Virtual reality and real welding training system and method

• US 10,083,627 B2
• Filed: 10/29/2014
• Issued: 09/25/2018
• Est. Priority Date: 11/05/2013
• Status: Active Grant

• Current Assignee: Lincoln Global Incorporated (Lincoln Electric Holdings Incorporated)
• Original Assignee: Lincoln Global Incorporated (Lincoln Electric Holdings Incorporated)
• Inventors: Daniel, Joseph A., Postlethwaite, Deanna, Blankenship, George D.
• Primary Examiner(s): Utama, Robert J
• Application Number:
  US14/526,914
• Publication Number:
  US 20150125836A1
• Time in Patent Office: 1,427 Days
• Field of Search: 434234
• 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 9/1056 by using digital means B23K9/1068 takes precedence
• CPC Class Codes: G09B 19/24 Use of tools

Abstract

A virtual welding station includes a virtual sequencer for simulating different welding techniques and non-welding operations. The virtual welding station can be used to train an operator on the production of complete assemblies.

Claims

1. A virtual welding system comprising:

a logic processor based subsystem operable to execute coded instructions for generating an interactive welding environment that emulates welding activity on a virtual weld joint defined by at least one of a welding coupon and a sample part;

a virtual sequence controller operatively connected to the logic processor based subsystem for implementing a virtual sequence;

a display operatively connected to the logic processor based subsystem for visually depicting the interactive welding environment including the virtual weld joint;

an input device for performing virtual welding activity on the virtual weld joint in real time; and

a spatial tracker comprising one or more sensors adapted to track movement of the input device in real time for communicating data about the movement of the input device to the logic processor based subsystem,

wherein the virtual sequence includes a plurality of operations to be performed in order, each operation intended to achieve a particular state,

wherein at least one of the operations is a manual operation to be performed by a user, and

wherein the manual operation is one of providing user information, retrieving a part, providing part information, placing a part, securing a part, and providing assembly information.

2. The virtual welding system of claim 1, further comprising a user interface for the user to provide input to the virtual welding system.

3. The virtual welding system of claim 1, wherein the virtual sequence controller comprises a microprocessor, a sequence control program, and a memory, and

wherein the memory stores one or more state table files.

4. The virtual welding system of claim 3, wherein the virtual sequence is defined by at least one of the state table files.

5. The virtual welding system of claim 3, wherein the user selects one of the state table files based on a task to be performed;

and

wherein the task is production of a complete virtual assembly.

6. The virtual welding system of claim 1, further comprising a virtual sequence display;

wherein the virtual sequence display displays information on the manual operation.

7. The virtual welding system of claim 1, wherein at least one of the operations is an automatic operation to be performed by the virtual welding system.

8. The virtual welding system of claim 7, wherein the automatic operation is one of specifying a weld process, specifying a gas type, specifying a gas flow rate, specifying a stick electrode type, specifying a flux cored wire type, specifying a wire feed speed, specifying a voltage level, specifying an amperage, specifying a polarity, and specifying a background environment for the interactive welding environment.

9. The virtual welding system of claim 1, wherein each particular state is associated with a condition.

10. The virtual welding system of claim 9, wherein the virtual sequence controller performs an action if the condition is not met.

11. The virtual welding system of claim 1, wherein the display is a face-mounted display.

12. The virtual welding system of claim 1, further comprising a support structure.

13. The virtual welding system of claim 12, wherein the support structure is a stand comprising a base, a vertical post, an adjustable table, and an adjustable arm.

14. The virtual welding system of claim 12, wherein the support structure is an assembly fixture for holding the sample part.

15. The virtual welding system of claim 1, wherein the virtual welding system is operable to assign a quality score to the virtual welding activity.

16. A virtual welding system comprising:

a logic processor based subsystem operable to execute coded instructions for generating an interactive welding environment that emulates welding activity on a virtual weld joint defined by at least one of a welding coupon and a sample part;

a virtual sequence controller operatively connected to the logic processor based subsystem for implementing a virtual sequence;

a display operatively connected to the logic processor based subsystem for visually depicting the interactive welding environment including the virtual weld joint;

an input device for performing virtual welding activity on the virtual weld joint in real time; and

a spatial tracker comprising one or more sensors adapted to track movement of the input device in real time for communicating data about the movement of the input device to the logic processor based subsystem,

wherein the virtual sequence includes a plurality of operations to be performed in order, each operation intended to achieve a particular state,

wherein at least one of the operations is an automatic operation to be performed by the virtual welding system, and

wherein the automatic operation is one of specifying a weld process, specifying a gas type, specifying a gas flow rate, specifying a stick electrode type, specifying a flux cored wire type, specifying a wire feed speed, specifying a voltage level, specifying an amperage, specifying a polarity, and specifying a background environment for the interactive welding environment.

17. The virtual welding system of claim 16, further comprising a user interface for the user to provide input to the virtual welding system.

18. The virtual welding system of claim 16, wherein the virtual sequence controller comprises a microprocessor, a sequence control program, and a memory, and

wherein the memory stores one or more state table files.

19. The virtual welding system of claim 18, wherein the virtual sequence is defined by at least one of the state table files.

20. The virtual welding system of claim 18, wherein a user selects one of the state table files based on a task to be performed;

and

wherein the task is production of a complete virtual assembly.

21. The virtual welding system of claim 16, further comprising a virtual sequence display;

wherein the virtual sequence display displays information on the automatic operation.

22. The virtual welding system of claim 16, wherein each particular state is associated with a condition.

23. The virtual welding system of claim 22, wherein the virtual sequence controller performs an action if the condition is not met.

24. The virtual welding system of claim 16, wherein the display is a face-mounted display.

25. The virtual welding system of claim 16, further comprising a support structure.

26. The virtual welding system of claim 25, wherein the support structure is a stand comprising a base, a vertical post, an adjustable table, and an adjustable arm.

27. The virtual welding system of claim 25, wherein the support structure is an assembly fixture for holding the sample part.

28. The virtual welding system of claim 16, wherein the virtual welding system is operable to assign a quality score to the virtual welding activity.