Augmented vision system with active welder guidance

• US 10,406,638 B2
• Filed: 10/21/2015
• Issued: 09/10/2019
• Est. Priority Date: 02/27/2015
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Albrecht, Bruce, Beeson, Richard, Becker, William J.
• Primary Examiner(s): Jennison, Brian W
• Application Number:
  US14/918,654
• Publication Number:
  US 20160250723A1
• Time in Patent Office: 1,420 Days
• CPC Class Codes: B23K 37/006 Safety devices
• CPC Class Codes: B23K 9/0956 using sensing means, e.g. optical
• CPC Class Codes: B23K 9/322 Head protecting means masks, shields or hoods for weldersp A61F9/06
• CPC Class Codes: G05B 19/409 characterised by using manual data input [MDI] or by using control panel, e.g. controlling functions with the panel; characterised by control panel details or by setting parameters G05B19/408, G05B19/4093 take precedence
• CPC Class Codes: G05B 2219/31304 Identification of workpiece and data for control, inspection, safety, calibration
• CPC Class Codes: G05B 2219/32014 Augmented reality assists operator in maintenance, repair, programming, assembly, use of head mounted display with 2-D 3-D display and voice feedback, voice and gesture command
• CPC Class Codes: G05B 2219/35487 Display and voice output incorporated in safety helmet of operator
• CPC Class Codes: G05B 2219/45135 Welding
• CPC Class Codes: G06F 3/0304 Detection arrangements using opto-electronic means constructional details of pointing devices not related to the detection arrangement using opto-electronic means G06F3/033; optical digitisers G06F3/042
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

Welding headwear comprises a display operable to present images for viewing by a wearer of the welding headwear, and comprises circuitry operable to determine an identifier associated with a workpiece, retrieve, from memory, welding work instructions associated with the identifier, and generate the images for presentation on the display based on said work instructions.

Claims

1. A system comprising:

welding headwear comprising;

a display operable to present images for viewing by a wearer of said welding headwear; and

a processor operable to;

determine an identifier associated with a workpiece;

retrieve, from memory, welding work instructions associated with said identifier; and

generate said images for presentation on said display based on said work instructions,

wherein;

said work instructions comprise one or more instructions, and

said processor is operable to provide an interface via which an operator can switch between said one or more instructions.

2. The system of claim 1, wherein said processor is operable to determine said identifier by:

detecting, through an image processing algorithm implemented by said processor, of markers on one or both of said workpiece and features of said workpiece; and

retrieving said identifier from memory based on said one or both of said detected markers features.

3. The system of claim 1, wherein said processor is operable to:

determine, during a manual welding operation, a welding parameter for a welding torch;

generate a graphical representation of said welding parameter; and

include said graphical representation of said welding parameter in said images.

4. The system of claim 1, wherein said processor is operable to:

determine an output of a welding power source;

generate a graphical representation of said output of said welding power source; and

include said graphical representation of said output of said welding power source in said images.

5. The system of claim 1, wherein:

said work instructions comprise one or more images illustrating a sequence of welds to be performed on said workpiece; and

said one or more images illustrating said sequence of welds are included in said images generated for presentation on said display.

6. The system of claim 5, wherein:

said welding work instructions indicate welding equipment settings to be used for each weld of said sequence of welds; and

a graphical representation of said welding equipment settings is included in said images generated for presentation on said display.

7. The system of claim 5, wherein:

said welding work instructions indicate one or more welding parameter targets for each weld of said sequence of welds; and

a graphical representation of said welding parameter targets are included in said image generated for presentation on said display.

8. The system of claim 7, wherein said one or more welding parameter targets comprise one or more of:

a target work angle, a target travel angle, a target travel speed, and a target contact tip-to-work distance.

9. The system of claim 5, wherein:

said work instructions indicate a sequence of welds to be performed on said workpiece and identifiers of parts used in said sequence of welds; and

a graphical representation of said sequence of welds and said identifiers of said parts are included in said image generated for presentation on said display.

10. The system of claim 1,

wherein each of said one or more instructions is associated with a corresponding viewing distance.

11. The system of claim 1, wherein said processor is operable to determine a distance between said welding headwear and said workpiece.

12. The system of claim 11, wherein said processor is operable to determine said distance based using an image processing algorithm and stored information about one or more of:

size, shape, and/or features of said workpiece.

13. The system of claim 10 wherein:

said work instructions comprise one or more instructions, wherein each of said one or more instructions is associated with a corresponding viewing distance; and

said processor is operable to determine which of said one or more instructions to use for said generation of said images for presentation on said display based on said determined distance between said welding headwear and said workpiece.

14. The system of claim 1, comprising a camera operable to capture a picture of a field of view of a wearer of said welding headwear, wherein:

said processor is operable to determine, based on input from a wearer of said welding headwear, whether to use one or both of said picture and said work instructions for said generation of said images for presentation on said display.

15. The system of claim 14, wherein said input from said wearer of said welding headwear is one or more of:

input via a tactile control of said welding headwear, voice input via a microphone of said welding headwear, a gesture captured via a camera of said welding headwear, a gesture captured via an accelerometer, and a gesture captured via a gyroscope.

16. The system of claim 1, wherein said processor is operable to determine, through an image processing algorithm implemented by said processor, position and orientation of said workpiece.

17. The system of claim 16, wherein said generation of said image comprises generation of a 3-D rendering of said workpiece generated based on said determined position and orientation.

18. The system of claim 1, wherein said processor is operable to:

monitor one or both of welding parameters and welding equipment settings throughout the duration of a particular weld; and

store one or both of said monitored welding parameters and welding equipment settings to memory.

19. The system of claim 18, wherein said processor is operable to:

upon completion of said particular weld, generate a graphical summary of one or both of said stored welding parameters and equipment settings; and

include said graphical summary of said stored welding parameters and equipment settings in said images generated for presentation on said display.

20. The system of claim 1, wherein said images generated for presentation on said display comprise a graphical element that indicates output of welding equipment measured during a previously-completed welding operation.

21. The system of claim 1, comprising a camera operable to capture a video of a welding operation performed by a wearer of said welding headwear, wherein said processor is operable to:

after completion of said welding operation, analyze weld equipment output measured during said welding operation to identify a time period of interest during said welding operation; and

generate a graphical element that, when interacted with, triggers replay of a portion of said video corresponding to said identified time period.

22. The system of claim 1, wherein said processor is operable to:

retrieve, from memory, inventory of parts required for performance of said welding work; and

provide an interface via which a wearer of said headwear can order said parts.

23. A system comprising:

welding headwear comprising;

a display operable to present images for viewing by a wearer of said welding headwear; and

a processor operable to;

determine an identifier associated with a workpiece;

retrieve, from memory, welding work instructions associated with said identifier; and

generate said images for presentation on said display based on said work instructions,

wherein;

prior to beginning a welding operation, said images generated for presentation on said display correspond to a pre-weld interface;

during said welding operation, said images generated for presentation on said display correspond to an in-weld interface; and

after said welding operation, said images generated for presentation on said display correspond to a post-weld interface.