Feedback from a welding torch of a welding system

• US 10,105,782 B2
• Filed: 01/07/2014
• Issued: 10/23/2018
• Est. Priority Date: 01/07/2014
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Becker, William J., Walker, James M., Erdmann, Jeremy J.
• Primary Examiner(s): Paik, Sang Y
• Application Number:
  US14/149,331
• Publication Number:
  US 20150190875A1
• Time in Patent Office: 1,750 Days
• Field of Search: 2191251-1301, 219136, 219137 R
• 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: B23K 9/1062 with computing means
• CPC Class Codes: B23K 9/12 Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
• CPC Class Codes: B23K 9/126 Controlling the spatial relationship between the work and the gas torch between wire tip and piece B23K9/073
• CPC Class Codes: G09B 19/24 Use of tools

Abstract

A method includes displaying, on a display of a welding torch, a welding parameter in relation to a predetermined threshold range for the welding parameter, a target value for the welding parameter, or some combination thereof as a position of the welding torch changes, an orientation of the welding torch changes, a movement of the welding torch changes, or some combination thereof, to enable a welding operator to perform a welding operation with the welding parameter within the predetermined threshold range, at the target value, or some combination thereof. The welding parameter is associated with the position of the welding torch, the orientation of the welding torch, the movement of the welding torch, or some combination thereof.

Claims

1. A method comprising:

during a welding or welding simulation operation, tracking a position of a welding torch, an orientation of the welding torch, a movement of the welding torch, or some combination thereof, using a motion tracking system, to determine the position of the welding torch, the orientation of the welding torch, the movement of the welding torch, or some combination thereof; and

during the welding or welding simulation operation, displaying, on a display disposed on the welding torch viewable by an operator during the welding operation;

a value of a welding parameter represented by a first graphic, wherein the welding parameter comprises a travel speed, a tip-to-work distance, an aim, a work angle, a travel angle, or any combination thereof; and

a predetermined threshold range for the welding parameter, a target value for the welding parameter, or some combination thereof, represented by a second graphic having a spatial relationship to the first graphic based on the value of the welding parameter and the predetermined threshold range, the target value, or the combination thereof, to enable a welding operator to perform the welding operation with the welding parameter within the predetermined threshold range, at the target value, or some combination thereof.

2. The method of claim 1, wherein the predetermined threshold range comprises an upper limit and a lower limit.

3. The method of claim 1, wherein the predetermined threshold range comprises values greater than a predetermined limit.

4. The method of claim 3, wherein the predetermined threshold range comprises the predetermined limit.

5. The method of claim 1, wherein the predetermined threshold range comprises values less than a predetermined limit.

6. The method of claim 5, wherein the predetermined threshold range comprises the predetermined limit.

7. A method comprising:

detecting, via control circuitry coupled to a trigger of a welding torch, whether the trigger is actuated;

detecting whether the welding torch is within a predetermined distance from a welding joint via a motion tracking system configured to detect a position of the welding torch, an orientation of the welding torch, a movement of the welding torch, or some combination thereof; and

changing a display of the welding torch based on a detected actuation of the trigger and if the welding torch is within the predetermined distance from the welding joint, wherein the display is disposed on the welding torch.

8. The method of claim 7, wherein changing the display of the welding torch comprises clearing the display of the welding torch.

9. The method of claim 7, wherein changing the display of the welding torch comprises displaying an unchanging image on the display of the welding torch.

10. The method of claim 7, wherein changing the display of the welding torch comprises changing the display from showing dynamic data that updates based on a position of the welding torch and an orientation of the welding torch to showing static data that does not change while the trigger is actuated.

11. A method comprising:

detecting whether a welding torch is within a predetermined distance from a welding joint via a motion tracking system configured to detect a position of the welding torch, an orientation of the welding torch, a movement of the welding torch, or some combination thereof; and

enabling, via control circuitry coupled to a training switch, a live welding operation to begin only while the motion tracking system detects that the welding torch is within the predetermined distance from the welding joint, wherein the training switch is configured to enable welding power to the welding torch only while the training switch is in a closed position.

12. The method of claim 11, wherein the welding torch comprises a trigger actuated by a welding operator, wherein the live welding operation begins only while the trigger is actuated and the welding torch is within the predetermined distance from the welding joint.

13. The method of claim 11, comprising determining a spatial location of the welding joint via the motion tracking system.

14. The method of claim 11, comprising enabling the live welding operation to be completed while the welding torch is not within the predetermined distance from the welding joint.

15. A method comprising:

detecting whether a welding torch is within a predetermined distance from a welding joint via a motion tracking system configured to detect a position of the welding torch, an orientation of the welding torch, a movement of the welding torch, or some combination thereof, wherein the welding torch comprises a trigger configured to be actuated by a welding operator;

detecting, via control circuitry coupled to a training switch, whether a live welding mode is selected;

controlling the training switch to enable a live welding arc when the trigger is actuated only when the live welding mode is selected; and

providing feedback from the control circuitry if the motion tracking system detects that the welding torch is within the predetermined distance from the welding joint and if the live welding mode is selected.

16. The method of claim 15, wherein the feedback comprises at least one of a visual message and an audible message.

17. The method of claim 15, wherein the feedback comprises a visual message on a display.

18. The method of claim 15, wherein the feedback comprises a vibration feedback.

19. The method of claim 15, comprising controlling the training switch to block the live welding arc when a welding mode other than the live welding mode is selected.