KR102013475B1 - System for characterizing manual welding operations - Google Patents
System for characterizing manual welding operations Download PDFInfo
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- KR102013475B1 KR102013475B1 KR1020157003281A KR20157003281A KR102013475B1 KR 102013475 B1 KR102013475 B1 KR 102013475B1 KR 1020157003281 A KR1020157003281 A KR 1020157003281A KR 20157003281 A KR20157003281 A KR 20157003281A KR 102013475 B1 KR102013475 B1 KR 102013475B1
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- orientation
- work path
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- G—PHYSICS
- G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
- G09B—EDUCATIONAL OR DEMONSTRATION APPLIANCES; APPLIANCES FOR TEACHING, OR COMMUNICATING WITH, THE BLIND, DEAF OR MUTE; MODELS; PLANETARIA; GLOBES; MAPS; DIAGRAMS
- G09B25/00—Models for purposes not provided for in G09B23/00, e.g. full-sized devices for demonstration purposes
- G09B25/02—Models for purposes not provided for in G09B23/00, e.g. full-sized devices for demonstration purposes of industrial processes; of machinery
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- G—PHYSICS
- G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
- G09B—EDUCATIONAL OR DEMONSTRATION APPLIANCES; APPLIANCES FOR TEACHING, OR COMMUNICATING WITH, THE BLIND, DEAF OR MUTE; MODELS; PLANETARIA; GLOBES; MAPS; DIAGRAMS
- G09B19/00—Teaching not covered by other main groups of this subclass
- G09B19/24—Use of tools
Abstract
A system is disclosed that provides a welder with valuable training including components that characterize welding practice and generate, capture, and process data. The data generation component further comprises a jig, a workpiece, at least one calibration device each having at least two point markers integral, and a welding tool. The data capture component further includes an imaging system for capturing an image of the point marker, wherein the data processing component is used to receive information from the data capture component and perform various position and orientation calculations.
Description
Cross Reference of Related Applications
This patent application was filed on July 8, 2009, and entitled "Method and System for Monitoring and Characterizing the Creation of a Manual Weld," US Patent Application No. 12 / 499,687, filed December 13, 2010. Some of the serial applications of US Patent Application No. 12 / 966,570, filed and entitled "Welding Training System", the disclosures of which are incorporated herein by reference in their entirety, as if fully set forth herein.
Field of technology
The present invention is directed to welding trainees by capturing, processing, and presenting data generated by welding trainees in a system for specifying manual welding operations, and more particularly, in real time manual welding in real time. A system for providing useful information.
A system for monitoring and characterizing manual welding operations is known from US 2011/0006047 A1.
The manufacturing industry's desire for efficient and economical welding training has been a widely documented topic over the past decade because the perception of serious shortages of skilled welders is surprisingly evident in today's factories, shipyards, and construction sites. Combined with the slow pace of traditional instructor-based welder training, early retiring workers were the impetus for the development of more effective training skills. Along with the rapid injection of arc welding fundamentals, innovations are required to accelerate the training of dexterity specific to welding. The characterization and training system disclosed herein addresses this essential need for improved welder training and enables the monitoring of manual welding processes to ensure that the process is within the acceptable limits needed to meet industry quality requirements. . To date, most of the welding processes are performed manually, and there are no real commercially available tools on site to track the performance of these manual processes. Thus, there is a continuing need for an effective system for training welders to properly perform various types of welding under various conditions.
The following provides specific exemplary embodiments of the present invention. This summary is not an extensive overview and is not intended to identify and describe the scope or essential aspects or elements of the invention.
According to one aspect of the present invention, a system is provided for specifying manual and / or semi-automatic welding operations and practices. The system includes a data generation component, a data capture component, and a data processing component. The data generation component may comprise a fixture in which geometrical characteristics are predetermined; A workpiece adapted to be mounted on a jig, wherein the workpiece includes at least one joint to be welded, the vector extending along the joint to be welded to define a work path; At least one calibration device, each calibration device further comprising at least two point markers, wherein the geometric relationship between the point marker and the work path is predetermined; And a welding tool used to form a weld in the joint to be welded, the welding tool defining tool points and tool vectors, the welding tool further comprising a target attached to the welding tool, the target being mounted in a predetermined pattern; Further comprises three point markers, wherein the predetermined pattern of point markers comprises a welding tool that is used to form a rigid body. The data capture component includes an imaging system for capturing an image of a point marker. The data processing component is used to receive information from the data capture component, and then the position and orientation of the working path with respect to the three-dimensional space seen by the imaging system; The position of the tool point relative to the rigid body and the orientation of the tool vector; And the position of the tool point relative to the work path and the orientation of the tool vector.
According to another aspect of the present invention, there is also provided a system for specifying manual and / or semi-automatic welding operations and practices. The system includes a data generation component, a data capture component, and a data processing component. The data generation component comprises: a jig whose geometrical characteristics are predetermined; A workpiece adapted to be mounted on a jig, wherein the workpiece includes at least one joint to be welded, the vector extending along the joint to be welded to define a work path; At least one calibration device, each calibration device further comprising at least two point markers, wherein the geometric relationship between the point marker and the work path is predetermined; And a welding tool used to form a weld in the joint to be welded, the welding tool defining tool points and tool vectors, the welding tool further comprising a target attached to the welding tool, the target being mounted in a predetermined pattern; Further includes three point markers, wherein the predetermined pattern of the point markers also includes a welding tool that is used to form the rigid body. The data capture component also includes an imaging system for capturing an image of the point marker, the imaging system further comprising a plurality of digital cameras. At least one band-pass filter is incorporated into the optical sequence of each of the plurality of digital cameras to allow only light from wavelengths reflected or emitted from the point marker to improve the image signal to noise ratio. The data processing component is used to receive information from the data capture component, and then the position and orientation of the working path with respect to the three-dimensional space seen by the imaging system; The position of the tool point relative to the rigid body and the orientation of the tool vector; And the position of the tool point relative to the work path and the orientation of the tool vector.
Further features and aspects of the present invention will become apparent to those skilled in the art upon reading and understanding the following detailed description of exemplary embodiments. As will be appreciated by those skilled in the art, further embodiments of the invention are possible without departing from the scope and spirit of the invention. Accordingly, the drawings and associated descriptions are to be regarded as illustrative and not restrictive.
The accompanying drawings, which are incorporated in and form a part of the specification, schematically illustrate one or more exemplary embodiments of the invention, and together with the overall description set forth above and the detailed description provided below, serve to explain the principles of the invention. Do it.
1 is a flow diagram illustrating the flow of information through data processing and visualization components of an exemplary embodiment of the present invention.
2 is an isometric view of a portable or semi-portable system for the specification of a manual welding operation, in accordance with an exemplary embodiment of the present invention.
3 is an isometric view of a flat assembly of the system of FIG. 2.
4 is an isometric view of a horizontal assembly of the system of FIG. 2.
5 is an isometric view of a vertical assembly of the system of FIG.
FIG. 6 illustrates the placement of two point markers on the flat assembly of FIG. 2.
7 illustrates an example workpiece work path.
8 illustrates the placement of two active or passive point markers on an example workpiece for determining a workpiece work path.
9 is a flowchart detailing the process steps involved in an exemplary embodiment of a first calibration component of the present invention.
10 illustrates a welding tool of an exemplary embodiment of the present invention showing the placement of point markers used to form rigid bodies.
11 illustrates a welding tool of an exemplary embodiment of the present invention showing the placement of a point marker used to form a tool vector and a rigid body.
12 is a flowchart detailing the process steps involved in an exemplary embodiment of a second calibration component of the present invention.
Hereinafter, exemplary embodiments of the present invention will be described with reference to the drawings. Reference numerals are used to refer to various elements and structures throughout the description. In other instances, well-known structures and devices are shown in block diagram form in order to simplify the description thereof. Although the following detailed description includes many details for purposes of illustration, those skilled in the art will recognize that many changes and substitutions to the details below are within the scope of the present invention. Accordingly, the following examples of the present invention are described without loss of any generality and without limitation to the claimed invention.
The present invention relates to an advanced system for observing and characterizing manual welding practice and work. This system is particularly useful for welding instructions and welder training, which provides a suitable tool for measuring manual welding techniques and comparing them with established procedures. The training application of the present invention includes: (i) verifying the applicant's skill level, (ii) evaluating the trainee's progress over time, and (iii) providing real time teaching to reduce training time and costs , And (iv) periodically retesting the welder's skill level with an elementable result. Process monitoring and quality control applications may include: (i) real time identification of deviations from desirable conditions, (ii) recording and tracking procedure compliance over time, and (iii) statistical process control purposes (eg, thermal Capturing in-process data for input measurements, and (iv) identifying welders in need of further training. The system of the present invention provides unique advantages that enable the determination of compliance with various approved welding procedures.
The present invention, in various exemplary embodiments, measures torch motion and collects process data during welding practice using a single or multiple camera tracking system based on point cloud image analysis. The present invention is not necessarily limited but can be applied to a wide range of processes including GMAW, FCAW, SMAW, GTAW, and cleavage. The invention can be extended to a wide range of workpiece shapes, including large sizes, various joint types, pipes, plates, and complex shapes. Parameters measured include one angle, angle of travel, tool standoff, speed of travel, bead placement, weave, voltage, current, wire feed speed, and arc length. Training components of the present invention may be pre-specified for a particular welding procedure or may be customized by an instructor. Data is automatically stored and recorded, post-weld analysis scores performance, and progress is tracked over time. The system can be used throughout the entire welding training program and can include both in helmet and on-screen feedback. Hereinafter, with reference to the drawings, one or more specific embodiments of the present invention will be described in more detail.
As shown in FIG. 1, in an exemplary embodiment of the present invention, the
2-5 provide an exemplary view of a
2 and 3, a particular welding practice utilizes a
The
In most cases (if not all), the
The first calibration aspect of the present invention typically involves calibration of the welding operation with respect to the global coordinate system, ie the other structural components of the
In the calibration process represented by the flow chart of FIG. 9, the table 38 is fixed at position i (0,1,2) in
In one embodiment of the invention, the position and orientation of the workpiece is determined by two or more passive or active point markers for the calibration device disposed at a known translational and rotational offset relative to the jig that maintains the workpiece at a known translational and rotational offset. Calibrated through application. In another embodiment of the present invention, the position and orientation of the workpiece is corrected through the application of two or more passive or active point markers to the jig that maintain the workpiece at a known translational and rotational offset. In another embodiment, the workpiece is non-linear, and the position and orientation of the workpiece can be mapped using a calibration tool with two or more passive or active point markers and stored for later use. The position and orientation of the workpiece work path can receive a predetermined translational and rotational offset from its original calibration plane based on the sequential steps in the overall work.
Important tool operating parameters such as position, orientation, velocity, acceleration, and spatial relationship to the workpiece work path can be determined from the analysis of the various tool paths and the continuous tool position and orientation over time. Tool operating parameters can be compared with predetermined desired values to determine deviations from known and preferred procedures. Tool operating parameters may also be combined with other manufacturing process parameters to determine deviations from the desired procedure, which deviations assess progress towards skill objectives to assess skill levels, to provide feedback for training Can be used for quality control purposes or for quality control purposes. The motion parameters recorded for the workpiece work path can be synthesized from a number of tasks for statistical process control purposes. Deviations from preferred procedures can be aggregated from a number of tasks for statistical process control purposes. Critical tool operating parameters and tool position and orientation relative to the workpiece work path can also be recorded to establish a signal of the skilled worker's motion used as a baseline to assess compliance with the desired procedure.
The second calibration aspect typically involves calibration of the
In the calibration process shown by the flow chart of FIG. 12, the
In an embodiment of the invention, the calibration of the tool point and the tool vector is performed by applying two or more passive or active point markers to the calibration device at points along the tool vector at known offsets to the tool point. In another embodiment, the calibration of the tool point and tool vector is performed by inserting the tool into a calibration block of known position and orientation relative to the workpiece. With respect to the rigid body formed by the point markers (eg, 502, 504, 506), in one embodiment, the passive or active point markers are multifaceted in such a way that a wide range of rotation and orientation changes can be adjusted within the field of view of the imaging system. It is fixed to the tool. In another embodiment, the passive or active point marker is fixed to the tool in a spherical manner such that a wide range of rotational and orientation changes can be adjusted within the field of view of the imaging system. In another embodiment, the passive or active point marker is fixed to a ring shaped tool such that a wide range of rotation and orientation changes can be adjusted within the field of view of the imaging system.
Numerous additional useful features may be incorporated into the present invention. For example, for image filtering, a band-pass or high-pass filter may allow only light from wavelengths reflected or emitted from a point marker to improve image signal-to-noise ratio so that a plurality of digital Each camera is integrated in the optical sequence. Unnecessary data can be rejected by analyzing only image information obtained from that dynamic region with a limited offset from a known rigid body neighborhood. This corresponding dynamic zone is integrated or otherwise predefined within each digital camera field of view (ie, programmed from a box or zone of width (x) and height (y) and centered at a known location on the target 98). Is processed only from this predetermined zone. The zone changes when the rigid body moves, and is therefore based on the position of the rigid body known in advance. This approach allows the imaging system to see only the pixels within that dynamic zone when searching for point markers while ignoring or blocking pixels in larger image frames that are not included within that dynamic zone.
Although the present invention has been illustrated by the description of its exemplary embodiments, and specific details of the embodiments have been described, it is not the intention of the applicant to limit or in any way limit the appended claims to those details. Additional advantages and modifications will readily appear to those skilled in the art. Accordingly, the invention is not limited to any of the specific details, representative devices and methods, and / or illustrative examples shown and described in its broadest aspect. Accordingly, departures may be made from such details without departing from the spirit or scope of Applicants' overall inventive concept.
Claims (24)
(a) a data generation component,
(i) fixtures whose geometrical properties are predetermined;
(ii) a workpiece adapted to be mounted on the jig, wherein the workpiece includes at least one joint to be welded, wherein a vector extending along the joint to be welded defines a work path;
(iii) at least one calibration device, each calibration device further comprising at least two point markers, wherein the geometric relationship between the point marker and the work path is predetermined; And
(iv) a welding tool used to form a weld in a joint to be welded, the welding tool defining a tool point and a tool vector, the welding tool further comprising a target attached to the welding tool, the target being targeted in a predetermined pattern. And a plurality of point markers mounted on the substrate, wherein the predetermined pattern of point markers is used to form a rigid body.
A data generation component comprising a;
(b) a data capture component comprising an imaging system for capturing an image of a point marker; And
(c) data processing components;
Wherein the data processing component is used to receive information from the data capture component, and then
(i) the position and orientation of the work path relative to the three-dimensional space as seen by the imaging system
(ii) the position of the tool point relative to the rigid body and the orientation of the tool vector; And
(iii) the position of the tool point with respect to the work path and the orientation of the tool vector
To calculate,
Calibration of the tool point and tool vector of the welding tool is performed using two or more point markers integrated into a removable calibration device, the point marker of the calibration device having a predetermined offset relative to the tool point of the welding tool. A system of characterization of a welding operation that is disposed along.
(a) a data generation component,
(i) fixtures whose geometrical properties are predetermined;
(ii) a workpiece adapted to be mounted on the jig, wherein the workpiece includes at least one joint to be welded, wherein a vector extending along the joint to be welded defines a work path;
(iii) at least one calibration device, each calibration device further comprising at least two point markers, wherein the geometric relationship between the point marker and the work path is predetermined; And
(iv) a welding tool used to form a weld in a joint to be welded, the welding tool defining a tool point and a tool vector, the welding tool further comprising a target attached to the welding tool, the target being targeted in a predetermined pattern. And a plurality of point markers mounted on the substrate, wherein the predetermined pattern of point markers is used to form a rigid body.
A data generation component comprising a;
(b) a data capture component comprising an imaging system for capturing an image of a point marker, the imaging system further comprising a plurality of digital cameras, allowing only light from wavelengths reflected or emitted from the point marker A data capture component, wherein at least one filter is integrated into the optical sequence of each of the plurality of digital cameras to improve the image signal to noise ratio; And
(c) data processing components;
Wherein the data processing component is used to receive information from the data capture component, and then
(i) the position and orientation of the work path relative to the three-dimensional space as seen by the imaging system
(ii) the position of the tool point relative to the rigid body and the orientation of the tool vector; And
(iii) the position of the tool point with respect to the work path and the orientation of the tool vector
To calculate,
Calibration of the tool point and tool vector of the welding tool is performed using two or more point markers integrated into a removable calibration device, the point marker of the calibration device having a predetermined offset relative to the tool point of the welding tool. The system of specification of a manual welding operation that is arranged along.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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PCT/US2012/045776 WO2014007830A1 (en) | 2012-07-06 | 2012-07-06 | System for characterizing manual welding operations |
US13/543,240 | 2012-07-06 | ||
US13/543,240 US9221117B2 (en) | 2009-07-08 | 2012-07-06 | System for characterizing manual welding operations |
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KR20150048715A KR20150048715A (en) | 2015-05-07 |
KR102013475B1 true KR102013475B1 (en) | 2019-08-22 |
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KR1020157003281A KR102013475B1 (en) | 2012-07-06 | 2012-07-06 | System for characterizing manual welding operations |
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JP (1) | JP3198723U (en) |
KR (1) | KR102013475B1 (en) |
CN (3) | CN107293191B (en) |
BR (1) | BR112015000235A2 (en) |
DE (1) | DE202012013151U1 (en) |
WO (1) | WO2014007830A1 (en) |
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JP3198723U (en) | 2015-07-23 |
WO2014007830A1 (en) | 2014-01-09 |
BR112015000235A2 (en) | 2017-06-27 |
CN107731079A (en) | 2018-02-23 |
CN104603860B (en) | 2017-10-20 |
CN104603860A (en) | 2015-05-06 |
KR20150048715A (en) | 2015-05-07 |
CN107731079B (en) | 2019-11-22 |
CN107293191B (en) | 2019-07-09 |
CN107293191A (en) | 2017-10-24 |
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