JP4129342B2 - Manual welding support device, manual welding support method, manual welding training device, and manual welding training method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a manual welding support apparatus and a manual welding support method for supporting a construction work of a welder engaged in manual welding construction, and a manual welding training apparatus and a manual welding training method used in training of a welder.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, in the field of welding construction, an apparatus for performing welding practice training for a welder is known (for example, see Japanese Patent Application Laid-Open No. 4-97383). This conventional example is shown in FIG. 11 is a construction condition setting unit 201 for setting an item to be trained from among items such as material and construction know-how within predetermined welding construction conditions, and an attempt to train. A light pen 202 for simulating a welding arc to be generated between the welder to be welded and the welding arc simulated by the light pen 202 to evaluate the welding arc viewed from the material to be welded. The light receiving board 203 that receives an optical signal that carries information on the pseudo welding result, the false welding result obtained by the light receiving board 203 and the contents set by the construction condition setting unit 201 are compared, and based on the comparison result A comparator 204 for judging the training result and the like, and a display 205 for displaying or instructing the training result by the comparator 204. It has become possible 摸擬 practical training of welding that.
[0003]
[Problems to be solved by the invention]
However, since the above-described conventional pseudo-practical skill training apparatus is intended to allow a welder to acquire a skill so that a welding arc can be stably generated and maintained, Information that can be perceived by the trainee at the pseudo welding location is only the shape of the welding arc simulated by a light pen, and is determined by the shape of the melted part such as the stability of the penetration depth and the securing of fusion to the groove wall. There was a problem that the welding technique had to be acquired while actually carrying out welding.
[0004]
On the other hand, it has been pointed out that human welding work can flexibly cope with the shape of the welded part, etc., compared to automatic welding work, but is greatly inferior in terms of stability of welding quality and work efficiency.
[0005]
For example, in automatic welding construction, devices that monitor the automatic welding process online by monitoring some typical features in the welding process have been developed and put to practical use, and various methods related to this have been developed. It has been proposed and attempts have been made to patent its technology development research and methods. On the other hand, the technique of monitoring and supporting manual welding operations performed by human welders does not apply such automatic welding monitoring technology, and the welding quality is not limited to the skill and skill of the welder. It was very dependent on the degree.
[0006]
In other words, in the conventional manual welding environment, there is no application example where the welding state is monitored online or the work of the welder is supported by providing information, etc. Examples of application have been considered difficult because there are no known problems such as what to measure in the manual welding conditions and devices that do not disturb the welding environment.
[0007]
The present invention has been made in consideration of such conventional problems, and maintains the welding quality stably regardless of the skill and skill level of the welder during manual welding work in welding monitoring, and improves work efficiency. For the purpose.
[0008]
In addition, the present invention is intended to easily and efficiently acquire the technique on welding construction in which the melted part shape and the like such as the stability of the penetration depth and the securing of the fusion to the groove wall are determined in the practice training. Another purpose.
[0009]
[Means for Solving the Problems]
In order to achieve the above-mentioned object, the manual welding support apparatus according to the present invention monitors the state of manual welding while monitoring the state of manual welding when the welder performs manual welding on the object to be welded. A device that supports the manual welding by presenting it to the welder in a recognizable manner, and includes data relating to the welding environment including the welding object and the behavior of the welder during the welding operation when the manual welding is performed. Data measuring means for measuring the position of the welder in the welding state during the welding operation, head movement, hand position, hand movement, face orientation, welding from the data measured by the data measuring means Heat input and heat input direction welded part A feature amount extraction means for extracting at least one feature amount of the melted state or the welded state; Data reference means for referring to data at the time of normal operation and failure occurrence obtained at the time of welding work performed in the past, and data referred to by this data reference means; The feature quantity extracted by the feature quantity extraction means; Means for determining the quality of the welding state based on Welding state determination means, and welding state presentation means for presenting information relating to the transition of the welding state including the determination result by the welding state determination means to the welder who is performing the welding recognizable. . Further, in addition to this configuration, there is provided a welding process recording means for recording / holding data obtained by the data measuring means, calculation processing results and determination results, and a welding process display means for displaying the determination results by the welding state determination means. It is desirable to have it.
[0010]
The data measuring means has a plurality of different data. A plurality of data obtained by the data measuring means It is preferable to include a plurality of measuring devices that simultaneously measure multidimensional data composed of According to the plurality of measuring devices, the welding state can be described in more detail.
[0011]
The feature amount extraction means includes a plurality of arithmetic processing devices that process a plurality of different feature amounts simultaneously and in parallel from the multidimensional data measured by the plurality of measurement devices and extract them in a multifaceted manner. Is preferred.
[0012]
The welding state determination means has been performed in the past Appropriate It is preferable to include data reference means for referring to data obtained at the time of welding, and means for determining the quality of the welding state based on the data referred to by the data reference means.
[0013]
The welding state presenting means directly presents the determination result of the welding state determined by the welding state determining means as a sensory stimulus for a perception excluding the sight of the welder, for example, hearing, touch, force sense, etc. It is preferable that the perception transmitting means includes a means for alerting the welder and urging the welding operation to be changed.
[0014]
It is preferable that the welding state presentation unit includes a unit that superimposes and displays information on an action path of an action to be taken by the welder on the field of view of the welder.
[0015]
The welding state presentation means includes data comparison means for comparing data obtained at the time of appropriate welding construction performed in the past and data relating to the current welding operation, and the welding state based on the comparison result by the data comparison means. It is preferable to include a means for judging whether the quality is good or bad.
[0016]
The welding state presenting means is a specific one during the welding operation. A plurality of data obtained by the data measuring means Is preferably provided on the field of view of the welder selectively and preferentially.
[0017]
It is preferable that the feature amount extraction unit includes a unit that estimates compensation data when the data measured by the data measurement unit is not appropriate due to disturbance such as mixing of welding noise. The estimation of the compensation data is preferably based on, for example, another measurement amount or a physical model.
[0018]
In order to achieve the above-described object, the manual welding construction method according to the present invention is configured to monitor the progress of manual welding while monitoring the state of manual welding when the welding is performed on the object to be welded by the welder. A method for supporting the manual welding by presenting it to a welder in a recognizable manner, and the data relating to the welding environment including the welding object and the behavior of the welder during the welding operation when the manual welding is performed. From the measured data, the position of the welder's head, the movement of the head, the position of the hand, the movement of the hand, the direction of the face, the amount of heat applied to the weld and the heat input from the measured data. Direction and welded part Extract at least one feature amount from the melted or welded state of Data obtained at the time of normal operation and malfunctions obtained during past welding operations The extracted feature quantity and And refer to this referenced data It is characterized by having each process which judges the quality of the above-mentioned manual welding state based on this, and presents the information about the transition of the welding state including this judgment result to the welder who is performing the welding operation so that it can be recognized.
[0019]
In order to achieve the above object, the manual welding training apparatus according to the present invention monitors the progress of manual welding while monitoring the state of manual welding when a welder performs manual welding on a welding target. A device that supports the manual welding by presenting it to the welder in a recognizable manner, and includes data relating to the welding environment including the welding object and the behavior of the welder during the welding operation when the manual welding is performed. Data measuring means for measuring the position of the welder in the welding state during the welding operation, head movement, hand position, hand movement, face orientation, welding from the data measured by the data measuring means A feature quantity extraction means for extracting at least one feature quantity from among a heat input amount and a heat input direction to be given to a part, and a melting state and a welding state of a simulated weld, Data reference means for referring to data at the time of normal operation and failure occurrence obtained at the time of welding work performed in the past, and data referred to by this data reference means; The feature quantity extracted by the feature quantity extraction means; Means for determining the quality of the welding state based on Welding state determination means, and welding state presentation means for presenting information relating to the transition of the welding state including the determination result by the welding state determination means to the welder who is performing the welding recognizable. .
[0020]
In addition to this configuration, simulated welding process recording means for recording / holding data obtained by measuring means, calculation processing results, and determination results, and simulated welding process for displaying welder's behavior and simulated welding status in training It is desirable to include display means.
[0021]
With this configuration, the information obtained from the welder training operation measuring means and the welding training environment measuring means is calculated using the calculation processing means and the simulated welding information determination means, and the calculation result is stored in the simulated welding process recording means. In addition, the welder's behavior and simulated welding status in the training are displayed by the simulated welding process display means, and the simulated welding environment generated by the simulated welding environment image generating means is displayed to the welder during the welding training. The visual information of the part and the auditory, tactile, and haptic information derived from the result of the arithmetic processing means and the like are presented using the simulated welding state perception presenting means. Thereby, it is possible to provide an environment where it is felt that welding is actually performed to the welder, and more advanced welding training is possible.
[0022]
The data measuring means has a plurality of different data. A plurality of data obtained by the data measuring means It is preferable to include a plurality of measuring devices that simultaneously measure multidimensional data composed of According to the plurality of measuring devices, the simulated welding state can be described in detail.
[0023]
The feature amount extraction means includes a plurality of arithmetic processing devices that process a plurality of different feature amounts simultaneously and in parallel from the multidimensional data measured by the plurality of measurement devices and extract them in a multifaceted manner. Is preferred.
[0024]
It is preferable that the feature amount extraction unit includes a unit that estimates compensation data when the data measured by the data measurement unit is not appropriate due to disturbance such as mixing of welding noise. The estimation of the compensation data is preferably based on, for example, another measurement amount or a physical model.
[0025]
The simulated welding state determination means has been performed in the past Appropriate It is preferable that the apparatus includes data reference means for referring to data obtained at the time of various welding operations, and means for determining the quality of the simulated welding state based on data referred to by the data reference means.
[0026]
The simulated welding state presenting means is configured to determine whether the simulated welding state is good or bad as a result of the simulated welding state determination unit by using a sensory stimulus for a perception excluding the sight of the welder, for example, hearing, tactile sense, and force sense. It is preferable that the sensory transmission means is provided with means for prompting the welder to change the welding operation.
[0027]
The simulated welding state presenting means preferably includes means for superimposing and presenting guidance information on an action path of an action to be taken by the welder on the field of view of the welder.
[0028]
The simulated welding state presentation means has been performed in the past Appropriate Data comparison means for comparing data obtained at the time of various welding operations and data relating to the current simulated welding operation, means for determining the quality of the welding operation in the welder training based on the comparison result by the data comparison means, and It is preferable to provide.
[0029]
It is preferable that the simulated welding state presentation unit includes a unit that reproduces data related to the behavior of the welder obtained in the past welding training.
[0030]
In order to achieve the above object, a manual welding training method according to the present invention trains a welder engaged in manual welding construction, and measures the behavior of the welder during welding training, and the state of the welding training environment. And the welder's head position, head movement, hand position, hand movement, facial movement of the simulated welding in progress from signals that define the welding training status obtained by these measurement processes. Extract at least one characteristic among the direction, the amount of heat input given to the weld and the heat input direction, and the melting state and welding state of the simulated weld, Data obtained at the time of normal operation and malfunctions obtained during past welding operations The extracted feature quantity and And based on this referenced data It is characterized by comprising a step of judging the quality of the simulated welding state and a step of presenting the transition of the welding state to a welder during welding training.
[0031]
In addition to this configuration, the process of recording / holding the data, calculation results, and judgment results obtained in these processes, the process of displaying the welder's behavior and simulated welding status in training, and the simulated welding process It is desirable to further include a step of generating an image of the obtained welded portion.
[0032]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the apparatus and method according to the present invention will be described below with reference to the drawings.
[0033]
(First embodiment)
First, an embodiment of a manual welding support device and a manual welding support method according to the present invention will be described with reference to FIGS.
[0034]
In FIG. 1, a manual welding support device generates an arc between a welding torch held by a welder when manual welding is performed and a groove formed by two base materials to be welded, for example. A weld pool is formed in the groove with heat, and the weld pool is moved continuously to generate a belt-like bead in the direction of movement, thereby supporting welding work to weld two base materials. To do.
[0035]
Such a manual welding support device, as shown in FIG. 1, is a welder motion measurement device (hereinafter abbreviated as “motion measurement device”) that measures information related to the welding operation state of the welder PS when welding is performed. 101 and welding environment measuring device (hereinafter referred to as “environmental measuring device”) 102 and the subsequent stage (output side) of both measuring devices 101 and 102, and recording maintenance / management / signal processing / determination, etc. of the welding operation status are online. A welding process recording device (hereinafter referred to as “recording device”) 103, an arithmetic processing device 104 and a welding condition determination device (hereinafter referred to as “determination device”) 105, and the results of processing by these devices 103 to 105 as welders. A welding process display device (hereinafter “display device”) 106 to be presented to the PS and a welding state perception presentation device (hereinafter “perception presentation device”) 107 are provided.
[0036]
As shown in FIG. 2, the motion measuring device 101 includes motion measuring sensors 121 (CCD camera 121a and position / orientation sensor 121b, etc.) incorporated in the protective gloves 110 and the protective mask 108 worn by the welder PS, and the motion measurement. A welder operation feature amount extraction unit 122 that extracts a feature amount related to operations such as the head / hand position (field of view) and movement of the welder PS based on a measurement signal from the sensor 121 is provided.
[0037]
With this configuration, the motion measurement device 101 uses the motion measurement sensor 121 to measure the three-dimensional position coordinate values (X, Y, Z) and the Euler angles (Pitch, Yaw, Roll) 6-degree-of-freedom time-series signals are acquired to obtain information on the continuous operation of the welder PS in real time during the welding process, and feature values are extracted from these measurement signals. The feature 122 relating to the movement of the welder PS such as the hand movement and the face orientation is extracted by the section 122 and these signals are sent to the recording apparatus 103 and the arithmetic processing apparatus 104.
[0038]
The environment measuring device 102 is composed of a system capable of measuring the physical state of the welding process environment and the progress of the process in real time, and includes a plurality of materials related to the base material 112 on which welding is performed, the molten pool 115 where the arc is generated, and the torch 114. Environmental measurement sensor 123 (current / voltmeter 123a, torch position / orientation sensor 123b, CCD camera 123c, infrared camera 123d, acoustic microphone (ultrasonic microphone having sensitivity up to the ultrasonic band) 123e for measuring various state quantities , A base material position sensor 123f, an accelerometer 123g, and the like, and a welding environment feature extraction unit 124 that extracts feature amounts related to the welding environment based on various measurement signals from the sensor 123.
[0039]
In such a sensor 123, for example, a CCD camera 123c monitors an arc generation state, a molten pool shape, a bead shape, and a torch tip shape, and an infrared temperature sensor 123d evaluates a temperature rise of the base material 112. The angle of the welding torch 114 is measured by the position / orientation sensor 123f for the torch, and the sound pressure and state change of the sound generated by the welding work can be accurately and quickly captured by the acoustic microphone 123e. In order to prevent the oxidation of the welding torch 114, the flow rate of the cover gas supplied is measured, and the arc voltage / current value is measured by a voltmeter / ammeter to evaluate the heat input of the welding torch 114. Then, the measurement / measurement values from each of these sensors 123 are sent to the welding environment feature extraction unit 124, where the feature values of the welding environment are extracted, and the extracted feature values are used as the welding process recording device 103 and the arithmetic processing. Sent to the device 104.
[0040]
The recording device 103 records the data collection / analysis processing / display / presentation information of the device related to welding work, enables the playback of the information after welding work, and information processing and feature extraction related to manual welding work offline. Is stored in a database (not shown) for use as basic data. This system retains and manages a large amount of welding process data recorded in the past as well as all measured quantities recorded during operation and subsequent processing results, and online as necessary as described below. In addition, offline retrieval and retrieval processing of retained data is possible.
[0041]
The arithmetic processing unit 104 calculates a physical feature amount of the welding state such as a frequency spectrum based on the measurement amount related to welding obtained by the two measurement devices 101 and 102. For example, not only calculation processing such as frequency spectrum distribution analysis processing of sound generated at the time of welding collected by the microphone 123e but also the positional relationship between welding equipment and a welder based on the position of the welding torch 103 or the position of the molten pool 115 Are processed based on image processing and position sensor information.
[0042]
In this arithmetic processing unit 105, there is a high possibility that data will be lost due to noise in actual measurement. To compensate for this, the data before and after the loss is complemented and used, or a physical model of the welding state is used. The missing data is estimated based on the measured amount, and the missing data is estimated or the non-measured amount is calculated. For example, in the case of torch position information, the position sensor / orientation sensor 123b or the like is usually installed as a sensor that provides the information, but these data are partially unavailable due to the influence of noise or the like. The information can be acquired by a process of extracting position information by image processing based on information of an image sensor such as the CCD camera 123c.
[0043]
A result processed by the arithmetic processing device 104 is supplied to the recording device 103, the determination device 105, and the perceptual presentation device 107.
[0044]
The determination device 105 is based on arithmetic processing performed by the arithmetic processing device 104, welding conditions set in advance, data obtained by similar welding operations performed in the past recorded and held in the recording device 103, and the like. Whether or not the construction state of the welded part already performed is good, whether the current arc state is good or not, and whether or not there is a possibility of deviation from the appropriate state, and the determination result is recorded in the recording device 103, the display device 106, And sent to the perceptual presentation device 107.
[0045]
Here, non-destructive inspection after normal construction is performed for welding construction carried out in the past, and the correspondence between online data during construction and the occurrence of defective welds is performed in detail. By holding these data in the recording device 103 and using them effectively, it can be used for the reasoning of the current welding condition determination. In this case, as a determination method, a sequential likelihood ratio test method or the like that can quickly detect a change in the measurement amount characteristic between the normal time and the time of occurrence of the failure is adopted.
[0046]
The perceptual presentation device 107 has a central function for supporting a welder online during welding construction, and partially processes the output from the arithmetic processing device 104 and the determination device 105, and the information is welded during construction work. Present online In this case, the presentation of information to the welder is performed in consideration of how to move as a human action, and at what timing the welder should perform the next action. An example of this perceptual presentation device 107 is shown in FIGS.
[0047]
FIG. 3 illustrates an example of an apparatus that visualizes various types of information necessary for supporting welding work through the field of view of the welding protective mask 108 worn by the welder PS. In this apparatus, in addition to the actual visual field 141 in the visual field seen through the protective mask 108, the on-line measurement information 142 regarding the current welding process, the enlarged welded image 143, etc. can be displayed along with the visual field 141. Yes. Among these, the online measurement information 142 presents a plot image indicating a time series signal from each sensor 123 as a process trend, and the welded portion enlarged image 143 has an arc position 144 and a torch tip position 145 on the weld pool 147. Information that serves as a guide for the movement of the welder's hand is presented. In addition, on the actual visual field 141, information corresponding to the trajectory is superimposed and displayed as a guide for the torch operation, so that the movement of the next hand can be easily grasped, and a better welding operation can be expected. It has become.
[0048]
In addition to the visual presentation means described above, this perceptual presentation device 107 can also adopt means (tactile presentation means, auditory presentation means, etc.) that directly presents various perceptions such as human tactile sensation and hearing. It is. For example, there is a certain time lag between visually presenting textual information, etc., actually recognizing it, logically interpreting it, and reflecting it in the action. It can have a decisive influence on the construction status.
[0049]
As a countermeasure against this, a case will be described in which means for prompting a welder's quick response operation by directly stimulating a sense other than vision is adopted, and thereby processing of presentation information and presentation processing to the welder are performed. In this case, there is a considerable degree of freedom in the movement of the welder's hand, the torch position and angle etc. are not fixed as in the automatic welding machine, and an appropriate torch position is specified as a condition with some tolerance This is considered to be one of the major factors determining the quality of manual welding.
[0050]
Therefore, as means for directly stimulating a sense other than vision, information such as the relative angle and position of the torch held by the welder PS with respect to the molten pool is difficult to objectively detect. As shown in the figure, when the tendency of whether or not it is within the appropriate range as a welding condition is monitored and an attempt is made to deviate from that range, the movement of the hand holding the torch based on the tendency monitoring result It is preferable to employ a force sense presentation device that imposes a restriction on the degree of freedom of movement and prevents a hand from moving beyond a certain angle. An example of this is shown in FIG.
[0051]
As shown in FIG. Perceptual presentation device 107 Is incorporated in the protective gloves 111 for the welder, and a plurality of pressurizing sheets 134... 134 attached to predetermined positions of the respective fingers in the protective gloves 111, and the pressurizing sheets 134 individually. A plurality of pressurizing tubes 133 to be connected 133, a pressurizing device 131 that feeds oil, air, or the like pressurized to each pressurizing sheet 134 via each pressurizing sheet 133, and the pressurizing And a pressurization control device 132 that controls the feeding by the device 131 based on the output of the welding condition determination device 105.
[0052]
With this configuration, this Perceptual presentation device 107 , When the torch position or angle becomes inappropriate due to the movement of the hand, the pressurization control device 132 feeds the pressurization device 131 to the pressurization tube 133 based on the output of the welding condition determination device 105. Tactile stimulation can be generated by controlling and inflating the pressurizing sheet 134 corresponding to the direction in which it is desired to restrict the movement of the welder's hand.
[0053]
The display device 106 displays information on the current construction state in correspondence with the actual construction state when online based on the determination result by the determination device 105, and displays various information for performing welding construction confirmation when offline. To do. Here, a display example when offline is shown in FIG.
[0054]
On the display screen shown in FIG. 5, in addition to the welded portion enlarged image playback screen 154 and the field-of-view image playback screen 155 from the protective mask, a bead image (welded portion bead visible image) 151 formed by welding work, a welder The time series signal (sensor output time series signal) 152 obtained by the motion measuring device 101 and the welding environment measuring device 102 and the image 153 showing the signal processing result by the arithmetic processing device 104 can be displayed side by side in correspondence with the time series. It has become.
[0055]
According to this display device 106, a plurality of data relating to welding construction are displayed in correspondence with each other, and other conditions at the time of construction, etc., for locations where a significant change is recognized in the feature amount are displayed. And the visual field image playback screen 155 can be reconfirmed, so with such support by providing detailed information, the welder can judge the construction status more efficiently after construction, and after the construction is completed It is possible to provide information that can be referred to as a welding construction history in the nondestructive inspection.
[0056]
Therefore, according to this embodiment, the welding quality can be kept stable and work efficiency can be improved regardless of the skill and skill level of the welder during manual welding work in welding monitoring.
[0057]
(Second Embodiment)
Next, an embodiment of a manual welding training apparatus and manual welding training method according to the present invention will be described. FIG. Description will be made with reference to FIG.
[0058]
In FIG. 6, a manual welding training device includes a welder training motion measuring device (hereinafter “motion measuring device”) 209, a welding training environment measuring device (hereinafter “environmental measuring device”) 212, an arithmetic processing device 213, and a simulated welding process. Recording device (hereinafter “recording device”) 214, simulated welding state determination device (hereinafter “determination device”) 215, simulated welding environment image generation device (hereinafter “image generation device”) 216, simulated welding process display device ( Hereinafter “display device”) 217 and simulated welding state perception presentation device (hereinafter “perception presentation device”) 218.
[0059]
The motion measuring device 209 includes, for example, a plurality of sensors attached to the protective gloves 207 and the protective mask 208 provided by the welder 206 during welding training (in the example of FIG. 7, the CCD camera 222 and the protective gloves 207 at predetermined positions in the space. The sensor 220 for measuring the position / orientation of 6 degrees of freedom of the position coordinate values (X, Y, Z) and Euler angles (Pitch, Yaw, Roll), and the position / orientation of 6 degrees of freedom at a predetermined position of the protective mask 208 Sensors 221) for measuring the information about the movement of the welder's hand and the face orientation during welding training, and supplying the measurement signals to the arithmetic processing unit 213 and the recording unit 214. To do.
[0060]
The environment measuring device 212 is attached to the dummy welding torch 211 and the dummy welding training specimen 210, and each sensor for measuring the physical state of the dummy welding environment during welding training, for example, as shown in FIG. In addition, the position sensor 223 and the shape measurement sensor 224 for measuring the position (position coordinate value (X, Y, Z) in space) and the three-dimensional shape of the test body 210 for simulated welding training, and simulated welding. A position sensor 225 for a pseudo welding torch that measures the position and angle of the torch 211, a CCD sensor 226, and the like are provided, and signals measured by these sensors 224 to 226 are supplied to the arithmetic processing unit 213 and the recording unit 214. .
[0061]
The arithmetic processing unit 213 inputs the measurement amounts from the two measurement devices 209 and 212, and virtually calculates an amount representing the feature of the welding state from the measurement amounts.
[0062]
The recording device 214 stores basic data such as all data collection / analysis processing / presentation information related to the simulated welding training, and the simulated welding status of an expert who should be input in advance, and can be stored in other devices as necessary. Supply.
[0063]
The determination device 215 inputs the virtual welding state feature amount calculated by the arithmetic processing device 213 and information on the appropriate welding state recorded in advance in the recording device 214, and based on these information, simulated welding is performed. The quality of the construction state of the parts, the quality of the dummy welding torch position, the possibility of deviation from the appropriate construction conditions, etc. are determined.
[0064]
The image generation device 216 inputs the virtual welding state feature amount obtained by the arithmetic processing device 213 and each measurement amount measured by the two measurement devices 209 and 212, and actually welds from the viewpoint of the welder. A virtual image simulating a welded portion obtained as visual information when the above is performed is generated.
[0065]
The display device 217 is a virtual device that imitates the virtual welding state feature amount obtained by the arithmetic processing device 213, the determination result obtained by the determination device 215, and the welded portion generated by the image generation device 216. The image and the information on the proper welding state inputted in advance in the recording device 214 can be inputted, and the pseudo welding process can be displayed in comparison with the appropriate welding state.
[0066]
The perceptual presentation device 218 uses the virtual welding state feature amount obtained by the arithmetic processing device 213, the determination result obtained by the determination device 215, and the virtual welded portion image generated by the image generation device 216. Input and present the current simulated welding state to the welder with respect to various perceptions such as visual, tactile, and auditory senses, and the action content that the welder should take in performing appropriate welding from the current situation Present timing.
[0067]
Next, the overall operation of this embodiment will be described.
[0068]
First, simulated welding training of the welder PS is started, and measurement by the two measuring devices 209 and 212 is performed while the simulated welding process is in progress. In this measurement, the motion measuring device 209 welds the position / orientation / movement of the hand and the position / movement of the head based on the measurement information from the two position / orientation sensors 220 and 221 and the CCD camera 222. Information regarding the continuous operation of the PS is acquired in real time as a time-series signal indicating the temporal change, and this is sent to the arithmetic processing unit 213 and the recording unit 214.
[0069]
At the same time, the environment measurement device 212 uses the measurement information from the position sensor 223 and the shape measurement sensor 224 on the side of the test body 210 and the position sensor 225 and the CCD camera 226 on the side of the torch 211 to simulate the test body 210 and the simulation. Information such as the position and shape of the welded part, the position and angle of the simulated welding torch 211, and the continuous positional relationship between the simulated welding part and the simulated welding torch 211 is real-time as a time-series signal indicating the change over time. Is sent to the arithmetic processing unit 213 and the recording unit 214.
[0070]
Next, feature values of various virtual welding states are calculated by the arithmetic processing of the arithmetic processing device 213 as follows.
[0071]
First, a welding voltage value and a welding current value are derived from the shape of the simulated welding portion and the relative positional relationship of the simulated welding torch 211 based on the measurement amounts from the two measuring devices 209 and 212, thereby The amount of heat input and the direction of heat input given to the pseudo-welded part, which is one feature amount representing the feature of the welding state, are calculated.
[0072]
Welding based on the heat input and heat input direction calculated in this way, the shape of the simulated welding part, the moving speed of the simulated welding torch 211 obtained from the movement of the welder's hand, and the feed amount of the filler metal A melted state and a welded state of the pseudo welded portion, which is one feature amount representing the feature of the state, are calculated.
[0073]
By comparing the welding voltage value and the welding current value calculated above with conditions preliminarily input to the simulated welding process recording device 214, the frequency characteristics of the audible sound generated from the simulated welding part are calculated.
[0074]
When calculating such feature values, if some of the measurement values from both measurement devices 209 and 212 required for the calculation are missing due to environmental noise, etc., information on the measurement values not missing is set in advance. Information is complemented by using a value estimated in light of a physical model or the like and a measured value stored in the recording device 14 before unit time.
[0075]
The feature quantities of the various virtual welding states calculated in this way are sent to the recording device 214, the determination device 215, the image generation device 216, and the perceptual presentation device 218.
[0076]
First, in the determination device 215, the feature amounts of various virtual welding states calculated by the arithmetic processing device 213 are compared with the information on the feature amounts of appropriate welding states recorded in advance in the recording device 212. Possibility of deviation from proper construction conditions from the amount of change in the characteristic quantity of the time-series welding state that is always recorded in the recording device 212 of the pseudo-welding process and the presence or absence of welding defects at the present time If there is a deviation, the amount of deviation is also calculated, and the values such as the position / angle and moving speed of the simulated welding torch 211 necessary to lead to the optimum welding state are calculated. The The determination result and the calculation amount here are sent to the recording device 214, the display device 217, and the perceptual presentation device 218.
[0077]
Further, in the image generation device 216, a three-dimensional model of the simulated welding portion is created from various virtual welding state feature amounts from the arithmetic processing device 213. Then, computer graphics is obtained from the information on the position and movement of the welder's 6 head obtained by the motion measuring device 209 and the information on the three-dimensional positional relationship and shape of the simulated welding portion obtained by the environment measuring device 212. A virtual image 241 (see FIG. 9) simulating the welded portion obtained as visual information when welding is actually performed from the viewpoint of the welder 206 by using the technique, and the position / movement of the welder's head Regardless of, a virtual image 233 (see FIG. 8) simulating a welded portion at a place where the viewpoint position is fixed is generated. The two images 241 and 233 generated here are sent to the perceptual presentation device 218 and the display device 217.
[0078]
Next, the display device 217 is attached to the environment measuring device 212 as shown in FIG. Be The image 231 of the CCD camera 226, various training conditions 232 such as the material and welding method of the test body 210 used in the training, and the welded part at a place where the viewpoint position generated by the image generation device 216 is fixed. , A virtual image 234 of a welded portion to be an example of a skilled person previously recorded in the recording device 214, and various virtual welding states calculated by the arithmetic processing device 213 The process trend 235 of the feature amount, the determination result obtained by the determination device 215, and the information 236 of the calculated amount are displayed, respectively, so that a third party such as an instructor who performs welding training guidance can grasp the current training situation It becomes.
[0079]
At the same time, in the perceptual presentation device 218, various virtual welding state feature amounts calculated by the arithmetic processing device 213, determination results and calculation amounts obtained by the determination device 215, and an image generation device 216 Based on the virtual image that simulates the generated welded part, the current simulated welding state is presented to the welder for various perceptions such as visual, tactile, and auditory senses, and appropriate welding from the current situation The operation content and timing that the welder should take in performing the test are presented.
[0080]
As shown in FIG. 9, visually, a virtual image 241 simulating the welded portion obtained by the image generation device 216 and various virtual welding state feature amounts calculated by the arithmetic processing device 213 are visually shown. An image obtained by combining the process trend 235 and a line drawing 242 that serves as a guide for the next movement of the hand performed by the welder 206 when performing appropriate welding from the calculated amount obtained by the determination device 215 is obtained as a protective mask. The visual information 244 is presented to the welder 206 by superimposing and displaying it in the field of view 243 where the welder 206 can be seen through 209.
[0081]
As a presentation method other than sight, as shown in FIG. 10, the next movement of the hand performed by the welder 206 when performing appropriate welding based on the calculated amount obtained by the determination device 215 as a force sense or a tactile sense. The pressure control device 251 controls the pressure supply from the pressurization device 252 to the pressurization tube 253, and generates a tactile stimulus by inflating a plurality of pressurization sheets 254 attached to the protective gloves 207. It is also possible to adopt. In this case, for example, when it is desired to present the moving speed of the pseudo welding torch, the pressure is applied to the pressurizing sheet 254a other than the thumb to give the welder 206 a feeling of being pressed.
[0082]
Further, as means utilizing hearing, it is possible to adopt, for example, one that generates and presents synthesized sound from the frequency characteristics of audible sound calculated by the arithmetic processing unit 213.
[0083]
Further, after the simulated welding is completed, the information recorded in the recording device 214 is played back to the arithmetic processing device 213, the determining device 215, and the display device 217, thereby reproducing the contents performed in the simulated welding training. This makes it possible for the welder to easily understand the problems of the actions he has performed.
[0084]
Therefore, according to this embodiment, since the information imitating the situation of the welded part close to the actual welding construction is presented to the welder during the welding training, and there is a presentation means that leads to proper welding construction, Effective welding training can be performed.
[0085]
【The invention's effect】
As described above, according to the manual welding support apparatus and the manual welding support method according to the present invention, it is possible to perform a welding task by providing detailed information regarding a welding process to a welder in a manual welding environment that has not been conventionally performed. Online support can be realized, welding quality can be stabilized, manual welding can be removed, and the burden on the welder can be reduced. In addition, using this support device and support method, the collected manual welding process data is used offline, and the correspondence between weld defects obtained by nondestructive inspection after welding and the state of manual welding work is detailed. If analyzed, it will be possible to grasp in detail the mechanism and characteristics of poor welding.
[0086]
According to the manual welding training apparatus and the manual welding training method according to the present invention, information imitating the situation of the welded part close to the actual welding construction can be presented to the welder who is performing the welding training, thereby determining whether the welding conditions are good or bad. Not only can you train with immediate judgment, you can also objectively compare your own welding behavior with that of an expert after training. As a result, the welder can easily understand the quality of his / her welding work, and can easily and efficiently acquire the welding technique in the simulated welding training.
[Brief description of the drawings]
FIG. 1 is a schematic block diagram showing the overall configuration of a manual welding support apparatus according to a first embodiment.
FIG. 2 is a schematic diagram showing details of a welder operation measuring device and a welding environment measuring device.
FIG. 3 is a schematic diagram for explaining a visual presentation example of a welding state perception presentation apparatus.
FIG. 4 is a schematic diagram illustrating a visual presentation example of a welding state perception presentation device.
FIG. 5 is a schematic diagram showing a screen display example of a welding process display device.
FIG. 6 is a schematic block diagram showing an overall configuration of a manual welding training apparatus according to a second embodiment.
FIG. 7 is a schematic diagram showing details of a dummy welding training motion measuring device and a welding training environment measuring device.
FIG. 8 is a schematic diagram for explaining the display content of a pseudo welding process display device.
FIG. 9 is a schematic diagram for explaining presentation contents related to vision of a simulated welding state perception presentation apparatus.
FIG. 10 is a schematic diagram for explaining a presentation method related to haptic sense and tactile sense of the simulated welding state perception presentation device.
FIG. 11 is a conceptual diagram showing an overall configuration of an apparatus used in a conventional example of a virtual practice training.
[Explanation of symbols]
101 Welder motion measuring device (data measuring means)
102 Welding environment measuring device (data measuring means)
103 Welding process recording device (recording holding means)
104 Arithmetic processing device (feature amount extraction means)
105 Welding state determination device (welding state determination means)
106 Welding process display device (display means)
107 Welding state perception presenting device (welding state presenting means)
108 Protective mask
110 Protective gloves
111 groove
112 Welding base metal
113 beads
114 torch
115 molten pool
121 Motion measurement sensor unit
122 Welder operation feature extraction unit
123 Environmental measurement sensor
124 Welding environment feature extraction unit
131 Pressurizer
132 Pressure control device
133 Pressurized tube
134 Pressurized sheet
141 Field of view from protective mask
142 Sensor time series signal
143 Welded part enlarged image
144 Arc position
145 Torch tip position
146 Bead
147 molten pool
151 Welded part bead visible image
152 Sensor output time series signal
153 Signal processing result image
154 Corresponding welded part enlarged image playback screen
155 Field image playback screen from protective mask
201 Setter for construction conditions
202 light pen
203 Light receiving board
204 Comparator
205 Result display
207 Protective gloves
208 Protective mask
209 Welder training motion measuring device (data measuring means)
210 Specimen
211 pseudo welding torch
212 Welding training environment measuring device (data measuring means)
213 Arithmetic processing device (feature amount extraction means)
214 摸 Pseudo Welding Process Recorder (Record Keeping Unit)
215 Pseudo welding state determination device (Pseudo welding state determination means)
216 Pseudo welding environment image generation device (image generation means)
217 Pseudo welding process display device (display means)
218 摸 Pseudo welding state perception presentation device (simulated welding state presentation means)
220, 221 Position / orientation sensor
222, 226 CCD camera
223, 225 Position sensor
224 Shape measurement sensor
251 Pressure control device
252 Pressurizing device
253 Pressurized tube
254 Pressurized sheet
PS Welder

Claims (18)

An apparatus for supporting the manual welding by presenting the progress of the manual welding to the welder in a recognizable manner while monitoring the state of the manual welding when the welder performs manual welding on the object to be welded. The data measuring means for measuring data relating to the welding environment including the welding object and the behavior of the welder during the welding work when the manual welding work is performed, and the data measured by the data measuring means From the position of the welder's head, the movement of the head, the position of the hand, the movement of the hand, the direction of the face, the amount of heat input and the direction of heat input to the welded part , and the molten state and welding of the welded part a feature extraction means for extracting at least one feature quantity among the state, the data reference means and the data referring to the data of the normal state and failure time of occurrence obtained at the time of welding was performed in the past A welding state determining means for chromatic means for determining the quality of the welding conditions based on the referenced by reference means data and the feature amount extracted by the feature extracting unit, the determination result by the welding condition determining means And a welding state presentation means for presenting information relating to the transition of the welding state including recognizable information to the welder who is performing the welding.   The recording and holding means for recording and holding the data measured by the data measuring means, the determination result by the welding state determining means, and the feature amount extracted by the feature amount extracting means according to claim 1 A manual welding support apparatus further comprising at least display means for displaying a determination result by the welding state determination means.   The invention according to claim 1, wherein the data measuring means includes a plurality of measuring devices that simultaneously measure multidimensional data composed of a plurality of data obtained by a plurality of different data measuring means as the data. A hand welding support device characterized by comprising.   4. The invention according to claim 3, wherein the feature quantity extracting means extracts a plurality of different features from the multi-dimensional data measured by the plurality of measuring devices by simultaneously processing a plurality of different feature quantities. A manual welding support device comprising a processing device.   In the invention according to claim 1, the welding state presentation unit directly presents the determination result of the quality of the welding state determined by the welding state determination unit as a sensory stimulus for the perception excluding the visual perception of the welder. A manual welding support apparatus comprising a perceptual transmission means, and the perceptual transmission means includes means for alerting the welder and urging the welding operation to change.   2. The hand according to claim 1, wherein the welding state presentation means includes means for superimposing and presenting information on an action path of an action to be taken by the welder on a visual field of the welder. Welding support device.     The invention according to claim 1, wherein the welding state presentation unit selectively and preferentially superimposes a plurality of data obtained by the data measurement unit during the welding operation on the field of view of the welder. A hand welding support device comprising means for presenting.     2. The manual welding support apparatus according to claim 1, wherein the feature quantity extraction means includes means for estimating compensation data when the data measured by the data measurement means is not appropriate. A method for supporting the manual welding by presenting the progress of the manual welding to the welder in a recognizable manner while monitoring the state of the manual welding when the welder performs the manual welding operation on the welding target. And when the manual welding construction is performed, the welding environment including the welding object and the data on the behavior of the welder during the welding construction work are measured, and the welding state during the welding construction is measured from the measured data. At least one of the features of the welder's head position, head movement, hand position, hand movement, face orientation, amount of heat input and direction of heat input to the weld , and melted or welded state of the weld The normal welding and defect occurrence data obtained at the time of welding work performed in the past and the extracted feature quantity are referred to and the quality of the manual welding state is determined based on the referenced data. The And, manual welding 援方 method characterized by the information on changes in the welding conditions, including the determination result to perceptible presented to the welder in the welding, with the steps. This is a device for training welders engaged in manual welding construction, and measures data related to the behavior of the welder during the welding training and the state of the welding training environment when the simulated welding training for the manual welding construction is performed. Based on the data measured by the measurement means and the data measurement means, the position of the welder's head, the movement of the head, the position of the hand, the movement of the hand, the orientation of the face, the amount of heat input given to the welded part during the welding training And feature quantity extraction means for extracting at least one feature quantity from the heat input direction and the melted state or welded state of the simulated welded part, and data obtained at the time of normal operation and malfunctions obtained during previous welding operations. to have the means for determining the quality of the welding conditions based on the data reference means for referring and the reference data by the data reference means and the feature quantity extracted by the feature extracting unit A simulated welding state determination unit, an image generation unit that generates an image of a welded portion based on the feature amount extracted by the feature amount extraction unit, a determination result by the simulated welding state determination, and the image generation unit A manual welding training apparatus comprising: simulated welding state presentation means for presenting information on transition of simulated welding state including an image to a welder during the welding training. The recording and holding means for recording and holding the data measured by the data measuring means, the determination result by the welding state determining means, and the feature amount extracted by the feature amount extracting means according to claim 10. A manual welding training apparatus further comprising display means for displaying a welder's behavior and simulated welding state in training based on the data held by the record holding means. The invention according to claim 10 , wherein the data measuring means includes a plurality of measuring devices that simultaneously measure multidimensional data composed of a plurality of data obtained by a plurality of different data measuring means as the data. A manual welding training device characterized by comprising. The invention according to claim 10 , wherein the feature amount extraction unit performs a plurality of operations for simultaneously processing a plurality of different feature amounts from multidimensional data measured by the plurality of measurement apparatuses and extracting the feature amounts in a multifaceted manner. A manual welding training device comprising a processing device. 11. The manual welding training apparatus according to claim 10 , wherein the feature amount extraction means includes means for estimating and obtaining compensation data when the data measured by the data measurement means is not appropriate. . The invention according to claim 10 , wherein the simulated welding state presentation means includes means for superimposing and presenting guidance information on an action path of an action to be taken by the welder on the field of view of the welder. Manual welding training equipment. 11. The invention according to claim 10 , wherein said simulated welding state presentation means includes data comparison means for comparing data obtained at the time of proper welding construction performed in the past with data relating to the current simulated welding operation, and this data comparison. Means for judging whether or not the welding operation is good in the welder training based on the comparison result by the means. 11. The manual welding training apparatus according to claim 10 , wherein the simulated welding state presentation means includes means for reproducing data relating to a welder's behavior obtained in past welding training. It is a method of training a welder engaged in manual welding construction, and when the simulated welding training of the manual welding construction is performed, data on the behavior of the welder during the welding training and the state of the welding training environment is measured, Based on the measured data, the head position, head movement, hand position, hand movement, face orientation of the welder during the welding training, the amount of heat input to the weld, the heat input direction, and the simulated weld Extract at least one feature amount from the melted state and the welded state of the steel , refer to the data at the time of normal and failure occurrence obtained at the time of welding work performed in the past and the extracted feature amount and While determining the quality of the simulated welding state based on the referenced data, an image of the welded portion is generated based on the feature amount, and information regarding the transition of the simulated welding state including the generated image and the determination result is displayed. in front To perceptible presented to the welder during the welding training manual welding training method characterized by comprising the steps.

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