WELDING TRAINING SYSTEM

• US 20090298024A1
• Filed: 05/28/2009
• Published: 12/03/2009
• Est. Priority Date: 05/28/2008
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Batzler, Todd, Becker, William J., Albrecht, Bruce
• Granted Patent: US 9,352,411 B2
• Time in Patent Office: Days
• US Class Current: 434/234
• CPC Class Codes: B23K 37/00 Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups eye-shields for welders worn on the operator's body or carried in the hand A61F9/00 , i.e. A61F9/02; applicable to metal-working machines other than soldering, welding, or flame-cutting machines B23Q; laser protective screens B23K26/706; protective shields for other welding methods F16P1/06
• CPC Class Codes: B23K 9/095 Monitoring or automatic control of welding parameters
• CPC Class Codes: B23K 9/32 Accessories earthing connections H01R
• CPC Class Codes: G05B 2219/37396 Tactile feedback, operator feels reaction, force reflection
• CPC Class Codes: G09B 19/003 Repetitive work cycles; Sequence of movements
• 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 9/00 Simulators for teaching or training purposes for the use of weapons F41; computing aspects G06; protocols for games, networked simulations or virtual reality H04L67/131

Abstract

A welding training system includes one or more welding operator device which provides positional feedback relevant to a quality weld. The positional feedback is analyzed and, when the positional feedback is outside of a predetermined range, a signal is provided to the welding operator. In one embodiment, tactile feedback is provided in a welding gun.

Claims

1. A welding operator device for use by a welding operator while performing a weld, the welding operator device comprising:

a controller;

a position sensor, providing position feedback data to the operator device controller; and

a position indicator operatively coupled to the controller, wherein the controller is programmed to receive position data from the position sensor, to determine a position of the welding operator device that is relevant to a quality weld, and to activate the position indicator to provide feedback to the welding operator to correct the position during the weld.

2. The welding operator device as recited in claim 1, wherein the position sensor comprises at least one of an angle sensor and an altimeter.

3. The welding operator device as recited in claim 2, wherein the angle sensor comprises at least one of a global positioning sensor, a gyroscopic sensor, an accelerometer, and a micro-electromechanical gyroscope.

4. The welding operator device as recited in claim 1, wherein the position sensor comprises at least one of a visual feedback device, an audio feedback device, and a tactile feedback device.

5. The welding operator device as recited in claim 4, wherein the visual feedback device comprises at least one of a LCD, LED, or OLED display.

6. The welding operator device of claim 5, wherein the tactile feedback device comprises at least one of a vibrational motor, a piezeo-electric device, an air bladder, and an exoskeleton.

7. The welding operator device of claim 6, further comprising a plurality of tactile feedback devices, wherein each of the plurality of tactile feedback device is located on the welding operator device to provide a directional feedback signal to the operator.

8. The welding operator device of claim 6, wherein the operator device is at least one of a welding gun, a welding glove, and a wristband.

9. The welding operator device of claim 4, wherein the welding operator device comprises an eye shield for shielding the operator'"'"'s eyes during a weld.

10. The welding operator device of claim 9, wherein the welding operator device comprises at least one of a weld helmet and a pair of shielded eye goggles.

11. The welding operator device of claim 1, further comprising a communications device for communicating position feedback data to at least one of a welding power source and a welding network.

12. A welding system, comprising:

a welding power source for providing welding power to the weld, the welding power source comprising a power source controller and a power source communications device; and

a welding operator device in communications with the power source communications device in the welding power source, the welding operator device comprising;

a position feedback sensor;

an operator indicator; and

a communications device operatively coupled to the position feedback sensor and the operator indicator, wherein the communications device provides position feedback data to the welding power source controller, and the welding power source controller is programmed to evaluate the position feedback and to activate the operator indicator when the position feedback is outside of a predetermined range.

13. The welding system as recited in claim 12, further comprising at least one weld position locator device comprising a position sensor operatively coupled to a weld position communications device, the weld position locator device being positionable adjacent a part to be welded wherein the communications device provides weld position feedback data from the position sensor to the welding power source for use in evaluating the position feedback.

14. The welding system as recited in claim 12, wherein the welding operator device comprises at least one of a protective eye shielding device, a welding gun, a glove, and a wrist band.

15. The welding system as recited in claim 14, further comprising a second welding operator device, the second welding operator device providing position feedback data to the welding power source, and wherein the second welding operator device comprises at least one of a protective eye shielding device, a welding gun, a glove, and a wrist band.

16. The welding system as recited in claim 12, wherein the welding operator device includes a plurality of operator indicators, the operator indicators being selectively positioned to provide directional feedback to the welding operator.

17. A welding power source comprising:

a welding power supply for conditioning raw power for a welding-type process;

a controller; and

a communications device in communication with the controller and one or more peripheral device configured to provide position feedback relevant to a quality of the welding-type process, wherein the controller is programmed to receive the position feedback, compare the position feedback to stored data, and to provide a signal to a weld operator when the position feedback is outside of a predetermined range.

18. The welding power source as recited in claim 17, wherein the controller is further programmed to selectively provide an actual weld where the position data is monitored and stored data during a weld and a simulated welding-type process where the position feedback is monitored and compared to stored data without starting an arc.

19. The welding power source as recited in claim 17, wherein the controller is further programmed to calculate a rate of travel speed based on the position feedback.

20. The welding power source as recited in claim 17, wherein the peripheral device comprises at least one of a protective eye shielding device, a welding gun, a glove, and a wrist band.