SYSTEM AND METHOD FOR MANUAL WELDER TRAINING

• US 20150056584A1
• Filed: 06/02/2014
• Published: 02/26/2015
• Est. Priority Date: 07/08/2009
• Status: Active Grant

• Current Assignee: Lincoln Global Incorporated (Lincoln Electric Holdings Incorporated)
• Original Assignee: EMI (Entegris Incorporated)
• Inventors: Boulware, Paul Christopher, Conrardy, Christopher C., Clark, Douglas A., Forquer, M. William
• Granted Patent: US 9,773,429 B2
• Time in Patent Office: Days
• US Class Current: 434/234
• CPC Class Codes: B23K 9/0956 using sensing means, e.g. optical
• CPC Class Codes: B23K 9/173 and of a consumable electrode
• CPC Class Codes: B23K 9/295 using consumable electrode-wire
• CPC Class Codes: B23K 9/32 Accessories earthing connections H01R
• CPC Class Codes: G09B 19/24 Use of tools
• CPC Class Codes: G09B 25/02 of industrial processes; of machinery

Abstract

A method for manual welder training that includes providing a welding training apparatus that includes both hardware and software components and that is operative to gather and process data in real time, wherein the data is derived from an actual training exercise conducted by a welding trainee; selecting training objectives from a predetermined number of predefined objectives; initializing a curriculum, wherein the curriculum is based on the selected training objectives; performing at least one training exercise, wherein the training exercise is a component of the curriculum; providing real-time feedback to the trainee, wherein the real-time feedback is based on the performance of the trainee during the training exercise; evaluating the performance of the trainee based on data gathered and processed during the training exercise; optionally, adapting the curriculum based on the trainee'"'"'s performance evaluation; and awarding credentials or certifications to the trainee following successful completion of the curriculum.

Claims

1. A method for manual welder training, comprising:

(a) providing a welding training apparatus, wherein the training apparatus further includes both hardware and software components, wherein the training apparatus is operative to gather and process data in real time, and wherein the data is derived from an actual training exercise conducted by a welding trainee;

(b) selecting training objectives from a predetermined number of predefined objectives;

(c) initializing a curriculum for the trainee, wherein the curriculum is based on the selected training objectives;

(d) performing at least one training exercise, wherein the training exercise is based on or is a component of the curriculum, and wherein the at least one training exercise further includes at least one execution task;

(e) providing real-time feedback to the trainee, wherein the real-time feedback is based on the performance of the trainee during the training exercise;

(f) evaluating the performance of the trainee based on weld quality data gathered and processed during the training exercise;

(g) optionally, adapting the curriculum based on the trainee'"'"'s performance evaluation; and

(h) awarding credentials, certifications, or the like to the trainee following successful completion of the curriculum.

2. The method of claim 1, wherein the welding training apparatus further includes:

(a) a data generating component, wherein the data generating component further includes;

(i) a fixture, wherein the geometric characteristics of the fixture are predetermined;

(ii) a workpiece adapted to be mounted on the fixture, wherein the workpiece includes at least one joint to be welded, and wherein the vector extending along the joint to be welded defines an operation path;

(iii) at least one calibration device, wherein each calibration device further includes at least two point markers integral therewith, and wherein the geometric relationship between the point markers and the operation path is predetermined; and

(iv) a welding tool, wherein the welding tool is operative to form a weld at the joint to be welded, wherein the welding tool defines a tool point and a tool vector, and wherein the welding tool further includes a target attached to the welding tool, wherein the target further includes a plurality of point markers mounted thereon in a predetermined pattern, and wherein the predetermined pattern of point markers is operative to define a rigid body; and

(b) a data capturing component, wherein the data capturing component further includes an imaging system for capturing images of the point markers; and

(c) a data processing component, wherein the data processing component is operative to receive information from the data capturing component and then calculate;

(i) the position and orientation of the operation path relative to the three-dimensional space viewable by the imaging system;

(ii) the position of the tool point and orientation of the tool vector relative to the rigid body; and

(iii) the position of the tool point and orientation of the tool vector relative to the operation path.

3. The method of claim 1, wherein the welding training apparatus is in communication with at least one cloud-based server.

4. The method of claim 1, wherein the training objectives further includes public objectives, private objectives, or both public and private objectives.

5. The method of claim 1, wherein the curriculum further includes a series of predetermined tasks, and wherein the tasks are in the form of welding procedure specifications.

6. The method of claim 1, wherein the curriculum further includes form variables, and wherein the form variables further include:

process type;

joint type;

position;

material type;

thickness;

root gap;

root landing;

included angle; and

combinations thereof.

7. The method of claim 1, wherein the curriculum further includes execution variables, and wherein the execution variables further include:

polarity;

electrode type;

work angle;

travel angle;

arc length;

travel speed;

tool placement;

current;

voltage;

weld size;

or combinations thereof.

8. The method of claim 1, wherein the curriculum further includes tasks for quizzes and tutorials;

mechanical testing for certification objectives; and

cleaning and joint preparation tasks.

9. The method of claim 1, wherein the at least one training exercise is performed in either arc-off mode or arc-on mode.

10. The method of claim 2, wherein the real-time feedback is operative to highlight the differences between acceptable and unacceptable performance while allowing to the trainee to visualize the execution task;

prevent the trainee from manipulating the welding tool in a manner far-removed from the proper technique; and

guide the trainee to proper welding technique.

11. The method of claim 1, wherein the real-time feedback further includes automated audio coaching;

instructor-assisted audio coaching;

transfer mode feedback;

augmented reality weld rendering;

or combinations thereof.

12. The method of claim 11, wherein automated audio coaching further includes real-time feedback in the form of automated voice commands, and wherein the automated voice commands further includes prerecorded audio files that are played to the trainee based on predetermined variables being outside of set control limits.

13. The method of claim 12, wherein the predetermined variables are arranged in a hierarchy of high-priority variables to low-priority variables, and wherein the variables include in descending order of priority:

tool placement;

tool offset;

travel speed;

work angle; and

travel angle.

14. The method of claim 11, wherein the instructor-assisted audio coaching further includes interactive real-time feedback wherein an instructor remotely views the trainee during a training exercise through a welding lens used by the trainee, and wherein the instructor relays live audio feedback from a microphone to a wireless headset within a welding helmet worn by the trainee.

15. The method of claim 11, wherein the transfer mode feedback provides real-time feedback for helping the trainee learn differences between transfer modes when transfer modes are present, wherein a microphone integrated into a welding helmet worn by the trainee measures the transfer mode by detecting a sound signal signature, and wherein the sound signal signature is then analyzed to determine if the transfer mode is short-circuit, globular, spray, or pulsed-spray.

16. The method of claim 11, wherein the augmented reality weld rendering further includes the use of sensors that provide real-time position and orientation values of both a welding helmet worn by the trainee and a welding tool used by the trainee in addition to processing data gathered during the training exercise to a cloud-based server, wherein the server performs rendering calculations or finite element calculations, and wherein image data is generated based on these calculations and is superimposed over the trainee'"'"'s view of a welding joint being created during a welding exercise.

17. The method of claim 16, wherein the training exercise is performed in arc-off mode, and wherein the superimposed imagery further includes a virtual welding arc and pool;

3D renderings of a virtual weld bead superimposed on the real weld joint;

highlights of the welding joint root location;

a pencil trace of the intersection location between the welding tool vector and the workpiece;

or combinations thereof.

18. The method of claim 16, wherein the training exercise is performed in arc-on mode, and wherein the superimposed imagery further includes target and actual weld pool shape and position;

target and actual arc placement within the joint;

target and actual tool angles;

target and actual tool offset;

target and actual travel speed;

live indication of defect formation along the weld;

or combinations thereof.

19. The method of claim 1, wherein the performance evaluation further includes an assessment of compliance with training goals;

compliance with qualified procedure essential variables;

variability compliance;

compliance with weld quality specifications;

compliance with standardized certification specifications;

comparison to relative population;

performance over time;

work ethic;

or combinations thereof.

20. The method of claim 19, wherein assessing compliance with training goals further includes assessing upper and lower control limits for predetermined variables;

welding directions and sequence;

weave parameters;

or combinations thereof.

21. The method of claim 19, wherein assessing compliance with qualified procedure essential variables further includes use of an archive of welding standards and approved procedures for particular applications which are stored in a database, accessible across a network, and take the form of a procedure qualification record or a welding procedure specification.

22. The method of claim 19, wherein assessing variability further includes assessing variations in motion measurements taken from the trainee, and wherein the variations provide an indication of the trainee'"'"'s fluidity of motion.

23. The method of claim 19, wherein assessing weld quality further includes visual inspection of a completed weld;

laser profilometry;

capturing digital photos or videos of the completed weld;

post weld non-destructive inspection;

or combinations thereof.

24. The method of claim 1, wherein the curriculum is adaptive, and wherein the adaptive curriculum further includes dynamic control limits;

dynamic adjustment of active WPS;

dynamic variable enablement;

dynamic mode enablement;

dynamic tutorials;

disparate segments within the weld;

position-based dynamic control limits;

integrated quizzes and combinations thereof.

25. The method of claim 1, wherein awarding credentials further includes the awarding of portable badges, wherein the portable badges are awarded to a welding trainee based on the successful completion of one or more aspects of the curriculum, and wherein the successful completion of one or more aspects of the curriculum is recognized by one or more credentialing agencies or entities as representing at least one measurement of key performance metrics of welding proficiency.

26. A method for manual welder training, comprising:

(a) providing a welding training apparatus, wherein the training apparatus further includes both hardware and software components, wherein the training apparatus is operative to gather and process data in real time, and wherein the data is derived from an actual training exercise conducted by a welding trainee;

(b) selecting training objectives from a predetermined number of predefined objectives, wherein the training objectives further includes public objectives, private objectives, or both public and private objectives;

(c) initializing a curriculum for the trainee, wherein the curriculum is based on the selected training objectives, wherein the curriculum further includes a series of predetermined tasks, and wherein the tasks are in the form of welding procedure specifications;

(d) performing at least one training exercise, wherein the training exercise is based on or is a component of the curriculum, wherein the at least one training exercise further includes at least one execution task, and wherein the at least one training exercise is performed in either arc-off mode or arc-on mode;

(e) providing real-time feedback to the trainee, wherein the real-time feedback is based on the performance of the trainee during the training exercise, wherein the real-time feedback further includes automated audio coaching;

instructor-assisted audio coaching;

transfer mode feedback;

augmented reality weld rendering;

or combinations thereof;

(f) evaluating the performance of the trainee based on weld quality data gathered and processed during the training exercise;

(g) optionally, adapting the curriculum based on the trainee'"'"'s performance evaluation; and

(h) awarding credentials, certifications, or the like to the trainee following successful completion of the curriculum.

27. The method of claim 26, wherein the welding training apparatus further includes:

(a) a data generating component, wherein the data generating component further includes;

(i) a fixture, wherein the geometric characteristics of the fixture are predetermined;

(ii) a workpiece adapted to be mounted on the fixture, wherein the workpiece includes at least one joint to be welded, and wherein the vector extending along the joint to be welded defines an operation path;

(iii) at least one calibration device, wherein each calibration device further includes at least two point markers integral therewith, and wherein the geometric relationship between the point markers and the operation path is predetermined; and

(iv) a welding tool, wherein the welding tool is operative to form a weld at the joint to be welded, wherein the welding tool defines a tool point and a tool vector, and wherein the welding tool further includes a target attached to the welding tool, wherein the target further includes a plurality of point markers mounted thereon in a predetermined pattern, and wherein the predetermined pattern of point markers is operative to define a rigid body; and

(b) a data capturing component, wherein the data capturing component further includes an imaging system for capturing images of the point markers; and

(c) a data processing component, wherein the data processing component is operative to receive information from the data capturing component and then calculate;

(i) the position and orientation of the operation path relative to the three-dimensional space viewable by the imaging system;

(ii) the position of the tool point and orientation of the tool vector relative to the rigid body; and

(iii) the position of the tool point and orientation of the tool vector relative to the operation path.

28. The method of claim 26, wherein the welding training apparatus is in communication with at least one cloud-based server.

29. The method of claim 26, wherein the curriculum further includes form variables, and wherein the form variables further include:

process type;

joint type;

position;

material type;

thickness;

root gap;

root landing;

included angle; and

combinations thereof.

30. The method of claim 26, wherein the curriculum further includes execution variables, and wherein the execution variables further include:

polarity;

electrode type;

work angle;

travel angle;

arc length;

travel speed;

tool placement;

current;

voltage;

weld size;

or combinations thereof.

31. The method of claim 26, wherein the curriculum further includes tasks for quizzes and tutorials;

mechanical testing for certification objectives; and

cleaning and joint preparation tasks.

32. The method of claim 27, wherein the real-time feedback is operative to highlight the differences between acceptable and unacceptable performance while allowing to the trainee to visualize the execution task;

prevent the trainee from manipulating the welding tool in a manner far-removed from the proper technique; and

guide the trainee to proper welding technique.

33. The method of claim 27, wherein the real-time feedback further includes automated audio coaching;

instructor-assisted audio coaching;

transfer mode feedback;

augmented reality weld rendering;

or combinations thereof.

34. The method of claim 33, wherein automated audio coaching further includes real-time feedback in the form of automated voice commands, and wherein the automated voice commands further includes prerecorded audio files that are played to the trainee based on predetermined variables being outside of set control limits.

35. The method of claim 34, wherein the predetermined variables are arranged in a hierarchy of high-priority variables to low-priority variables, and wherein the variables include in descending order of priority:

tool placement;

tool offset;

travel speed;

work angle; and

travel angle.

36. The method of claim 33 wherein the instructor-assisted audio coaching further includes interactive real-time feedback wherein an instructor remotely views the trainee during a training exercise through a welding lens used by the trainee, and wherein the instructor relays live audio feedback from a microphone to a wireless headset within a welding helmet worn by the trainee.

37. The method of claim 33, wherein the transfer mode feedback provides real-time feedback for helping the trainee learn differences between transfer modes when transfer modes are present, wherein a microphone integrated into a welding helmet worn by the trainee measures the transfer mode by detecting a sound signal signature, and wherein the sound signal signature is then analyzed to determine if the transfer mode is short-circuit, globular, spray, or pulsed-spray.

38. The method of claim 33, wherein the augmented reality weld rendering further includes the use of sensors that provide real-time position and orientation values of both a welding helmet worn by the trainee and a welding tool used by the trainee in addition to processing data gathered during the training exercise to a cloud-based server, wherein the server performs rendering calculations or finite element calculations, and wherein image data is generated based on these calculations and is superimposed over the trainee'"'"'s view of a welding joint being created during a welding exercise.

39. The method of claim 38, wherein the training exercise is performed in arc-off mode, and wherein the superimposed imagery further includes a virtual welding arc and pool;

3D renderings of a virtual weld bead superimposed on the real weld joint;

highlights of the welding joint root location;

a pencil trace of the intersection location between the welding tool vector and the workpiece;

or combinations thereof.

40. The method of claim 38, wherein the training exercise is performed in arc-on mode, and wherein the superimposed imagery further includes target and actual weld pool shape and position;

target and actual arc placement within the joint;

target and actual tool angles;

target and actual tool offset;

target and actual travel speed;

live indication of defect formation along the weld;

or combinations thereof.

41. The method of claim 26, wherein the performance evaluation further includes an assessment of compliance with training goals;

compliance with qualified procedure essential variables;

variability compliance;

compliance with weld quality specifications;

compliance with standardized certification specifications;

comparison to relative population;

performance over time;

work ethic;

or combinations thereof.

42. The method of claim 41, wherein assessing compliance with training goals further includes assessing upper and lower control limits for predetermined variables;

welding directions and sequence;

weave parameters;

or combinations thereof.

43. The method of claim 41, wherein assessing compliance with qualified procedure essential variables further includes use of an archive of welding standards and approved procedures for particular applications which are stored in a database, accessible across a network, and take the form of a procedure qualification record or a welding procedure specification.

44. The method of claim 41, wherein assessing variability further includes assessing variations in motion measurements taken from the trainee, and wherein the variations provide an indication of the trainee'"'"'s fluidity of motion.

45. The method of claim 41, wherein assessing weld quality further includes visual inspection of a completed weld;

laser profilometry;

capturing digital photos or videos of the completed weld;

post weld non-destructive inspection;

or combinations thereof.

46. The method of claim 26, wherein the curriculum is adaptive, and wherein the adaptive curriculum further includes dynamic control limits;

dynamic adjustment of active WPS;

dynamic variable enablement;

dynamic mode enablement;

dynamic tutorials;

disparate segments within the weld;

position-based dynamic control limits;

integrated quizzes and combinations thereof.

47. The method of claim 26, wherein awarding credentials further includes the awarding of portable badges, wherein the portable badges are awarded to a welding trainee based on the successful completion of one or more aspects of the curriculum, and wherein the successful completion of one or more aspects of the curriculum is recognized by one or more credentialing agencies or entities as representing at least one measurement of key performance metrics of welding proficiency.

48. A method for manual welder training, comprising:

(a) providing a welding training apparatus for use by a welding trainee, wherein the welding apparatus further includes;

(i) a data generating component, wherein the data generating component further includes;

a) a fixture, wherein the geometric characteristics of the fixture are predetermined;

b) a workpiece adapted to be mounted on the fixture, wherein the workpiece includes at least one joint to be welded, and wherein the vector extending along the joint to be welded defines an operation path;

c) at least one calibration device, wherein each calibration device further includes at least two point markers integral therewith, and wherein the geometric relationship between the point markers and the operation path is predetermined; and

d) a welding tool, wherein the welding tool is operative to form a weld at the joint to be welded, wherein the welding tool defines a tool point and a tool vector, and wherein the welding tool further includes a target attached to the welding tool, wherein the target further includes a plurality of point markers mounted thereon in a predetermined pattern, and wherein the predetermined pattern of point markers is operative to define a rigid body; and

(ii) a data capturing component, wherein the data capturing component further includes an imaging system for capturing images of the point markers; and

(iii) a data processing component, wherein the data processing component is operative to receive information from the data capturing component and then calculate;

a) the position and orientation of the operation path relative to the three-dimensional space viewable by the imaging system;

b) the position of the tool point and orientation of the tool vector relative to the rigid body; and

c) the position of the tool point and orientation of the tool vector relative to the operation path; and

(b) selecting training objectives from a predetermined number of predefined objectives, wherein the training objectives further includes public objectives, private objectives, or both public and private objectives;

(c) initializing a curriculum for the trainee, wherein the curriculum is based on the selected training objectives, wherein the curriculum further includes a series of predetermined tasks, and wherein the tasks are in the form of welding procedure specifications;

(d) performing at least one training exercise, wherein the training exercise is based on or is a component of the curriculum, wherein the at least one training exercise further includes at least one execution task, and wherein the at least one training exercise is performed in either arc-off mode or arc-on mode;

(e) providing real-time feedback to the trainee, wherein the real-time feedback is based on the performance of the trainee during the training exercise, wherein the real-time feedback further includes automated audio coaching;

instructor-assisted audio coaching;

transfer mode feedback;

augmented reality weld rendering;

or combinations thereof;

(f) evaluating the performance of the trainee based on weld quality data gathered and processed during the training exercise;

(g) optionally, adapting the curriculum based on the trainee'"'"'s performance evaluation; and

(h) awarding credentials, certifications, or the like to the trainee following successful completion of the curriculum.

49. The method of claim 48, wherein the welding training apparatus is in communication with at least one cloud-based server.

50. The method of claim 48, wherein the curriculum further includes form variables, and wherein the form variables further include:

process type;

joint type;

position;

material type;

thickness;

root gap;

root landing;

included angle; and

combinations thereof.

51. The method of claim 48, wherein the curriculum further includes execution variables, and wherein the execution variables further include:

polarity;

electrode type;

work angle;

travel angle;

arc length;

travel speed;

tool placement;

current;

voltage;

weld size;

or combinations thereof.

52. The method of claim 48, wherein the curriculum further includes tasks for quizzes and tutorials;

mechanical testing for certification objectives; and

cleaning and joint preparation tasks.

53. The method of claim 48, wherein the real-time feedback is operative to highlight the differences between acceptable and unacceptable performance while allowing to the trainee to visualize the execution task;

prevent the trainee from manipulating the welding tool in a manner far-removed from the proper technique; and

guide the trainee to proper welding technique.

54. The method of claim 48, wherein the real-time feedback further includes automated audio coaching;

instructor-assisted audio coaching;

transfer mode feedback;

augmented reality weld rendering;

or combinations thereof.

55. The method of claim 54, wherein automated audio coaching further includes real-time feedback in the form of automated voice commands, and wherein the automated voice commands further includes prerecorded audio files that are played to the trainee based on predetermined variables being outside of set control limits.

56. The method of claim 55, wherein the predetermined variables are arranged in a hierarchy of high-priority variables to low-priority variables, and wherein the variables include in descending order of priority:

tool placement;

tool offset;

travel speed;

work angle; and

travel angle.

57. The method of claim 54 wherein the instructor-assisted audio coaching further includes interactive real-time feedback wherein an instructor remotely views the trainee during a training exercise through a welding lens used by the trainee, and wherein the instructor relays live audio feedback from a microphone to a wireless headset within a welding helmet worn by the trainee.

58. The method of claim 54, wherein the transfer mode feedback provides real-time feedback for helping the trainee learn differences between transfer modes when transfer modes are present, wherein a microphone integrated into a welding helmet worn by the trainee measures the transfer mode by detecting a sound signal signature, and wherein the sound signal signature is then analyzed to determine if the transfer mode is short-circuit, globular, spray, or pulsed-spray.

59. The method of claim 54, wherein the augmented reality weld rendering further includes the use of sensors that provide real-time position and orientation values of both a welding helmet worn by the trainee and a welding tool used by the trainee in addition to processing data gathered during the training exercise to a cloud-based server, wherein the server performs rendering calculations or finite element calculations, and wherein image data is generated based on these calculations and is superimposed over the trainee'"'"'s view of a welding joint being created during a welding exercise.

60. The method of claim 59, wherein the training exercise is performed in arc-off mode, and wherein the superimposed imagery further includes a virtual welding arc and pool;

3D renderings of a virtual weld bead superimposed on the real weld joint;

highlights of the welding joint root location;

a pencil trace of the intersection location between the welding tool vector and the workpiece;

or combinations thereof.

61. The method of claim 59, wherein the training exercise is performed in arc-on mode, and wherein the superimposed imagery further includes target and actual weld pool shape and position;

target and actual arc placement within the joint;

target and actual tool angles;

target and actual tool offset;

target and actual travel speed;

live indication of defect formation along the weld;

or combinations thereof.

62. The method of claim 48, wherein the performance evaluation further includes an assessment of compliance with training goals;

compliance with qualified procedure essential variables;

variability compliance;

compliance with weld quality specifications;

compliance with standardized certification specifications;

comparison to relative population;

performance over time;

work ethic;

or combinations thereof.

63. The method of claim 62, wherein assessing compliance with training goals further includes assessing upper and lower control limits for predetermined variables;

welding directions and sequence;

weave parameters;

or combinations thereof.

64. The method of claim 62, wherein assessing compliance with qualified procedure essential variables further includes use of an archive of welding standards and approved procedures for particular applications which are stored in a database, accessible across a network, and take the form of a procedure qualification record or a welding procedure specification.

65. The method of claim 62, wherein assessing variability further includes assessing variations in motion measurements taken from the trainee, and wherein the variations provide an indication of the trainee'"'"'s fluidity of motion.

66. The method of claim 62, wherein assessing weld quality further includes visual inspection of a completed weld;

laser profilometry;

capturing digital photos or videos of the completed weld;

post weld non-destructive inspection;

or combinations thereof.

67. The method of claim 48, wherein the curriculum is adaptive, and wherein the adaptive curriculum further includes dynamic control limits;

dynamic adjustment of active WPS;

dynamic variable enablement;

dynamic mode enablement;

dynamic tutorials;

disparate segments within the weld;

position-based dynamic control limits;

integrated quizzes and combinations thereof.

68. The method of claim 48, wherein awarding credentials further includes the awarding of portable badges, wherein the portable badges are awarded to a welding trainee based on the successful completion of one or more aspects of the curriculum, and wherein the successful completion of one or more aspects of the curriculum is recognized by one or more credentialing agencies or entities as representing at least one measurement of key performance metrics of welding proficiency.