Importing and analyzing external data using a virtual reality welding system

• US 10,056,011 B2
• Filed: 08/17/2017
• Issued: 08/21/2018
• Est. Priority Date: 08/21/2008
• Status: Active Grant

• Current Assignee: Lincoln Global Incorporated (Lincoln Electric Holdings Incorporated)
• Original Assignee: Lincoln Global Incorporated (Lincoln Electric Holdings Incorporated)
• Inventors: Zboray, David Anthony, Bennett, Matthew Alan, Wallace, Matthew Wayne, Hennessey, Jeremiah, Dudac, Yvette Christine, Lenker, Zachary Steven, Lundell, Andrew Paul, Dana, Paul, Preisz, Eric A.
• Primary Examiner(s): Utama, Robert J
• Application Number:
  US15/679,621
• Publication Number:
  US 20170345336A1
• Time in Patent Office: 369 Days
• CPC Class Codes: A42B 3/042 Optical devices night vision goggles G02B23/12
• CPC Class Codes: A42B 3/30 Mounting radio sets or communication systems
• CPC Class Codes: A61F 9/06 Masks, shields or hoods for welders safety devices for welding in general F16P1/00
• CPC Class Codes: B23K 9/00 Arc welding or cutting electro-slag welding B23K25/00; welding transformers H01F; welding generators H02K
• CPC Class Codes: B23K 9/09 Arrangements or circuits for arc welding with pulsed current or voltage
• CPC Class Codes: B23K 9/095 Monitoring or automatic control of welding parameters
• CPC Class Codes: B23K 9/0953 using computing means
• CPC Class Codes: B23K 9/0956 using sensing means, e.g. optical
• CPC Class Codes: B23K 9/10 Other electric circuits therefor; Protective circuits; Remote controls
• CPC Class Codes: G09B 19/24 Use of tools
• CPC Class Codes: G09B 5/00 Electrically-operated educational appliances working with questions and answers G09B7/00; simulators G09B9/00; advertising or displaying in general G09F
• CPC Class Codes: G09B 5/02 with visual presentation of the material to be studied, e.g. using film strip
• CPC Class Codes: G09B 5/04 with audible presentation of the material to be studied sound recording or reproducing G11B
• CPC Class Codes: G09B 5/06 with both visual and audible presentation of the material to be studied
• CPC Class Codes: G09B 5/065 Combinations of audio and video presentations, e.g. videotapes, videodiscs, television systems
• CPC Class Codes: H04L 67/131 Protocols for games, networked simulations or virtual reality

Abstract

A real-time virtual reality welding system including a programmable processor-based subsystem, a spatial tracker operatively connected to the programmable processor-based subsystem, at least one mock welding tool capable of being spatially tracked by the spatial tracker, and at least one display device operatively connected to the programmable processor-based subsystem. The system is capable of simulating, in virtual reality space, a weld puddle having real-time molten metal fluidity and heat dissipation characteristics. The system is further capable of importing data into the virtual reality welding system and analyzing the data to characterize a student welder'"'"'s progress and to provide training.

Claims

1. A method for simulating welding activity, said method comprising:

tracking a movement and orientation of a welding tool using an optical sensor during a simulated welding operation;

generating a plurality of simulated welding parameters based on said movement and orientation of said welding tool;

modeling, during said simulated welding operation, a simulated welding surface for a welding coupon;

displaying said simulated welding surface on a first display device mounted in a helmet and second display device mounted in a simulated welding console;

creating, during said simulated welding operation, a simulated welding arc between an emitting end of said welding tool and said simulated welding surface;

simulating a creation of a weld puddle have real-time molten metal fluidity, real-time heat dissipation and real-time heat absorption characteristics during said simulated welding operation;

modeling said simulated weld puddle such that regions of a surface of said simulated weld puddle have both a displacement value and a heat value;

dynamically changing during said simulated welding operation each of said displacement values and heat values to display on each of said first and second display devices a simulated deposition of material into said simulated weld puddle, said dynamic changes to each of said displacement and heat values are based on said movement and orientation of said welding tool and on said plurality of simulated welding parameters, where said first and second display devices display a color for each of said regions which is based on said heat values; and

displaying a simulated completed weld bead on said first and second display devices which is based on said movement and orientation of said welding tool, based on said simulated welding parameters and based on a cooling threshold value for a transition of said regions from a molten state to a solid state,

wherein said displacement values are such that a solidified surface of said simulated completed weld bead is displayed above said welding surface of said welding coupon.

2. The method of claim 1, wherein said welding tool is an actual welding tool that can be used for a real world welding operation.

3. The method of claim 1, wherein said optical sensor is mounted on said helmet.

4. The method of claim 1, further comprising simulating welding sounds via a speaker in said helmet in real-time with said simulated welding operation.

5. The method of claim 1, wherein said second display device displays said plurality of simulated welding parameters, in real-time, during said simulated welding operation.

6. The method of claim 5, wherein at least one of said simulated welding parameters is displayed in graphical form in real time during said simulated welding operation.

7. The method of claim 5, wherein said welding parameters include weld angle, travel angle, and travel speed.

8. The method of claim 1, further comprising:

comparing at least one of said simulated welding parameters to a stored value for said at least one simulated welding parameter; and

displaying said comparison on said second display device.

9. The method of claim 8, wherein said comparison is displayed in a form of a graph.

10. The method of claim 1, further comprising:

comparing at least one of said simulated welding parameters to a tolerance window defined by limits around a setpoint for said at least one simulated welding parameter; and

displaying said comparison on said second display device.

11. The method of claim 10, wherein said comparison is displayed in a form of a graph.

12. The method of claim 1, further comprising providing a score for each of said simulated welding parameters based on a comparison between said simulated welding parameters and a desired value for each of said simulated welding parameters, respectively.

13. The method of claim 12, wherein each of said scores is a numerical score.

14. The method of claim 1, further comprising determining a presence of a discontinuity within said simulated weld bead, and where said discontinuity is a presence of at least one of spatter and porosity.

15. The method of claim 14, wherein said first display device displays said discontinuity during said simulated welding operation, in real time, and in said completed simulated weld bead.

16. The method of claim 1, further comprising displaying a plurality of visual cues on said first display device during said simulated welding operation, where each of said plurality of visual cues is for a distinct one of said simulated welding parameters, and where said visual cues are displayed based on a deviation of said simulated welding parameters during said simulated welding operation from a desired value for each of said simulated welding parameters, respectively.

17. The method of claim 1, further comprising:

generating at least one welding effect, which can be any one of simulated welding sparks, simulated welding spatter, simulated arc glow and simulated porosity during said simulated welding operation; and

displaying on said first display device said at least one welding effect, in real time, based on at least one of said simulated welding parameters.

18. The method of claim 1, wherein at least one of said displacement and heat values are changed dynamically based a distance between said regions and said emitting end of said welding tool.

19. The method of claim 1, wherein when said heat value is higher than said cooling threshold value said first and second display devices display said regions in a simulated fluid state and when said heat value is lower than said cooling threshold value said first and second display devices display said regions in a solid state.

20. The method of claim 1, further comprising changing displacement values of at least some regions of said completed weld bead when said welding tool is used to make a second simulated weld bead over said completed weld bead, and where each of said completed weld bead and said second simulated weld bead are displayed on said first and second display devices at the same time.

21. The method of claim 1, wherein said real-time molten metal fluidity and said heat dissipation characteristics are generated by a physics model operating on a least one GPU.

22. The method of claim 1, wherein said first display device displays a weld bead wake characteristic during creation of said simulated weld bead, where said wake characteristic is generated based on a real time fluidity-to-solidification transition of said simulated weld puddle as said simulated weld puddle is moved.

23. The method of claim 1, wherein said welding tool is a simulated welding tool.