动设备12可利用这些3D陀螺仪来确定移动设备12的相对于一个或多个参考平面旋转。在一些实施例中,一个或多个3D陀螺仪可利用来自一个或多个3D加速器的信号产生陀螺仪增强运动数据,包括,但不限于,移动设备12的欧拉角(例如俯仰角,偏航角,翻滚角)、姿态四元数、旋转炬阵、3D加速度的重力分量、3D加速度的使用者加速度分量或转速、或者它们的任意组合。在某些实施例中,由一个或者多个3D陀螺仪确定的移动设备12的欧拉角可以是以弧度或者角度为单位的。
此外,在某些实施例中,传感系统14可包括一个或多个全球定位系统(GPS)接收器,被配置成报告移动设备12的位置数据。该位置数据包括,但不限于,经纬度、相对于磁北极的磁航向、相对于正北方的真航向、运动的过程与速度、或者高度,或者它们的任意组合。如将能领会的那样,经纬度可以是使用世界大地测量系统(WGS84)坐标系的地理坐标系。过程数据可代表移动设备12和/或焊枪24行进的方向,它是以角度为单位的。过程值是以度为单位测量的,开始于正北方向,并绕罗盘以顺时针继续。例如,北方为0度,东方为90度,南方为180度,西方为270度。速度数据可代表移动设备12和/或焊枪24的瞬时速度,如米/秒。这个值代表了移动设备12和/或焊枪24在其目前航行方向上的瞬时速度。一个或多个磁力计提供了移动设备12和/或焊枪24的罗盘方向,例如以微特斯拉为单位。
在某些实施例中,基于从传感系统14接收到的传感器反馈,显示器22可描述模拟的焊接环境。例如,显示器22在焊接模拟时将会变暗以显示火花、电弧和发光焊渣,作为技术反馈。在焊枪或者其他设备上的开始开关或者触发器,例如脚踏板或手指控制装置,可与移动设备12通信。作为附加或替代,通过触碰显示器22上的开始图标可启动模拟焊接应用。相应地,在作业员开始模拟焊接之后,显示器22将变暗以描述模拟焊接体验和环境,并且作业员可在模拟焊接应用的时长内通过焊枪24移动移动设备12的显示器22,并观察焊接的模拟成形。
在某些实施例中,代替其中整个模拟焊缝是通过模拟焊接应用产生的模拟焊接环境,可以经由移动设备12的显示器22显示增强的焊接环境,其中真弧的现场视频通过其它视频和/或信息而增强。在这些实施例中,显示器22可基于从传感系统14接收到的传感器反馈来描述增强焊接环境。例如,如果作业员从显示器22上选择一个增强焊接模式,则移动设备12可以被配置用以增强现实仿真。作为这个增强现实仿真的一部分,移动设备12可以接收和显示焊接作业员用真弧执行真实焊接的视频直播。此外,基于从传感系统14接收到的传感器反馈,移动设备12可将虚拟焊接环境结合到真实焊接应用的视频直播。如此,显示器22是大体是透明的,以允许焊接作业员可以观察到在真实焊接环境中的真实物体。但是,虚拟的焊接环境可以被描绘到显示器22的诸个部分上,以同样允许焊接作业员可以观察到被叠加到在视频直播中捕获的真实(真实世界)物体上的虚拟物体。该虚拟物体可以是在真实焊接工艺过程中引导作业员的任何数量的图形、符号、文本或者图像。
在某些实施例中,焊接训练系统的元件被作业员(例如焊接学生、实习生、玩家、招聘员、教练等等)使用,来执行模拟的或者增强的焊接作业,该焊接作业提供给使用者模拟的或增强的焊接体验。例如,焊接训练系统10包括焊枪24(或者是真弧焊枪或者是假焊枪)、焊接电源24(在真弧焊接过程中供应焊接电源)、焊接送丝器28(在某些实施例中在真弧焊接过程中供应焊丝)、气体供应30(在某些实施例中在真弧焊接过程中供应保护气)、或者它们的任意组合。应当指出,在一些实施例中,焊接训练系统10可包括网关32来促进焊接训练系统10的各个元件之间的通信。例如,移动设备12可与焊接训练系统10的网关32无线通信,并且网关32可对于焊接训练系统10的外部元件(例如在焊接头盔36上的显示器34或外部显示器38)接收和传递信息(与模拟或增强焊接作业相关的传感器反馈信息、模拟或增强焊接参数、模拟或增强焊接任务的焊后汇总等等)。在某些实施例中,焊接训练系统10可通过有线或无线(例如Bluetooth,Wi-Fi等等)连接而耦接到焊接头盔36和/或外部显示器38,并可将反馈投影到到头盔36上。在某些实施例中,外部显示器38是一个增强现实显示器,它可包括光学投影系统、监视器、手持设备、头戴式显示器、眼镜(例如被配置成增强人的一部分视野范围的眼镜)等等。当运行带焊接头盔36的系统以更近似地模拟焊接而头盔没有变暗的时候,角度、指导、声音和其他信息对于反馈是有用的。
此外,在某些实施例中,一个或多个焊接训练系统10可耦接至监控/分析系统40。该监控/分析系统40可收集来自一个或多个焊接训练系统10的信息,并且该监控/分析系统40可以被配置成离线工作或者通过网络42(例如Wi-Fi网络)工作。网络42可将监控/分析系统40可通信地耦接到云储存/服务44中。云储存/服务44可包含提供反馈或者辅助指导员或作业员执行焊接工艺的信息。该焊接训练系统10也可利用正确技术、行进速度和距离以及其它训练变量的信息数据库提供触觉振动和/或声音反馈给作业员。至少部分基于作业员执行的一个或多个模拟或增强焊接的历史,可提供触觉振动和/或声音反馈。云储存/服务44可耦接至远程计算机46,该远程计算机46提供或者检索来自/去往云44的信息。
应当指出,虽然本实施例的各个方面总体在焊接训练系统的背景下被描述,但是本实施例的特征也可被用于其他类型的焊接系统中,例如本文上面描述的类型。
图2是根据本公开的一些方面的耦接至图1中的焊枪24的颈部50的移动设备12的实施例。移动设备12可以通过一个或多个安装设备52固定地或活动地安装在焊枪24上,例如安装在焊枪24的颈部50上。将能理解,尽管被图示为耦接至焊枪24的颈部50,然而在其他实施例中,一个或多个安装设备52也可以被配置成耦接到焊枪24的其他位置(例如把手)。在图示实施例中,作业员可移动移动设备12或者焊枪24,从而接合焊枪24和移动设备12两者以执行模拟或增强的焊接工艺。特别地,移动设备12上的显示器22可被定位在颈部50上,这样就可以指引作业员的眼睛在焊接时以期望的方式看着焊枪24。在某些实施例中,为了操作舒适和方便,该一个或多个安装设备52可以相对于焊枪24是活动的,以允许作业员些微地移动、转动、倾斜或者调节移动设备12的位置。另外,在某些实施例中,该一个或多个安装设备50可被配置成活动地耦接在焊枪24上的恰当位置。例如,当焊枪24没有被用于为焊接训练时,可以将一个或多个安装设备50拆掉。
如图2所示,在某些实施例中,安装设备52可包括或直接耦接到防护盖54上,该防护盖54被配置成将移动设备12相对于焊枪24支撑在恰当的位置上,同时也可以保护移动设备12在真实焊接过程中不受焊接材料(例如飞溅物)的伤害。在某些实施例中,该防护盖54可以是透明的,以使得在作业过程中移动设备12(和/或作业员)的视野范围不受限制。例如,在模拟或增强焊接工艺过程中,移动设备12能够通过透明防护盖54(通过靠近防护盖54布置的照相机,当移动设备12通过防护盖54固定就位时)收集信息或数据。进一步,焊枪24可包括触发器53。如上所述,通过移动设备12上的触屏显示器22或者按压焊枪24上触发器53或者它们的任意组合来开启模拟或增强焊接作业。在某些实施例中,附加的触发器或开关可被布置在焊枪24或脚踏板上。触发器和/或开关通过有线或无线(例如Wi-Fi,Bluetooth)连接通信以开始。例如,作业员可接合焊枪24上的触发器53以开始一个模拟或增强焊接作业。在某些实施例中,移动设备12可以通过藉由安装设备52的有线连接感应触发器53的致动或释放。
某些实施例中,移动设备12包括照相机56(或其他光学感应器),照相机56也可以是传感系统14中的元件。在某些实施例中,在增强焊接工艺过程中,可利用照相机56提供真实电弧的视频直播。例如,如上所述,在某些实施例中,防护盖54可以是透明的,并且移动设备12上的照相机56可配置成通过透明防护盖54收集信息或数据。作为替代或附加,在某些实施例中,照相机56可以配置成通过布置在防护盖54上的一个或多个孔收集信息或数据。在某些实施例中,在模拟焊接工艺过程中,可利用照相机56探测一个或多个方向设备58,如参照图3进一步描述的那样。当通过安装设备52被固定就位时,尽管图2中所示的照相机56看上去在移动设备12与焊枪24的作业端相反的一侧,但是将理解移动设备12的照相机56可在移动设备12的两侧上都有功能,由此在真弧焊接或模拟或虚拟的焊接作业过程中,照相机56能够收集来自工件(或方向设备58)周围的操作区域的视频和图像数据。
图3是耦接至图1的焊枪24的移动设备12的实施例,在这里,移动设备12利用了根据本公开一些方面的方向设备58。方向设备58可以是带有一系列标识符60(例如各种图案的点、线、曲线、网格、凹陷、凸起、几何形状、纹理、凸面、条形码、QR条码等等)的预制的二维或三维材料。在某些实施例中,方向设备58可以是一个单独的标记、一张纸、一片塑料、一个固体表面,一个标签等等。方向设备58被利用到模拟焊接工艺中,并可配置成导引焊枪24和指导作业员执行模拟焊接。例如,方向设备58可以是模拟的工作台,作业员可以在其上面对虚拟或者模拟焊接应用执行一模拟焊缝。
在某些实施例中,移动设备12上的传感系统14可利用照相机56探测在方向设备58上的标识符60。例如,照相机56可探测到一系列图案的标识符60,该标识符60帮助移动设备12确定移动设备12相对于方向设备58上的开始点位于什么位置、移动设备12(例如,引申到焊枪24)相对于方向设备58的行进速度、移动设备12(例如,引申到焊枪24)相对于方向设备58的附加角信息、移动设备12(例如,引申到焊枪24)相对于方向设备58的距离,用于焊接模拟。在某些实施例中,没有传感系统14中的其他传感器,照相机56也可单独工作,以将反馈提供到移动设备12上。在其它实施例中,移动设备12可使用照相机56和一个或多个传感器,所述一个或多个传感器包括,但不限于,一个或多个3D加速器、一个或多个接近传感器、一个或多个磁力计、一个或多个GPS接收器、一个或多个蓝牙传感器、或者其他无线场传感器,或者它们的任意组合。例如,照相机56可确定移动设备12(例如,引申到焊枪24)相对于方向设备58的位置和/或定向,并可使用其他传感器确认和/或微调所确定的位置和/或定向。在一些实施例中,移动设备12(例如,通过磁力计)可感应到布置在方向设备58上的小磁铁64以确定模拟焊接工艺的速度、方向、方位和其他反馈参数。
尤其是,照相机56可以探测在方向设备58上的标识符60的图案。标识符60可以是唯一的(例如,颜色、几何形状等等),并被布置在方向设备58的不同位置上,以允许系统10(例如,移动设备12、焊枪24等等)相对于方向设备58的精确的定向和/或定位信息。这种唯一图案能够使移动设备12确定模拟焊接的参数,例如行进距离,焊缝宽度、深度、一个或多个角度,或者它们的任意组合。照相机56可探测标识符60,并可提供该信息给移动设备12上的处理器16。处理器16可被配置成从标识符60提取信息,该标识符60确定焊枪24针对模拟焊接在方向设备58上的方向。进而,方向设备58可以在整个模拟焊接过程中引导作业员。在某些实施例中,作业员可以基于探测到的标识符(例如,基于焊枪24针对模拟焊接的位置和/或定向信息)动态地调整模拟焊接工艺中的一个或多个操作参数。
在一些实施例中,移动设备12中的一个或多个传感器被用于帮助确保照相机56生成的测量的精确性。在其它实施例中,没有标识符60和/或方向设备58,照相机56也可以使用。就是说,照相机56可以通过利用照相机56的视野范围内一个或多个物体作为方向设备确定移动设备12的相对运动和/或相对方向。在这种情况下,方向设备58可以是不需要的。
在一些实施例中,在真实的焊接应用过程中,移动设备12可被安装到焊枪24上,用于提供角度、位置、行进速度和其他传感器信息,这些都归因于焊枪24。换句话说,当移动设备12被安装到焊枪24上时,移动设备12起到与改进工具相似的功能,用于将移动设备12的照相机56、传感器、显示器22、处理器16、存储器18和存贮器20到焊枪24上,由此允许焊枪24起到移动焊接训练系统的作用。进一步,在这种情况下,移动设备12和焊枪24也可针对增强焊接应用而配置。在某些增强焊接应用中,移动设备12可被放置在作业员手和/或焊枪24上的不同区域,以提供反馈而不阻碍实际的焊接工艺。照相机56也可使用各种过滤装置来帮助追踪焊接甚至显示实际焊接送丝的发生。
在某些实施例中,便携式的焊接训练系统10可包含由移动设备12提供的模拟焊接体验的具有竞争的、游戏方面,并可基于接收到的反馈提供焊接分数给使用者。此外,移动设备12可以访问网络42或云44内的储存器以储存和/或检索每个焊接作业员的信息,例如,使用者的身份信息、历史焊接信息、和/或历史焊接分数。
图4是根据本公开一些方面的屏幕70的实施例,该屏幕70示出了与模拟的、增强的或者虚拟的真实焊接环境对应的数据,例如通过焊接训练系统10产生的那些数据。屏幕70可以由布置在移动设备12上的焊接训练软件产生,并可被显示在显示器22、外部显示器38和/或头盔36上。在焊接作业员执行模拟的、增强的或虚拟的真实焊接作业之前、过程中和/或之后,屏幕70展示可图形地显示给焊接作业员的参数。例如,参数可包括工作角72、行进角72、触尖到工件的距离76(例如CTWD 76)、焊枪行进速度78、焊枪24相对于工件的接近度80、焊接电压82、焊接电流84、焊枪的方向、焊枪的位置、焊枪24的目标、模拟的视频重播、增强的或虚拟的真实焊接环境86等等。
如上所述,图形地展示的参数包括参数(例如,当执行焊接训练任务时)当前值的指示88。此外,图表92可显示参数值的历史,分数92可显示一总百分比,其对应于焊接作业员执行焊接训练任务花费的多少时间是在可接受值的范围内。如上所述,焊接训练任务的视频重播86被提供在屏幕70上。视频重播86可显示焊接作业员以模拟环境、增强环境或者叠加在其上的虚拟真实环境执行模拟或真实焊接的视频直播。
在某些实施例中,焊接期间的时间94是可以被焊接作业员选择的,为了建立焊接参数和视频重播86之间的联系,通过选择时间94,焊接作业员可观看在选定的时间94内的视频重播86连同焊接参数。焊接训练软件可被配置成至少部分地基于焊接参数数据再生成焊接数据,以同步视频重播86和再生成的焊接数据并提供同步的视频重播86和再生成的焊接数据给显示器22、外部显示器38和/或头盔36。进一步,在某些实施例中,每个焊接作业员98的焊后数据和/或分数的汇总可被显示在汇总页96上。应当指出,在某些情况下,屏幕70可显示每个焊接个人98的总分数的比较。事实上,焊接训练系统可包括或者利用任何数量的焊接训练特征(例如总的焊接分数)或技术(例如比较焊接训练信息),这些都公开在2013年3月15日提交的公开号为2014/0272837,题目为“焊接训练系统的多模式软件和方法”的美国专利申请公布中,本申请参考引用了该专利的全部内容。
虽然仅仅说明和描述出本实施例的某些特征,但是本领域的技术人员依然会想到许多修改和变化。因此,所附的权利要求旨在覆盖本发明精神的所有修改和变化。
Claims (21)
1.一种焊接训练系统,包括:
移动设备,所述移动设备被配置成使用安装件附接至焊接附件,所述移动设备包括一个或多个传感器,其中所述移动设备被配置成:
经由所述移动设备的所述一个或多个传感器收集信息,所述信息指示所述移动设备在焊接作业过程中的动态位置或定向;以及
基于所述信息经由所述移动设备的显示器来显示焊接环境。
2.如权利要求1所述的焊接训练系统,进一步包括焊枪,所述移动设备被配置成可通信地耦接至所述焊枪。
3.如权利要求2所述的焊接训练系统,其中所述焊枪被配置成在模拟的工作表面上对模拟的焊缝执行模拟的焊接作业,并且其中所述移动设备被配置成至少部分地基于所述信息来显示模拟的焊接环境。
4.如权利要求2所述的焊接训练系统,其中所述焊枪被配置成用真弧对真实的焊缝执行真实的焊接作业,并且其中所述移动设备被配置成至少部分地基于所述信息显示增强的焊接环境。
5.如权利要求4所述的焊接训练系统,其中所述增强的焊接环境的显示包括对在所述真实的焊接作业中使用的真实物体的现场直播,其中一个或多个虚拟物体叠加在所述真实物体上。
6.如权利要求2所述的焊接训练系统,其中所述移动设备被配置成接收触发器的致动或释放的指示,并且所述移动设备被配置成响应于检测到所述触发器的致动的所述指示来执行焊接模拟。
7.如权利要求2所述的焊接训练系统,其中所述焊枪被配置成在模拟的工作表面上对模拟的焊缝执行模拟的焊接作业,并且其中所述移动设备被配置成将所述焊接环境显示为增强的焊接环境。
8.如权利要求7所述的焊接训练系统,其中所述移动设备被配置成将所述增强的焊接环境显示为在真实的焊接作业中使用的真实物体的现场直播,其中一个或多个虚拟物体叠加在所述真实物体上,所述一个或多个虚拟物体包括所述模拟的焊缝或所述模拟的工作表面中的至少一者。
9.如权利要求1所述的焊接训练系统,其中所述焊接训练系统被配置为提供触觉振动或声音反馈中的至少一者。
10.如权利要求1所述的焊接训练系统,其中所述一个或多个传感器包括照相机。
11.如权利要求10所述的焊接训练系统,其中所述照相机被配置成探测定向设备,所述移动设备被配置成基于所述照相机所捕捉的所述定向设备的图像来确定所述信息。
12.如权利要求10所述的焊接训练系统,其中所述一个或多个传感器进一步包括以下中的至少一者:加速度计、陀螺仪、接近传感器、磁力计、GPS接收器或电磁场传感器,所述移动设备被配置成基于由所述照相机捕捉的图像和以下各项中的所述至少一者的组合来确定所述信息,其中以下各项包括:所述加速度计、所述陀螺仪、所述接近传感器、所述磁力计、所述GPS接收器或所述电磁场传感器。
13.如权利要求1所述的焊接训练系统,其中所述移动设备被配置成通过显示由模拟的焊接应用生成模拟焊接的全部来显示所述模拟的焊接环境,所述模拟的焊接环境包括模拟的焊缝、模拟的工作表面以及真实的焊接作业中使用的真实物体的现场直播,其中一个或多个虚拟物体叠加在所述真实物体上,所述一个或多个虚拟物体包括所述模拟的焊缝或所述模拟的工作表面中的至少一者。
14.如权利要求1所述的焊接训练系统,其中所述移动设备被配置成基于所述信息确定操作参数,所述操作参数包括以下参数中的至少一者:焊枪的工作角、所述焊枪的行进角、所述焊枪的行进速度、触尖到工件的距离、所述焊枪相对于焊缝的接近度、焊接电压、焊接电流、所述焊枪的定向或所述焊枪的位置。
15.如权利要求1所述的焊接训练系统,进一步包括定向设备,其中所述定向设备包括标识符,其中所述移动设备的传感器被配置成探测所述标识符。
16.如权利要求15所述的焊接训练系统,其中所述移动设备被配置成至少基于对所述标识符的探测来确定所述移动设备的第一位置,并且其中所述移动设备被配置成至少部分地基于安装位置和所确定的所述移动设备的所述第一位置来确定焊枪相对于所述定向设备的第二位置。
17.如权利要求15所述的焊接训练系统,其中所述标识符包括以下中的至少一者:图案、点、线、曲线、网格、凹陷、凸起、几何形状、纹理、凸面、条形码或QR条码。
18.如权利要求1所述的焊接训练系统,其中所述移动设备被配置成基于所述信息和所述焊接作业来执行游戏应用。
19.如权利要求1所述的焊接训练系统,其中所述移动设备包括存储设备,并且所述移动设备被配置成存储以下中的至少一者:基于所述信息的使用者身份信息、基于所述信息的历史焊接信息或基于所述信息的历史焊接分数。
20.如权利要求1所述的焊接训练系统,其中所述移动设备被配置成将所述信息传送到外部设备上。
21.如权利要求20所述的焊接训练系统,其中所述外部设备是外部显示器、远程计算系统或云储存或者云处理。
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CA2927243C (en) | 2019-04-09 |
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MX2016004471A (es) | 2016-08-03 |
US11127313B2 (en) | 2021-09-21 |
CN105745696A (zh) | 2016-07-06 |
US10056010B2 (en) | 2018-08-21 |
MX358909B (es) | 2018-09-07 |
WO2015084734A1 (en) | 2015-06-11 |
CN105745696B (zh) | 2019-04-26 |
US20150154884A1 (en) | 2015-06-04 |
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