JP6184422B2 - Virtual welding system - Google Patents

Description

This application is a continuation-in-part of US patent application Ser. No. 12 / 501,257, filed Jul. 10, 2009.

  The present disclosure relates to virtual reality simulations, and more specifically to systems and methods for providing arc welding training in a simulated virtual reality environment or an augmented reality environment.

  To learn arc welding tips as before, many hours of education, training and practice were required. There are many different types of arc welding and arc welding processes to learn. Typically, welding is learned by students performing welding operations on actual metal pieces using actual welding equipment. Such real world training is constrained by insufficient welding materials and uses limited welding materials. Recently, however, the idea of training using welding simulation has become more common. Some welding simulations are performed online via a personal computer and / or via the Internet. However, currently known welding simulations tend to limit the focus of their welding training.

  For example, some welding simulations are focused solely on “muscle memory (memory for motor nerve abilities)” training and how to hold and position the welding tool. The other welding simulations focus on showing the visual and audio effects of the welding process, which gives the student the desired feedback that represents real-world welding with high reality. This is a limited and often impractical method that is not offered by the actual feedback that is required to instruct the student to make the necessary adjustments to make a good weld. Visibly learn arcs and / or paddles, not just by muscle memory.

  Also, the limitations and disadvantages of the conventional, traditional and previously proposed approach are that such a conventional approach can be compared with the embodiments according to the invention described in the following part of the application with reference to the drawings. A comparison will be apparent to those skilled in the art.

  In one aspect of the invention, a virtual welding system includes a programmable processor-based subsystem and a spatial tracker operably connected to the programmable processor-based subsystem. A mock welding tool that can be spatially tracked by a spatial tracker is used. A mock welding tool has one or more adapters, each adapter emulating a real world appearance of a particular weld type. A base is removably coupled to each of the one or more adapters.

  In another aspect of the invention, the mock welding tool is used in a virtual welding system. One or more adapters are used, each adapter emulating the physical characteristics of a particular weld type. A base is removably coupled to each of the one or more adapters, and the base identifies the real-time spatial position of the mock welding tool relative to a reference (datum) position.

  A method of using a mock welding tool in a virtual welding system is also used. The first adapter is removably coupled to the base, and the first adapter is associated with the first weld type. The first adapter has been removed from the base, wherein the second adapter is removably coupled to the base and the second adapter is associated with a second weld type. The use of multiple adapter types with a common base facilitates the use of a portable virtual welding system used at virtually any mobile location.

  This Summary is provided to introduce a selection of concepts in a simplified form that are further described herein. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to limit the scope of the claimed subject matter. It is not intended to be used to do so. Furthermore, the claimed subject matter is not limited to implementations that solve any or all disadvantages noted in any part of this disclosure. Further embodiments, aspects and advantages of the present invention can be inferred from the detailed description, drawings and claims.

1 is a block diagram of a virtual welding system that includes a replaceable mock welding tool that includes a base, where the base is connected to each of a plurality of adapters. FIG. 2 is a diagram illustrating one implementation of the system shown in FIG. 1. FIG. 6 is an exemplary side view of a GMAW adapter that removably couples to a base. FIG. 6 is an exemplary perspective view of a stick-shaped tool adapter removably coupled to a base. FIG. 2 is an exemplary perspective view of an oxyfuel adapter that is removably coupled to a base. FIG. 6 is a perspective view of a base that interfaces with the adapter shown in FIGS. 3, 4 and 5. FIG. 7 is a perspective view of the base shown in FIG. 6 with a part cut away. FIG. 3 is a perspective view of a mock welding tool in an assembled state including a base and adapter for a stick-shaped tool. FIG. 2 is a perspective view of a mock welding tool in an exploded state including a base and adapter for a stick-shaped tool. FIG. 2 is a perspective view of a stand utilized to hold a welding coupon and magnet in a known spatial position. FIG. 10 is a perspective view of the stand of FIG. 9 in an alternative, compactly retractable position to hold the welding coupon and magnet in a known spatial position. FIG. 2 is an assembly showing a kit including components for transferring and operating a mobile virtual welding system. It is a front view which shows the user interface which communicates with a virtual welding system. FIG. 6 is a front view of an alternative user interface communicating with a virtual welding system. 1 is a perspective view of a helmet used by a user in a virtual welding system. 1 is a rear perspective view of an FMDD mounted in a welding helmet used in a virtual welding system. FIG. FIG. 2 is a flow diagram of an exemplary embodiment of a subsystem block diagram in the programmable processor-based subsystem (PPS) shown in FIG. FIG. 17 is a flow diagram of an exemplary embodiment of a block diagram of a graphics processing device in the PPS of FIG. FIG. 2 is a flow diagram of an exemplary embodiment of a functional block diagram of the system of FIG. 2 is a flowchart of an embodiment of a method for training using the virtual reality training system of FIG. 1. FIG. 6 is a front view showing a displacement map of a weld pixel according to an embodiment of the present invention. FIG. 2 is a perspective view of a coupon space of a flat weld coupon simulated in the system of FIG. 1 and a corresponding xy weld space plot. FIG. 2 is a perspective view of a corner of a corner (T-joint) weld coupon simulated in the system of FIG. 1 and a corresponding TS welding space plot. FIG. 2 is a perspective view of a pipe coupon of a pipe weld coupon simulated in the system of FIG. 1 and a corresponding TS weld space plot. It is a front view which shows the concept of the double displacement paddle of the system of FIG. It is a front view which shows the concept of the double displacement paddle of the system of FIG. It is a front view which shows the concept of the double displacement paddle of the system of FIG.

Reference is made to the attached drawings. Particular embodiments and further advantages of the present invention are shown as described in detail in the following detailed description.
Referring now to the drawings, some embodiments or implementations of the invention are described below in conjunction with the drawings. Here, like reference numerals are used to refer to like elements throughout. Embodiments of the present invention are directed to a virtual welding system that uses a mock welding tool having a base for housing a plurality of adapters, where each adapter simulates a different welding type. The adapters can have a common size that allows for a removable seamless connection with the base when needed. Various exemplary virtual welding systems are shown and described below in the context of this specification, but the invention is not limited to the examples shown.

  More specifically, the subject embodiments include a programmable processor-based subsystem, a spatial tracker operably connected to the programmable processor-based subsystem, and a spatial tracker by means of a spatial tracker. A virtual reality welding system that includes at least one mock welding tool that can be tracked and at least one display device operably connected to a programmable processor-based subsystem. To provide additional flexibility, the mock welding tool includes a base and a plurality of adapters, each adapter being used to simulate a different weld type. For example, the first adapter can simulate GMAW welding, the second adapter can simulate SMAW welding, the third adapter can simulate oxycombustion welding, and the like. Alternatively or additionally, the tool can be used to simulate a cutting device such as oxyfuel combustion or other cutting torch. All adapters can have a standardized size that allows seamless switch switching when these adapters are connected to and removed from a common base. To accommodate portable use, a compact retractable stand is used to hold the weld coupon in space for use with a mock welding tool. In this way, the system can simulate multiple weld types in virtual reality space, and the weld paddle has real-time melt fluidity and heat dissipation characteristics appropriate for each weld type.

  The real-time melt fluidity and heat dissipation characteristics of the simulated weld paddle provide real-time visual feedback to the mock welding tool user when displayed, and the user responds to this real-time visual feedback It becomes possible to adjust or maintain the welding technique in real time. The displayed weld paddle represents a weld paddle as formed in the real world based on the user's welding technique and the selected welding process and parameters. By checking the paddle (e.g., shape, color, slug, size), the user can change their welding technique to form a good weld and determine the type of weld to perform. The paddle shape responds to the movement of the mock welding tool. As used herein, the term “real time” perceives and experiences in that time in a simulated environment in the same way that a user perceives and experiences in a real-world welding scenario. Means that. In addition, the weld paddle responds to the effects of the physical environment, including gravity, allowing the user to weld at various positions, including horizontal, vertical and overhead welding as well as pipe welding at various angles. It makes it possible to practice realistically.

  Referring now to the drawings shown for purposes of illustrating exemplary embodiments, FIG. 1 is a block diagram of a virtual welding system 100 that provides arc welding training within a real-time virtual reality environment. Virtual welding system 100 includes a programmable processor-based subsystem (PPS) 110. Virtual welding system 100 further includes a spatial tracker (ST) 120 operably connected to subsystem (PPS) 110. The virtual welding system 100 is operatively connected to a tangible welding user interface (WUI) 130 operably connected to a subsystem (PPS) 110 and to the subsystem (PPS) 110 and space tracker (ST) 120. And a face-mounted display device (FMDD) 140. Virtual welding system 100 further includes an observer display device (ODD) 150 operably connected to subsystem (PPS) 110. The virtual welding system 100 also includes at least one mock welding tool (MWT) 160 operably connected to the space tracker (ST) 120 and subsystem (PPS) 110. Virtual welding system 100 further includes a stand 170 and at least one welding coupon (WC) 180 that can be attached to the stand 170. The mock welding tool (MWT) 160 can include a base (not shown) that couples to one or more adapters (not shown) to simulate a plurality of different weld types.

  FIG. 2 shows a system 200 that represents one implementation of the system shown in FIG. A face-mounted display device (FMDD) 140 is used to display a simulated virtual environment for the user to visually experience welding. In order to provide accurate rendering of this simulated environment (three-dimensionalization of the image), the face-mounted display device (FMDD) 140 communicates with the subsystem (PPS) 110 to face-mount the system 200. Data relating to the spatial position of the display device (FMDD) 140 is transmitted and received. Communication can be facilitated using known wiring connections and / or wireless technologies such as Bluetooth®, Wireless Ethernet®, and the like. One or more sensors 142 are placed in and / or in close proximity to a face-mounted display device (FMDD) 140 to obtain spatial position data. The sensor 142 then evaluates the spatial position relative to a particular reference (datum) within the system 200, such as the magnet 172. The magnet 172 is positioned at a known reference point and is disposed at a predetermined distance 178 with respect to the welding coupon 180. This predetermined distance 178 can be maintained by utilizing a form factor, template, or pre-configured structure associated with the stand 170. Thus, movement of the sensor 142 relative to the magnet 172 can essentially provide position data for the face-mounted display device (FMDD) 140 relative to the weld coupon 180 within the stand 170. The sensor 142 can communicate wirelessly to determine its position relative to the magnet using known communication protocols and updates the face-mounted display device (FMDD) 140 in real time to match the user's movement.

  The system 200 also includes a mock welding tool (MWT) 160, such as including an adapter 162 coupled to the base 166. It should be appreciated that the adapter 162 simply represents one of a plurality of adapters and that each adapter simulates a particular weld type. The adapter 162 is removably coupled to the base 166 and, as another alternative, allows for the removal and replacement of an adapter. Removable coupling can be accomplished using tabs, dimples, sliders, push buttons, etc., and the user can push down adapter 162 and / or base 166, twist, or otherwise mechanically change. . In order to accurately simulate a particular weld type, each adapter 162 is sized to represent the real-world equivalent used to perform the actual welding operation. Once a particular adapter is coupled to the base, the user enters the type of adapter in use, allowing the PPS to load and execute the appropriate instruction set associated with this PPS. Thus, the correct rendering for each adapter type is displayed on the face-mounted display device (FMDD) 140.

  One or more sensors 168 can be disposed within or proximate to the base 166. Similar to the face-mounted display device (FMDD) 140, the sensor 68 can wirelessly determine the spatial position relative to the magnet 172 on the stand 170. Thus, adapter 162 and base 166 are combined to have a known position and space for magnet 172 when the dimensions of both adapter 162 and base 166 are defined. To ensure that system 200 is properly calibrated to accommodate each adapter 162, a user interfaces with subsystem (PPS) 110 (eg, via welding user interface (WUI) 130). , Showing an indication that a particular adapter is currently in use. Once such a display is shown, the subsystem (PPS) 110 can read a lookup table from the memory 112, which the user has experienced via the face-mounted display device (FMDD) 140. Includes a rule set to properly render such simulated environments.

  In one embodiment, subsystem (PPS) 110 is a computer operable to execute the disclosed architecture. In order to provide additional context for various aspects of the present invention, the following discussion is intended to provide a concise and general description of a suitable computing environment for implementing various aspects of the present invention. ing. Subsystem (PPS) 110 may use computer-executable instructions that are executed on one or more computers and implemented in combination with other program modules and / or as a combination of hardware and software. it can. Generally, program modules include routines, programs, components, data structures, etc. that perform particular tasks or implement particular abstract data types. For example, such programs and computer-executable instructions can be processed via a robot using various computer control paradigms.

  Moreover, those skilled in the art will recognize that the method of the present invention is not limited to other computer system configurations including single processor or multiprocessor computer systems, minicomputers, mainframe computers, as well as personal computers, handheld computer devices, microprocessor-based It will be understood that it can be implemented with programmable household appliances and the like. Each computer can be operatively connected to one or more associated devices. The illustrated aspects of the invention may also be practiced in distributed computing environments where certain tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules can be located in both local and remote memory storage devices.

  Subsystem (PPS) 110 can utilize an exemplary environment for implementing various aspects of the invention, including a computer, which includes processor 114, memory 112, and system bus for communication purposes. Including. The system bus couples system components including, but not limited to, memory 112 to processor 114. The processor 114 may be any of various commercially available processors. Dual microprocessors and other multiprocessor architectures can also be used as the processor 114.

  The system bus can be any of several types of bus structures, including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of commercially available bus architectures. The memory 112 may include read only memory (ROM) and random access memory (RAM). A basic input / output system (BIOS) that contains basic routines that help to transfer information between elements within the subsystem (PPS) 110, such as during startup, is stored in ROM.

  The subsystem (PPS) 110 is, for example, a hard disk drive for reading or writing from a removable disk, a magnetic disk drive, an optical disk drive for reading a CD-ROM disk or reading or writing from another optical medium, etc. Can further be included. Subsystem (PPS) 110 may include at least some form of computer readable media. Computer readable media can be any available media that can be accessed by a computer. By way of example, and not limitation, computer readable media may include computer storage media and communication media. Computer storage media includes volatile and non-volatile removable and non-removable media implemented in any method or technique for storing information such as computer-readable instructions, data structures, program modules or other data. . The computer storage medium is used to store RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disc (DVD) or other magnetic storage device, or desired information and This includes, but is not limited to, any other medium that can be accessed by subsystem (PPS) 110.

  Communication media typically embodies computer readable instructions, data structures, program modules or data in a modulated data signal such as a carrier wave or other transmission mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct wired connection, or wireless media such as acoustic, RF, infrared and other wireless media. Any combination of the above-described media is included within the scope of computer-readable media.

  Several program modules may be stored in the drive and RAM, including an operating system, one or more application programs, other program modules, and program data. The operating system of the subsystem (PPS) 110 can be any of a number of commercially available operating systems.

  Furthermore, the user can input commands and information into the computer via a keyboard or a pointing device such as a mouse. Other input devices may include a microphone, IR remote control, trackball, pen input device, joystick, game pad, digitizing tablet, satellite dish, scanner, and the like. These and other input devices are often coupled to the system bus, but other ports such as a parallel port, game port, universal serial bus (USB), IR interface, and / or various wireless technologies It is connected to the processor via a serial port interface, which can also be connected by an interface. A monitor (not shown) or other type of display device may be connected to the system bus via an interface, such as a video adapter. Visual output can also be achieved via a remote display network protocol such as a remote desktop protocol, VNC, X-Windows system or the like. In addition to visual output, computers typically include other peripheral output devices such as speakers and printers.

  Displays such as an observer display device (ODD) 150 and a welding user interface (WUI) 130 may be used with the subsystem (PPS) 110 to present data received electronically from the processor. For example, the display can be an LCD, plasma, CRT, monitor, etc. that presents data electronically. Alternatively or additionally, the display can present data received in a hardcopy format such as a printer, facsimile, plotter, etc. The display can display data in any color and can receive data from the subsystem (PPS) 110 via a wireless or any hardwire protocol and / or standard. In one embodiment, the weld user interface (WUI) 130 is a touch screen that allows a user to interface with the subsystem (PPS) 110 to review weld data from one or more previous simulations. The user can also search various data paradigms to identify information regarding a particular analysis (eg, weld quality). Such data is evaluated for one or more benchmarks for scoring or other comparison.

  The computer can operate against one or more remote computers, such as remote computer (s), in a network environment that uses logical and / or physical connections. The remote computer (s) can be a workstation, server computer, router, personal computer, microprocessor-based entertainment device, peer device, or other common network node, typically a computer Many or all of the elements described with respect to can be included. The logical connections shown include a local area network (LAN) and a wide area network (WAN). Such network environments are commonplace in offices, enterprise-wide computer networks, intranets, and the Internet.

  When used in a LAN networking environment, the computer is connected to the local network through a network interface or adapter. When used in a WAN network environment, the computer typically includes a modem, is connected to a communication server on the LAN, or has other means of establishing communication over the WAN, such as the Internet. In a network environment, program modules illustrated with respect to the computer or portions thereof may be stored in a remote memory storage device. The network connections described herein are exemplary and other means of establishing a communications link between computers may be used.

  3-5 illustrate a non-limiting example of the adapter 162. FIG. 3 shows an adapter 162 such as a GMAW welding gun 300. FIG. 4 shows an adapter 162 such as a stick-shaped welding tool 400. FIG. 5 illustrates an adapter 162 such as an oxyfuel torch 500. Although the adapter is described herein as having a plurality of different components, it is understood that both single-element and multi-element embodiments of the adapter are contemplated within the scope of the present invention. I want. Considering initially FIG. 3, the GMAW welding gun 300 includes a nozzle 310 connected to an interface 318 via a tube 312. The welding gun 300 can have substantially the same weight and dimensions as a GMAW gun when used in real-world applications. The dimensions of each component in the gun 300 are known values that can be used to calibrate the gun taking into account the welding coupon 180 and the magnet 172. The interface 318 can include one or more mechanical mechanisms that allow a removable coupling of the adapter 300 to the base.

  FIG. 4 shows a stick-shaped welding tool 400 for plate and pipe welding, which includes a holder 422 and a simulated stick-shaped electrode 410. In one embodiment, the simulated stick-shaped electrode 410 includes a tactile resistive tip for simulating resistance feedback that occurs during real-world pipe welding, for example during a root-pass welding procedure or when welding plates. Can be included. If the user moves the simulated stick-shaped electrode 162 to a location far away from this route, this allows the user to feel or sense a smaller resistance, thus the current Feedback can be derived that is used to adjust and maintain the welding process. Interface 418 allows for a removable connection of the stick-shaped welding tool 400 to the base.

  FIG. 5 shows an oxyfuel adapter 500 that includes a nozzle 510 and an interface 518, which allows a removable connection to the base of the oxyfuel adapter 500. In this embodiment, interface 518 includes a collar 522 secured around the diameter of the base. The push button 520 can include protrusions or other mechanisms that mechanically interface with complementary features (eg, dimples) on the base. In this way, the adapter 500 can “lock” to the base depending on whether the push button is depressed or otherwise operated. In other embodiments, oxyfuel adapters are used to represent cutting torches that are used to cut metal objects. In this embodiment, the cutting torch is displayed in the virtual welding system as if the cutting torch was operating in a real world application. For example, subsystem (PPS) 110 may load and execute code representing the application of a cutting torch instead of a welding torch.

  According to other embodiments of the present invention, other mock welding tools are possible as well, including MWTs, for example to simulate a handheld semi-automatic welding gun with wire electrodes fed through the welding gun. Further, according to some other embodiments of the present invention, a real world welding tool may be used even if the tool is not actually used to form a real arc in the virtual welding system 100. It can be used as a mock welding tool (MWT) 160 to better simulate the actual feel of the tool in the user's hand. A simulated grinding tool may also be provided for use in the simulated grinding mode of virtual welding system 100. Similarly, a simulated cutting tool may be provided for use in the simulated cutting mode of virtual welding system 100. Further, a simulated gas tungsten arc welding (GTAW) torch or filler material may be provided for use with the virtual welding system 100.

  FIG. 6 shows a base 600 that is used to interface to one or more adapters, such as a GMAW gun 300, a stick-shaped welding tool 400, an oxyfuel adapter 500, and the like. Base 600 includes a body 620 that can accommodate one or more electronic components, such as sensor 168 described herein. In one embodiment, the body 620 consists of two halves that are held together via fasteners 640 such as screws, bolts, rivets, and the like. The wiring connection cable 630 extends from the main body 620 to facilitate communication between the base 600 and the subsystem (PPS) 110.

  The interface 610 includes a landing 614 and a dimple 616 disposed on the opposite side of the interface 610. The combination of landing and dimple can function as an interlock that can be removed from complementary components within the interface of the exemplary adapter 300, 400, 500. However, any mechanical interface is substantially intended to facilitate efficient removal and replacement of the adapter to the base 600. A push button 618 located within the protrusion 636 is used to indicate that the user is in an active welding mode when the push button 618 is depressed. At least with respect to the adapter 400, a complementary form factor can be included in the adapter to fit as a sleeve on the push button 618, and the user can depress the push button via the form factor mechanism on the adapter. . For this purpose, the adapter form factor can simulate a real-world trigger or similar device to give the user a sense of real-world appearance and welding behavior.

  FIG. 7 is a cut-away perspective view of the base 600 revealing the sensor 652 disposed therein. Sensor 652 communicates with one or more different components (eg, subsystem (PPS) 110) via cable 654, is located at a predetermined location within base 600, and is predetermined via fastener 658. Held in position. A vane 672 provides structural support for the base 600 throughout the body 620. In one embodiment, sensor 652 utilizes known non-contact technologies such as capacitive sensors, piezoelectrics, eddy currents, induction, ultrasound, Hall effect, and / or infrared proximity sensor technology. Such techniques are used in conjunction with other sensors described herein, including sensors 142, 168 used in helmet 146 and base 166, respectively. FIG. 8 shows a mock welding tool 800 where an adapter 400 is removably coupled to a base 600 for use within the virtual welding system 100.

  FIG. 9 shows a stand 700 that is utilized to position the weld coupon 758 in a known location space with respect to the magnet 710. The stand 700 includes an arm 714 and a base 724 that are coupled to each other via an upright portion 722. In one embodiment, the uprights 722 are removably engaged with the base 724, allowing the stand 700 to be disassembled into individual components for packaging and shipping. Also, the base 724 and the upright 722 can have one or more structural features (eg, vanes) that add structural support to the components that simultaneously maintain a relatively small weight. . Plunger 732 can be retracted away from the arm, allowing coupons on stand 700 to be removed and replaced in repeatable spatial positions.

  The dimensions of the arm 714 and the position of the weld coupon 758 relative to the magnet 710 located on the landing 738 are all known, and the mock welding tool proximate the weld coupon 758 has a known output and a repeatable output. Thereby providing the user with an appropriate real-time virtual welding environment. Pins 762 and 764 can be removed from stand 700, allowing arm 714 to pivot about pin 764 as shown in FIG. In this embodiment, the pin 762 is removed from the holes 766,768, thereby allowing the arm 714 to rotate about the pin 764 to a second position. In this way, the user can simulate welds in multiple planes (eg, horizontal and vertical planes) to learn the nuances associated with each plane. The design of the stand 700 ensures that the spatial position of the magnet 710 relative to the weld coupon 758 is maintained at any position to provide accurate and reproducible results for the formation and display of real-time simulated environmental welds. It is noteworthy to guarantee.

  FIG. 11 shows a mobile welding kit that can be easily transferred from one location to another. The kit can be set up substantially at any location near the power source, including batteries, A / C, and other power sources. The vessel 810 can be substantially formed as a housing for a welding apparatus, the interior of which includes a plurality of shells, a platform or other storage area for receiving a welding user interface (WUI) 130, a stand 700, mock welding. Tool 800 and helmet 900 are included. The container further includes wheels to facilitate efficient transfer of the container 810.

  FIG. 12 shows an exemplary user interface 830 that displays a plurality of metrics associated with a typical welding system. The interface 830 includes a selector 832 to identify the type of adapter that utilizes the simulated welding system. Thermometer 836, ammeter 838, and voltmeter 842 may provide real-time feedback to the user during the welding operation. Similarly, 854, 856 displays additional information and allows user input to change the feedback. FIG. 13 shows an alternative user interface 860 that simulates the interface of a real-world hardware welding system. In one embodiment, a user can provide input to display 860 using a touch screen or other peripheral input method as described herein.

  14 and 15 show a helmet 900 worn by the user when operating the virtual welding system. FIG. 14 shows a front perspective view of a helmet 900, which can be an actual welded helmet used in real world applications and modified to include FMDD, as described above. In this way, the user can wear a welding helmet as in the real world scenario, and the virtual environment is displayed to the user in real time via the face-mounted display device (FMDD) 140. FIG. 15 illustrates an exemplary embodiment of a face-mounted display device (FMDD) 140 integrated within a welding helmet 900. The face-mounted display device (FMDD) 140 is operatively connected to the subsystem (PPS) 110 and the space tracker (ST) 120 via either wired or wireless means. The sensor 142 of the space tracker (ST) 120 can be attached to a face-mounted display device (FMDD) 140 or a welding helmet 900 according to various embodiments of the present invention, and the face-mounted display device (FMDD) 140. And / or allows the welding helmet 900 to track against a reference of a three-dimensional spatial frame formed by the spatial tracker (ST) 120.

  FIG. 16 shows an exemplary embodiment of a block diagram of a programmable processor-based subsystem (PPS) 110 subsystem of the virtual welding system 100 of FIG. The subsystem (PPS) 110 includes a central processing unit (CPU) 111 and one or more graphics processing units (GPUs) 115 according to an embodiment of the invention. In one embodiment, one GPU 115 is used to provide monoscopic on a face-mounted display device (FMDD) 140. In another embodiment, two GPUs 115 are used to provide stereoscopic on a face-mounted display device (FMDD) 140. In any case, the user views a virtual reality simulation of a weld paddle (also known as a weld pool) having real-time melt fluidity and heat absorption and heat dissipation characteristics according to embodiments of the present invention.

  FIG. 17 illustrates an exemplary embodiment of a block diagram of a graphics processing unit (GPU) 115 in the subsystem (PPS) 110 of FIG. Each GPU 115 supports implementation of a data parallel algorithm. In accordance with an embodiment of the present invention, each GPU 115 provides two video outputs 118, 119 that can provide two virtual reality views. The two video outputs can be sent to a face-mounted display device (FMDD) 140 to render the welder's viewpoint, and the third video output can be either a welder's viewpoint or some other viewpoint, for example. Can be sent to an observer display device (ODD) 150 that renders the image. The remaining fourth video output can be sent to a projector, for example. Both GPUs 15 perform the same weld physics calculations, but can render a virtual reality environment from the same or another point of view. The GPU 115 includes a computer integrated device architecture (CUDA) 116 and a shader 117. CUDA 116 is a computer engine of GPU 115 that is made accessible to software developers via an industry standard programming language. The CUDA 116 includes parallel cores and is used to execute the physical model of the weld paddle simulation described herein. The CPU 111 provides real-time welding input data to the CUDA 116 on the GPU 115. The shader 117 can respond to drawing and applying all visuals of the simulation. Beads and paddle visuals are driven by the state of the wexel displacement map described later in this specification. According to embodiments of the present invention, the physical model is executed and updated at a rate of about 30 times per second.

  FIG. 18 illustrates an exemplary embodiment of a functional block diagram of the virtual welding system 100 of FIG. As shown in FIG. 12, the various functional blocks of the virtual welding system 100 are implemented primarily through software instructions and modules that are executed in a subsystem (PPS) 110. Various functional blocks of the virtual welding system 100 include a physical interface 1201, a torch and clamp model 1202, an environment model 1203, a sound content function 1204, a welding sound 1205, a stand / table model 1206, an internal architecture function 1207, a calibration function 1208, Welding coupon model 1210, welding physics 1211, internal physical adjustment tool (tool for fine adjustment) 1212, graphical user interface function 1213, graph creation function 1214, student report function 1215, render 1216, bead rendering 1217, three-dimensional texture 1218 , Visual cues function 1219, scoring and tolerance function 1220, tolerance editor 1221, and spatial effects 1222.

  Internal architecture functions 1207 include higher level software management (logistics) of virtual welding system 100 processes, including, for example, file loading, information retention, thread management, physical model entry, menu triggering, and the like. I will provide a. The internal architecture function 1207 is executed on the CPU 111 according to the embodiment of the present invention. Specific real-time inputs to subsystem (PPS) 110 include arc position, gun position, FMDD or helmet position, gun on / off state, and contact mode state (yes / no).

  The graphical user interface function 1213 allows a user to set up a welding scenario via an observer display device (ODD) 150 using the joystick 132 of the physical user interface 130. According to embodiments of the present invention, welding scenario setup includes language selection, username input, trial plate (ie, welding coupon) selection, welding process (eg, FCAW, GMAW, SMAW) and associated axes. Selection of direction spray, pulse or short arc method, selection of gas type and flow rate, selection of stick-shaped electrode type (eg 6010 or 7018), fluxed wire (eg self-shielding, gas shielding type) Includes selection. The welding scenario setup also includes selection of table height, arm height, arm position, and arm rotation of stand 170. Welding scenario setup further includes selection of environment (eg, background environment in virtual reality space), setting of wire feed speed, setting of voltage level, setting of amperage, selection of polarity, specific visual Including turning a clue on or off.

  During a simulated welding scenario, the graphing function 1214 collects the user's capability parameters and displays the user's capability parameters for display in a graphical format (eg, on an observer display device (ODD) 150). Is provided to the graphical user interface function 1213. Tracking information from the space tracker (ST) 120 is supplied to the graph creation function 1214. The graph creation function 1214 includes a simple analysis module (SAM) and a whip / weave analysis module (WWAM). The SAM moves a certain distance by analyzing user welding parameters including welding movement angle, movement speed, welding angle, position, and tip and comparing the welding parameters to data stored in the bead table. WWAM analyzes the user's whipping parameters including dime (slight) intervals, whipping time, paddle time. WWAM analyzes the user's weave parameters including weaving width, weaving interval, and weaving timing. SAM and WWAM interpret raw data input (eg, position and orientation data) into functionally usable data for graph generation. For each parameter analyzed by the SAM and WWAM, the tolerance window is defined by parameters that are limited to the optimum and ideal setpoint input in the bead table using the tolerance editor 1221, and the scoring and tolerance function 1220 Executed.

  The tolerance editor 1221 includes a weldometer that approximates material usage, electricity usage, and welding time. Further, discontinuous welding (ie, weld defects) may occur if some parameters are outside the tolerance range. Any discontinuous welds are processed by the graph creation function 1214 and presented in graphical form via the graphical user interface function 1213. Such discontinuous welds can result in improper weld size, poor bead placement, concave beads, excessive convexity, undercut, porosity, incomplete melting, slag entrainment, excessive filler, burn through, and excessive Including spatter. According to embodiments of the invention, the level or amount of discontinuity depends on how far a particular user parameter is from the optimal or ideal set point.

  Different parameter limits may be pre-defined for various types of users, such as welding beginners, welding experts, and people at exhibitions. Scoring and tolerance function 1220 provides a numerical score depending on how close the user is to the optimal (ideal) value for a particular parameter and depending on the level of discontinuity and defects present in the weld To do. The optimal value is derived from real world data. Information from the scoring and tolerance function 1220 and the graphing function 1214 is used by the student reporting function 1215 to create an instructor and / or student performance report.

  The virtual welding system 100 can analyze and display the result of the virtual welding operation. By analyzing this result, the virtual welding system 100 allows the user to determine from the tolerance limits of the welding process, at what point in the weld pass, at which point along the weld joint it is off. It means that. The score may be attributed to the user's ability. In one embodiment, the score may be a function of deviations in the position, orientation, and speed of the mock welding tool 160 between the tolerance range, which tolerance is a critical or unacceptable weld from the ideal weld path. It may extend to work. Any gradient range can be incorporated into the virtual welding system 100 when selected to score a user's ability. Scoring can be displayed numerically or in alphabetical order. Further, the user's ability can graphically display how close the mock welding tool traverses the weld joint at time and / or location along the weld joint. Parameters such as travel angle, working angle, speed, and distance from the weld joint are examples to be measured, but any parameter can be analyzed for scoring purposes. Parameter tolerance ranges are obtained from real world welding data, thereby providing accurate feedback on how the user should perform in the real world. In another embodiment, an analysis of defects corresponding to the user's capabilities may be incorporated and displayed on an observer display device (ODD) 150. In this embodiment, a graph can be drawn to show what type of discontinuities are due to various measurement parameters monitored during the virtual welding operation. Although an occlusion may not be displayed on an observer display device (ODD) 150, a defect still occurs due to the result of the user's ability, which is still displayed correspondingly, i.e. graphed. can do.

  Visual cues function 1219 provides immediate feedback to the user by displaying overlaid colors and indicators on face-mounted display device (FMDD) 140 and / or surveillance display device (ODD) 150 To do. Visual cues are provided for each of the welding parameters 151 including position, tip-to-workpiece distance, welding angle, moving angle, moving speed, and arc length (eg, for stick welding), but the user's weld If some aspects of the technology are to be adjusted based on pre-determined limits and tolerances, the user is visually instructed. Visual cues may be provided, for example, for whip / weave techniques or weld bead “dime” spacing. The visual cues may be set individually or in any desired combination.

  The calibration function 1208 provides a function for harmonizing physical components of the real world space (3D frame reference) with visual components of the virtual reality space. Each different type of weld coupon (WC) attaches a WC to the arm 714 of the stand 170 and sets the WC in a predetermined position (eg, shown as three dimples on the WC) to the space tracker (ST) 120. It is calibrated at the factory by contacting a calibration stylus that is operatively connected to the factory. The spatial tracker (ST) 120 reads the magnetic field strength at a predetermined position and provides position information to the subsystem (PPS) 110, which uses the position information to perform calibration. (Ie, transition from real world space to virtual reality space).

  Any particular type of WC will fit into the arm 714 of the stand 170 in the same iterative manner and within very tight tolerances. In one example, the distance between the coupon 758 on the arm 714 and the magnet 710 is the known distance 178 as described above in FIG. Thus, once a particular WC type is calibrated, that WC type may not need to be recalibrated (ie, the calibration of a particular type of WC is a one-time event). The same type of WC is compatible. Calibration ensures that the actual feedback perceived by the user during the welding process is harmonized with what is displayed to the user in the virtual reality space, making the simulation more realistic. For example, if the user slides the tip of the mock welding tool (MWT) 160 around the corner of the actual welding coupon (WC) 180, the user moves the tip that the user slides around the actual corner. As you can feel, look at the tip of the face-mounted display device (FMDD) 140 that slides around the corner of the virtual WC. According to an embodiment of the present invention, a mock welding tool (MWT) 160 is placed in a pre-positioned jig and similarly calibrated based on this known jig position.

  In accordance with an alternative embodiment of the present invention, a “smart” coupon is provided, for example having a sensor at the corner of the coupon. The space tracker (ST) 120 can track the corners of the “smart” welding coupon, so that the virtual welding system 100 can locate where the “smart” welding coupon is located in the real world three-dimensional space. Can be recognized continuously. According to a further alternative embodiment of the present invention, a license key is provided for unlocking the welding coupon. If a particular WC is purchased, a license key is provided that allows the user to enter the license key into the virtual welding system 100 to unlock the software associated with that WC. According to another embodiment of the present invention, a spatial non-standard welding coupon is provided based on a real world CAD drawing of the part. The user can train to weld CAD parts even before the parts are actually produced in the real world.

  The sound content function 1204 and the welding sound 1205 provide specific types of welding sounds that vary depending on whether specific welding parameters are within or outside the tolerance range. The sound is adjusted for various welding processes and parameters. For example, in a MIG spray arc welding process, if the user does not place the mock welding tool (MWT) 160 correctly, a crackling sound is provided and the mock welding tool (MWT) 160 is accurately positioned. A hissing sound is provided. In the short arc welding process, a certain crackling sound or frying sound is provided for proper welding techniques, and a shoe sound is provided if undercut occurs. These sounds mimic real-world sounds corresponding to appropriate and inappropriate welding techniques.

  According to various embodiments of the present invention, high fidelity sound content can be obtained from real-world recordings of actual welds using a variety of electronic and mechanical means. According to embodiments of the present invention, the perceived volume and sound directivity is determined by the position of the user's head relative to the simulated arc between the mock welding tool (MWT) 160 and the welding coupon (WC) 180. , Depending on the orientation and distance (assuming the user is wearing a face-mounted display device (FMDD) 140 tracked by the spatial tracker (ST) 120). The sound can be provided to the user via a speaker configured in the console 135 or the stand 170 via the speaker of the earphone of the helmet 900, for example.

  The environment model 1203 provides various background scenes (still images and moving images) in the virtual reality space. Such background environments can include, for example, indoor weld shops, outdoor race tracks, garages, etc., and may include moving cars, people, birds, clouds, and various environmental sounds. The background environment may be interactive according to an embodiment of the invention. For example, the user must inspect the background area before starting the weld to ensure that the environment is appropriate (eg, safe) for the weld. For example, a torch and clamp 1202 model is provided that models various mock welding tools (MWT) 160 including guns, holders including stick-shaped electrodes, etc. in virtual reality space.

  Various welding coupons including, for example, flat coupons, T joint coupons, butt joint coupons, groove weld coupons, pipe coupons (eg, pipes with a diameter of 5.08 cm (2 inches) and pipes with a diameter of 15.24 cm (6 inches)) A coupon model 1210 is provided that models WC) 180 in virtual reality space. Alternatively or additionally, the weld coupon model may include multiple versions, the coupon including one or more weld coupons within a single form factor. For example, an exemplary multi-weld coupon may include a single component T-joint, butt joint, groove weld. Various parts of the stand 700, including an adjustable arm 714, a base 724, and an upright 174 used to couple the adjustable arm to the base, are modeled for use in virtual reality space. A stand / table model 1206 is provided. A physical interface model 1201 is provided that models various portions of the welding user interface 130, console 135, and observer display device (ODD) 150 in virtual reality space.

  According to an embodiment of the present invention, a simulation of a weld paddle or pool in virtual reality space is achieved, where the simulated weld paddle has real-time melt fluidity and heat dissipation characteristics. At the center of the weld paddle, according to an embodiment of the present invention, the simulation is a weld physics function 1211 (aka physical model) that is executed on the GPU 115. Weld physics functions accurately model dynamic fluidity / viscosity, solidity, thermal gradients (heat absorption and heat dissipation), paddle wakes, and bead shapes using double layer displacement techniques. This is described in more detail herein with respect to FIG. 14C.

  The weld physics function 1211 communicates with the bead rendering function 1217 to render all states of the weld bead from the heated molten state to the cooled solidified state. The bead rendering function 1217 uses information 1211 from the weld physical function (eg, heat, fluidity, displacement, dime spacing) to accurately and realistically render weld beads in virtual reality space in real time. . The three-dimensional texture function 1218 provides a texture map to the bead rendering function 1217 to superimpose additional textures (eg, scorching, slag, grains) on the simulated weld bead. For example, the slag can be shown to be rendered on the weld bead during and immediately after the welding process and then removed to reveal the underlying weld bead. Using the rendering function 1216, various identifications using information from the spatial effects module 1222 including sparks, spatter, smoke, arc glow, harmful smoke and gas, and specific discontinuities such as undercuts and porosity, for example. Render non-paddle features of.

  The internal physical adjustment tool 1212 is a fine adjustment tool that allows various welding physical parameters to be defined, updated, and changed for various welding processes. According to an embodiment of the present invention, the internal physical adjustment tool 1212 is executed on the CPU 111 and the adjusted or updated parameters are downloaded to the GPU 115. The types of parameters that are adjusted via the internal physical adjustment tool 1212 are parameters related to the weld coupon, process parameters that allow the process to be changed without resetting the weld coupon (allows to make a second pass), Includes various global parameters that can be changed without resetting the entire simulation, and various other parameters.

  FIG. 19 is a flowchart of an embodiment of a method 1300 for training using the virtual welding system 100 of FIG. In step 1310, the mock welding tool is moved relative to the welding coupon according to the welding technique. In step 1320, the virtual reality system is used to track the position and orientation of the mock welding tool in 3D space. In step 1330, the simulated mock welding tool forms a simulated weld paddle in the vicinity of the simulated arc emitted from the simulated mock welding tool, thereby creating a simulated welding coupon. View virtual reality welding system display showing real-time virtual reality simulation of mock welding tools and weld coupons in virtual reality space when depositing simulated weld bead material on at least one simulated surface of . In step 1340, the real-time melt fluidity and heat dissipation characteristics of the simulated weld paddle are verified on the display. In step 1350, in response to confirming the simulated weld paddle real-time melt fluidity and heat dissipation characteristics, at least one aspect of the welding technique is modified in real-time.

  The method 300 is responsive to the user confirming various properties of the simulated weld paddle, including real-time melt fluidity (eg, viscosity) and heat dissipation, in a virtual reality space. And show how to change your welding technique. The user confirms and responds to other characteristics, including real-time paddle wake and dime intervals. Confirmation and response to the characteristics of the weld paddle shows how most welding operations are actually performed in the real world. The double displacement layer modeling of the welding physics function 1211 performed on the GPU 115 allows real time melt flow and heat dissipation characteristics to be accurately modeled and presented to the user. For example, heat dissipation determines the solidification time (ie, how long does it take for wexel to fully solidify).

  Further, the user can form a second pass on the weld bead material using the same or different (eg, second) mock welding tool and / or welding process. In such a second pass scenario, the simulation shows that the simulated mock welding tool places a second simulated weld paddle near the simulated arc emitted from the simulated mock welding tool. A simulated mock welding tool, weld coupon, and original simulation in depositing a second simulated weld bead material that is integrated with the first simulated weld bead material by forming The welded bead material part is shown in the virtual reality space. Additional subsequent passes using the same or different welding tools and processes can be formed in a similar manner. In a second or subsequent pass, the previous weld bead material may be replaced according to some embodiments of the present invention by the new weld paddle in the virtual reality space, the previous weld bead material, the new weld bead material, And possibly integrated with the new weld bead material to be deposited when formed from any combination of the underlying weld coupon materials. Such a subsequent pass needs to form, for example, a wide fillet or groove weld, may be made to repair the weld bead formed by the previous pass, or was made by pipe welding. A hot pass and one or more filling and cap passes may be included after the root pass. According to various embodiments of the present invention, the weld bead and base material may include mild steel, stainless steel, aluminum, nickel base alloy, or other materials.

  20A-20B illustrate the concept of a weldment displacement map 1420 according to an embodiment of the present invention. FIG. 20A shows a side view of a flat weld coupon (WC) 1400 having a flat top surface 1410. The welding coupon 1400 exists in the real world as, for example, a plastic part, and also exists in the virtual reality space as a simulated welding coupon. FIG. 20B shows a representation of the top surface 1410 of a simulated WC 1400 that is divided into a grid or array of weld elements (ie, wexels) that form a wexel map 1420. Each wexel (eg, wexel 1421) defines a small portion of the surface 1410 of the weld coupon. The wexel map defines the surface resolution. A changeable channel parameter value is assigned to each wexel, allowing the value of each wexel to be dynamically changed in real time in the virtual reality welding space during the simulated welding process. Channel parameter values that can be changed include channel paddles (melt fluidity / viscosity displacement), heat (heat absorption / heat dissipation), displacement (solid displacement), additional (extra) (eg slag, grain, stoving, Corresponding to various additional states such as metals used). These changeable channels are referred to herein as PHEDs for paddles, heat, extras and displacements, respectively.

  FIG. 20 illustrates an exemplary embodiment of the weld coupon space and weld space of the flat weld coupon (WC) 1400 of FIG. 14, as simulated in the virtual welding system 100 of FIG. Points O, X, Y, and Z define a local three-dimensional welding coupon space. In general, each welding coupon type defines a mapping from a 3D welding coupon space to a 2D virtual reality welding space. The wexel map 1420 in FIG. 20 is a two-dimensional array value that maps to a virtual reality welding space. The user welds from point B to point E as shown in FIG. The locus line from the point B to the point E is shown in both the three-dimensional welding coupon space and the two-dimensional welding space in FIG.

  Each type of welding coupon defines the direction of displacement for each position in the map wexel. For the flat weld coupon of FIG. 21, the direction of displacement is the same at all positions in the wexel map (ie, the Z direction). The texture coordinates of the wexel map are shown as S, T (sometimes also called U, V) in both the 3D welding coupon space and the 2D welding space for clarity of mapping. The wexel map is mapped to and represents the rectangular area 1410 of the welding coupon 1400.

  FIG. 22 illustrates an exemplary embodiment of a weld coupon space and weld space for a corner (T-joint) weld coupon (WC) 1600 as simulated in the virtual welding system 100 of FIG. The corner WC 1600 has two faces 1610 and 1620 of the three-dimensional welding coupon space that are mapped to the two-dimensional welding space as shown in FIG. Again, points O, X, Y, and Z define a local three-dimensional welding coupon space. The texture coordinates of the wexel map are shown as S, T in both the 3D welding coupon space and the 2D welding space for clarity of mapping. The user welds from point B to point E as shown in FIG. The locus line from the point B to the point E is shown in both the three-dimensional welding coupon space and the two-dimensional welding space in FIG. However, the direction of displacement is towards the line X'-O 'as shown in the three-dimensional welding coupon space towards the opposite corner as shown in FIG.

  FIG. 23 illustrates an exemplary embodiment of a weld coupon space and weld space for a pipe weld coupon (WC) 1700 as simulated in the virtual welding system 100 of FIG. The pipe WC 1700 has a curved surface 1710 of the three-dimensional welding coupon space mapped to the two-dimensional welding space as shown in FIG. Again, points O, X, Y, and Z define a local three-dimensional welding coupon space. The texture coordinates of the wexel map are shown as S and T in both the 3D welding coupon space and the 2D welding space for clarity of mapping. The user welds from point B to point E along a curved trajectory as shown in FIG. The trajectory curve and the line from point B to point E are respectively shown in the three-dimensional welding coupon space and the two-dimensional welding space in FIG. The direction of displacement is the direction away from the line YO (ie, away from the center of the pipe).

  In a similar manner such that the texture map is mapped to a rectangular surface area of the geometric shape, the weldable wexel map can be mapped to the rectangular surface of the weld coupon. Each element of the weldable map is called a wexel in the same sense, with each element of the image called a pixel (pixel reduction). A pixel includes an information channel that defines a color (eg, red, green, blue, etc.). Wexel includes information channels (eg, P, H, E, D) that define weldable surfaces in virtual reality space.

  According to an embodiment of the present invention, the format of the wexel is summarized as a PHED (Puddle, Heat, Extra, Displacement) channel containing four floating point numbers. An extra channel is treated as a set of bits that store logical information about the wexel, such as whether there is a slag at the wexel position, for example. The paddle channel stores the displacement value for any liquefied metal at the wexel position. The displacement channel stores the displacement value for the solidified metal at the wexel position. The heat channel stores a given heat magnitude value at the wexel location. Thus, the weldable portion of the weld coupon can exhibit displacement due to weld beads, shimmering surface “paddles” due to liquid metal, color due to heat, and the like. All of these effects are achieved by vertices and pixel shaders applied to the weldable surface.

  According to embodiments of the present invention, a displacement map and a particle system are used where the particles interact with each other and collide with the displacement map. The particles are virtual hydrodynamic particles that provide the liquid behavior of the weld paddle, but are not rendered directly (ie, cannot be seen directly visually). Instead, only the particle effects on the displacement map can be visually seen. The heat input to wexel affects the motion of nearby particles. There are two types of displacements involved in welding paddle simulation, including paddles and displacements. The paddle is “temporary” but lasts as long as particles and heat are present. The displacement is “permanent”. Paddle displacement is a rapidly changing (eg, sparkling) welded liquid metal and can be considered “on top” of the displacement. The particles are superimposed on a portion of the virtual surface displacement map (ie, the wexel map). Displacement represents a permanent solid metal that includes both the initial base metal and the solidified weld bead.

  According to an embodiment of the present invention, a simulated welding process in virtual reality space operates as follows. The particles flow from an emitter (emitter of simulated mock welding tool (MWT) 160) in a thin cone. The particles first contact the surface of the simulated weld coupon, the surface of which is defined by a wexel map. Particles interact with each other and the wexel map and accumulate in real time. As more heat is added, the wexel is closer to the emitter. The heat is modeled as a function of the distance from the arc point and the time that heat is input from this arc. Some visuals (eg color, etc.) are moved by heat. Weld paddles are drawn or rendered in virtual reality space for wexels with sufficient heat. Where the weld paddle is hot enough, the wexel map liquefies, causing paddle displacement to “rise” for these wexel positions. The paddle displacement is determined by sampling the “highest” particle at each wexel position. As the emitter moves along the welding trajectory, the wexel position proceeds while being cooled. Heat is removed from the wexel location at a specific rate. The wexel map solidifies when cooling reaches a threshold. Thus, the paddle displacement is converted into displacement (ie solidified beads) in stages. The added displacement corresponds to the paddle removed so that the overall height does not change. The lifetime of the particles is fine tuned or adjusted to persist until solidification is complete. Specific particle characteristics modeled by the virtual welding system 100 include attractive / repulsive force, velocity (related to heat), damping (related to heat dissipation), direction (related to gravity).

  24A-24C illustrate an exemplary embodiment of the double displacement (displacement and particle) paddle model concept of the virtual welding system 100 of FIG. The welding coupon is simulated in a virtual reality space having at least one surface. The surface of the welding coupon is simulated in virtual reality space as a double displacement layer including a solid displacement layer and a paddle displacement layer. The paddle displacement layer can change the solid displacement layer.

As described herein, a “paddle” is defined by the area of the wexel map, where the value of the paddle is raised by the presence of particles. The sampling process is represented in FIGS. 24A-24C. The section of the wexel map is shown as having seven adjacent wexels. The current displacement value is represented by an unshaded rectangular bar 1910 of a predetermined height (ie, a predetermined displacement for each wexel). In FIG. 24A, particles 1920 are shown as non-shaded dots that collide with the current displacement level and are stacked. In FIG. 24B, the “highest” particle height 1930 is sampled at each wexel position. In FIG. 24C, the shaded rectangle 1940 shows how much paddle was added above the displacement as a result of the particles. The height of the weld paddle is not set instantaneously to the sampled value because the paddle is added at a specific liquefaction rate based on heat. Although not shown in FIGS. 24A-24C, the paddle (shaded rectangle) gradually contracts and the displacement (unshaded rectangle) gradually occupies the paddle location step by step from below. It is possible to visualize the solidification process as it grows. In this way, real-time melt fluidity characteristics are accurately simulated. As the user practices a particular welding process, the user can observe the melt fluidity and heat dissipation characteristics of the weld paddle in real time in virtual reality space, and use this information to develop his welding technique. Can be adjusted or maintained.

  The number of wexels representing the surface of the welding coupon is fixed. Furthermore, as described herein, paddle particles generated by simulation to model fluidity are temporary. Thus, once the initial paddle is generated in virtual reality space during a simulated welding process using virtual welding system 100, the number of wexels and paddle particles maintains a relatively constant value. Tend. This is because paddle particles are formed and “collapsed” at similar rates (ie, paddle particles are temporary), so the number of wexels processed is fixed and present during the welding process. And the number of paddle particles to be processed tends to be maintained at a relatively constant value. Thus, the processing load of the subsystem (PPS) 110 is kept relatively constant during the simulated welding session.

  According to another embodiment of the present invention, paddle particles are generated in or below the surface of the weld coupon. In such an embodiment, the displacement can be modeled to be positive or negative with respect to the original surface displacement of an unused (ie, not yet welded) weld coupon. Thus, paddle particles may not only accumulate on the surface of the weld coupon, but also penetrate the weld coupon. However, the number of wexels is still fixed, and the paddle particles that are formed and collapsed remain relatively constant.

  According to an alternative embodiment of the present invention, instead of the particles to be modeled, a wexel displacement map may be provided having multiple channels for modeling paddle fluidity. Alternatively, instead of modeling particles, a dense voxel map may be modeled. As used herein, a voxel (eg, a volume pixel) is a volume element that represents a value on a regular grid in three-dimensional space. Alternatively, instead of a wexel map, only the particles that are sampled and never disappear may be modeled. However, such an alternative embodiment cannot provide a relatively constant processing load of the system.

  Furthermore, according to embodiments of the present invention, air blowthrough or key holes are simulated by removing material. For example, if the user maintains the arc in the same place for a long time, in the real world, the material will burn out to create holes. Such a real world burn-out is simulated by the virtual welding system 100 by means of a wexel decimation technique. If the amount of heat absorbed by the wexel is determined to be very high by the virtual welding system 100, the wexel can be flagged or designated as burned out and rendered as such. (For example, rendered as a hole). However, the wexel reconstruction then occurs for certain welding processes (eg, pipe welding) where the material is added again after the material is initially burned off. In general, the virtual welding system 100 simulates wexel decimation (removing material) and wexel reconstruction (ie, adding material). Further, removing material in the root pass weld is properly simulated in the virtual welding system 100.

  Furthermore, removing material in the root pass weld is properly simulated in the virtual welding system 100. For example, in the real world, the grinding of the root pass takes place before the subsequent welding pass. Similarly, the virtual welding system 100 can simulate a grinding pass that removes material from the virtual weld joint. It will be appreciated that the removed material is modeled as a negative displacement in the wexel map. That is, the grinding pass removes the material modeled by the virtual welding system 100 and results in a modified bead profile. A grinding pass simulation such that the virtual welding system 100 removes a predetermined thickness of material can be automated, which can be done on each of the surfaces of the root pass weld bead.

  In an alternative embodiment, the actual grinding tool, or grinder, is simulated to turn on / off upon activation of the mock welding tool 160 or another input device. Note that the grinding tool can be simulated to resemble a real world grinder. In this embodiment, the user operates the grinding tool along the route path to remove material in response to the movement. It should be understood that the user can remove a great deal of material. Similar to what has been described above, holes and defects (described above) can occur when the user has ground too much material. Nevertheless, hard limits or stops are implemented, i.e., programmed to prevent the user from removing too much material or to indicate an indication that too much material has been removed.

  In addition to the invisible “paddle” particles described herein, the virtual welding system 100, in accordance with embodiments of the present invention, provides three other types of visible particles to represent arc, flame, and spark effects. May be used. These types of particles do not interact with other types of particles, but interact only within the displacement map. Although these particles strike the simulated weld surface, these particles do not interact with each other. According to embodiments of the present invention, only the paddle particles interact with each other. The physical properties of the spark particles are set up so that the spark particles bounce in the virtual reality space and are rendered as dots that shine in this space.

  The physical properties of the arc particles are set up so that the arc particles strike the simulated weld coupon or weld bead surface and stay for a while. Arc particles are rendered as large dim blue spots in virtual reality space. This requires a number of such spots superimposed to form a visual image permutation. The end result is a white glowing afterglow with a blue edge.

  The physical properties of the flame particles are modeled so that they are slowly lifted upwards. Flame particles are rendered as dim red yellow spots of medium size. This requires a number of superimposed spots to form a visual image permutation. The end result is an orange-red flame spot with a red edge that is lifted upward and gradually darkens. According to other embodiments of the present invention, other types of non-paddle particles may be implemented in the virtual welding system 100. For example, smoke particles can be modeled and simulated in a manner similar to flame particles.

  The final step in the simulated visualization is handled by the vertex and pixel shader provided by shader 117 of GPU 115. Vertex and pixel shaders are applied not only to paddles and displacements, but also to heat-modified surface colors and reflectivity. As previously described herein, the PHED wexel format extra (E) channel contains all of the additional information used per wexel. According to the embodiment of the present invention, the extra information includes an unused bit (true = bead, false = unused steel), a slag bit, an undercut value (undercut amount in this wexel, zero indicates no undercut) ), The porosity value (the amount of pores in this wexel, zero is equal to the absence of pores), and the bead wake value encoded time for the bead to solidify. There is a set of image maps associated with different weld coupon appearances including unused steel, slag, beads, and porosity. These image maps are used for both bump (projection) mapping and texture mapping. The mixing amount of these image maps is controlled by various flags and values described in this specification.

  The bead wake effect is achieved using a one-dimensional image map and a bead wake value per wexel that encodes the time at which a given bit of the bead solidifies. Once the hot paddle wexel location does not have enough heat to call it a “paddle”, time is saved at that location and is called a “bead shake”. The end result is that the shader code uses a one-dimensional texture map to draw a “ripple” that gives the bead a unique appearance that represents the direction in which the bead lies. According to an alternative embodiment of the present invention, the virtual welding system 100 can be simulated in virtual reality space and simulated as the simulated weld paddle is moved along the welding trajectory. Display a weld bead having real-time weld bead wake characteristics, such as that resulting from a real-time fluidization-solidification transition of a welded paddle.

  According to an alternative embodiment of the present invention, virtual welding system 100 can teach a user how to troubleshoot a welder. For example, a system troubleshooting mode can train the user so that the user can set up the system correctly (eg, correct gas flow, correct power cord connections). According to another alternative embodiment of the present invention, the virtual welding system 100 is capable of recording and playing back a welding session (or at least a portion of a welding session, eg, N frames). A trackball is provided to scroll through the frames of the video and allows the user or instructor to review the welding session. Playback is provided at a similarly selectable speed (eg, full speed, half speed, quarter speed). According to embodiments of the present invention, split screen playback is provided, allowing two welding sessions to be viewed side by side on, for example, an observer display device (ODD) 150. For example, a “good” welding session can be displayed next to an “insufficient” welding session for comparison purposes.

  In summary, a programmable processor-based subsystem, a spatial tracker operably connected to the programmable processor-based subsystem, at least one mock welding tool spatially trackable by the spatial tracker, and a program A real-time virtual reality welding apparatus is disclosed that includes at least one display device operably connected to a possible processor-based subsystem. The virtual reality welding device is designed to accommodate portable applications and uses a compact retractable stand to hold the weld coupon in space for use with a mock welding tool. The mock welding tool includes a common base that joins multiple adapters, each adapter simulating a specific weld type. In this way, the system can simulate a weld paddle with real-time melt fluidity and heat dissipation characteristics in virtual reality space. The system can further display the simulated weld paddle on the display device in real time.

  The above examples are merely illustrative of some possible embodiments of various aspects of the invention, and equivalent modifications and / or changes may be made to others by reading and understanding this specification and the accompanying drawings. It becomes possible to those skilled in the art. Specifically, with respect to the various functions performed by the components described above (assemblies, devices, systems, circuits, etc.), the terminology used to describe such components (reference to “means”) Unless otherwise stated, even though it is not structurally equivalent to the structure disclosed to perform the functions of the exemplary implementations of the invention, it does not It is intended to correspond to components such as hardware, software, or combinations thereof that perform certain functions. Furthermore, while specific features of the invention are disclosed with respect to only one of several implementations, such features may be desirable and advantageous for a given or specific application. Can be combined with one or more features of other implementations. Also, the scope of terms including "including", "includes", "having", "has", "with", or their conjugations is detailed. Used in the description and / or claims. Such terms are intended to be encompassed in a manner similar to the term “comprising”. As used herein, the terms “datum (reference)” and “reference point” refer to the reference from which measurements are made.

  This written description uses examples to disclose the invention, including the best mode, and that any person skilled in the art can make and use any device or system, or perform any built-in method. Makes it possible to implement the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such examples are the case where the examples have structural elements that do not differ from the language of the claims, or equivalent structural elements in which the examples have non-essential differences from the language of the claims. If it is included, it shall fall within the scope of the claims.

100 Virtual Welding System 110 Programmable Processor Based Subsystem 111 Central Processing Unit 112 Memory 114 Processor 115 Graphic Processing Unit 116 Computer Integrated Device Architecture 117 Shader 118 Video Output 119 Video Output 120 Spatial Tracker 130 Welding User Interface 132 Joystick 140 Face Wearable display device 142 Sensor 146 Helmet 150 Display device 160 Mock welding tool 162 Adapter 166 Base 168 Sensor 170 Stand 172 Magnet 178 Predetermined distance 180 Welding coupon 200 System 300 Welding gun 310 Nozzle 312 Tube 318 Interface 400 Stick-shaped welding tool 410 Calibrated stick-shaped electrode 422 holder 500 oxygen combustion torch 510 nozzle 518 interface 520 push button 522 color 600 base 610 interface 614 landing 616 dimple 618 push button 620 body 630 wiring connection cable 640 fastener 652 sensor 654 cable 658 fastener 672 (Wings)
700 Stand 710 Magnet 714 Arm 722 Upright 724 Base 732 Plunger 738 Landing 758 Welding Coupon 762 Pin 764 Pin 766 Hole 768 Hole 800 Mock Welding Tool 810 Container 830 User Interface 832 Selector 836 Thermometer 838 Ammeter 8542 Step 8 860 Alternative user interface 900 Helmet 1201 Physical interface 1202 Torch / clamp model 1203 Environmental model 1204 Sound content function 1205 Welding sound 1206 Stand / table model 1207 Internal architecture function 1208 Calibration function 1210 Welding coupon model 1211 Welding physics 1212 Internal physical adjustment tool 1213 User Interface Function 1214 Graph Creation Function 1215 Student Report Function 1216 Render 1217 Bead Rendering 1218 3D Texture 1219 Visual Cue Function 1220 Scoring / Tolerance Function 1221 Tolerance Editor 1222 Spatial Effects 1300 Method 1310 Step 1320 Step 1330 Step 1340 Step 1350 Step 1400 Flat Weld Coupon 1410 Flat Top 1420 Displacement Map 1421 Wexel
1600 Welding coupon 1610 Surface 1620 Surface 1700 Pipe welding coupon 1710 Curved surface 1910 Rectangular bar 1920 Particles 1930 Particle height 1940 Shaded rectangle 6010 Stick-shaped electrode 7018 Stick-shaped electrode B Point B
D Information channel E Information position / Channel H Information channel O Point O
O 'line P channel of information S texture coordinates T texture coordinates U texture coordinates V texture coordinates X point X
X 'line Y point Y
Z point Z

Claims (15)

A virtual welding system (100) comprising:
A programmable processor-based subsystem (110);
A spatial tracker (120) operably connected to the programmable processor-based subsystem (110);
A mock welding tool (160) spatially trackable by the spatial tracker (120);
The mock welding tool (160)
Two or more adapters (162, 300, 400, 500), each adapter (162, 300, 400, 500) emulating the real-world appearance of a particular weld type. , 400, 500);
A base (166) that includes one or more sensors for determining a spatial position relative to the spatial tracker, wherein each of the two or more adapters (162, 300, 400, 500) includes the base (166). It has a; Ru is removably connected, the base (166) to
Each of the two or more adapters (162, 300, 400, 500) interacts with the base (166), and the programmable processor-based subsystem (110) is associated with the appropriate adapter associated with each adapter. Executing a set of instructions to display a rendering for each of the two or more adapters (162, 300, 400, 500) on a display on a face-mounted display device;
Virtual welding system. One or more sensors (168) disposed within the base (166);
A magnet (172) having a spatial position, the magnet being tracked by the one or more sensors (168) to identify a relative position of the mock welding tool (160) relative to the magnet (172); A magnet (172); and
The virtual welding system according to claim 1. A weld coupon (180) having at least one surface and simulating a real-world part to be welded, the weld coupon (180) being located at a known distance from the magnet (172) Wherein at least one surface of the weld coupon (180) is simulated in virtual reality space as a double displacement layer comprising a solid displacement layer and a paddle displacement layer, the paddle displacement layer comprising the solid displacement layer Further comprising a weld coupon (180) that is changeable;
A stand (170) is provided that supports the magnet (172) and the welding coupon (80) in a predetermined spatial relationship.
The virtual welding system according to claim 2. A helmet (146) worn by the user;
A face-mounted display device (150) disposed in the helmet (146), wherein the face-mounted display device (150) is displayed in real time when displayed on the face-mounted display device (150). In response to real-time visual feedback, displaying real-time melt fluidity and heat dissipation characteristics of the simulated weld paddle to provide visual feedback to the user of the mock welding tool (160) Further comprising: a face-mounted display device (150) that allows a user to adjust or maintain the welding technique in real time;
The virtual welding system as described in any one of Claims 1 thru | or 3. The position of the helmet (146) is determined by the spatial tracker (120) and communicated to the programmable processor-based subsystem (110).
The virtual welding system according to claim 4. To track the spatial position of the helmet (146) with respect to magnets (172), one or more sensors disposed on the helmet (146) in (168); and wherein the
The sensor is preferably one or more of a capacitance sensor, a piezoelectric sensor, an infrared proximity sensor, a Hall effect sensor, an eddy current sensor, an inductive sensor, and an ultrasonic sensor.
The virtual welding system according to claim 4 or 5. A mock welding tool (160) used in the virtual welding system (100), the mock welding tool (160) being:
Two or more adapters (162), each adapter (162) emulating the physical characteristics of a particular weld type; and adapters (162);
Wherein a base that is removably coupled to each of the two or more adapters (162) (166), said base (166), the real-time spatial position to identify the relative reference position mock welding tool (160) The base includes one or more sensors to determine a spatial position relative to the spatial tracker;
Each of the two or more adapters interacts with the base (166), and a programmable processor-based subsystem (110) executes the appropriate instruction set associated with each adapter to execute the two Rendering suitable for each of the above adapters is displayed on the display on the face-mounted display device.
Mock welding tool. The reference point is a weld coupon (180) having at least one surface in simulating a real-world part to be welded, the weld coupon (180) having at least one surface and Simulating a real-world part to be welded, wherein at least one surface of the weld coupon (180) is simulated in virtual reality space as a double displacement layer comprising a solid displacement layer and a paddle displacement layer; The paddle displacement layer can change the solid displacement layer,
The mock welding tool according to claim 7. A magnet (172) disposed at a predetermined position with respect to the welding coupon (180);
A stand (170) is provided for fixing the spatial position of the magnet (172) relative to the welding coupon (180);
One or more sensors (168) are disposed within the base (166), the one or more sensors determining the position of the base (166) relative to the magnet (172);
The sensor preferably communicates these locations to the programmable processor-based subsystem (110);
The mock welding tool according to claim 8. A said base (166) first end arranged interface, the interface facilitates removable mechanical bond with each of the two or more adapters (162), an interface In addition,
The mock welding tool according to any one of claims 7 to 9. The interface includes at least one first mechanical mechanism complementary to at least one second mechanical mechanism in the adapter (162), wherein each adapter (162) relative to the base (166) Facilitates removable mechanical coupling,
The mock welding tool according to claim 10. The base (166) further includes a trigger used to indicate an active welding condition within the virtual welding system (100);
Preferably, the trigger is engaged within each adapter via a sleeve, and the sleeve is mechanically manipulated to initiate an active weld state by the user via the adapter.
The mock welding tool according to any one of claims 7 to 11. A method of using a mock welding tool (160) within a virtual welding system (100), the method comprising:
Removably connecting a first adapter (162) to a base (166), wherein the first adapter (162) is associated with a first weld type;
Removing the first adapter (162) from the base (166);
Removably connecting a second adapter (162) to the base (166), wherein the second adapter (162) is associated with a second weld type. ,
The base (166) includes a sensor (168) that determines a spatial position of the mock welding tool (160) relative to a welding coupon (180), the position of the base (166) being updated in real time on a display;
Method. A magnet (172) disposed at a known position relative to the welding coupon (180);
The sensor (168) determines the position of the magnet (172) and calculates the position of the welding coupon (180) based at least on the position of the magnet (172).
The method of claim 13. Moving the mock welding tool (160) including the first adapter (162) relative to the welding coupon (180) according to a first welding technique;
Tracking the mock welding tool (160) including the first adapter (162) in three-dimensional space using the virtual reality welding system (100);
A simulated mock welding tool (160) including a first adapter (162) is simulated in the vicinity of a simulated arc emitted from a mock welding tool (160) including a first adapter (162). Forming the first simulated weld bead material on at least one surface of the simulated weld coupon (180) by forming a simulated weld paddle ascertaining the display of the coupon virtual reality welding device are shown in a virtual reality space in real time virtual reality simulation of the mock welding tool (160) comprising (180) (100);
Confirming a first real-time melt fluidity and heat dissipation characteristics of the first simulated weld paddle on the display;
Modifying at least one aspect of the first welding technique in response to confirmation of the first real-time melt fluidity and heat dissipation characteristics of the first simulated weld paddle in real-time. ,
More preferably,
Moving the mock welding tool (160) including the second adapter (162) relative to the welding coupon (180) according to a second welding technique;
Tracking the mock welding tool (160) including a second adapter (162) in a three-dimensional space using the virtual reality welding system (100);
A simulated mock welding tool (160) including a second adapter (162) is emitted from a simulated mock welding tool (160) including a second adapter (162). Depositing a second simulated weld bead material on the simulated at least one surface of the simulated weld coupon (180) by forming a second simulated weld paddle in the vicinity. A display of the virtual reality welding apparatus (100) showing a real-time virtual reality simulation of the mock welding tool (160) including the second adapter (162) and the welding coupon (180) in a virtual reality space. A step to confirm;
Confirming a second real-time melt fluidity and heat dissipation characteristic of the second simulated weld paddle on the display;
Altering at least one aspect of the second welding technique in response to confirmation of the second real-time melt fluidity and heat dissipation characteristics of the second simulated weld paddle in real time; Including,
15. A method according to claim 13 or 14.

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