Welding software for detection and control of devices and for analysis of data

• US 9,589,481 B2
• Filed: 01/07/2014
• Issued: 03/07/2017
• 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): Utama, Robert J
• Application Number:
  US14/149,325
• Publication Number:
  US 20150194073A1
• Time in Patent Office: 1,155 Days
• US Class Current: 1/1
• CPC Class Codes: B23K 9/0956 using sensing means, e.g. optical
• CPC Class Codes: G01B 11/002 for measuring two or more coordinates
• CPC Class Codes: G01B 11/254 Projection of a pattern, viewing through a pattern, e.g. moiré
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05B 19/128 the workpiece itself serves as a record carrier, e.g. by its form, by marks or codes on it
• CPC Class Codes: G05B 2219/45135 Welding
• CPC Class Codes: G05B 2219/49304 Tool identification, code
• 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

Abstract

A method used in a welding system includes detecting multiple markers on a welding torch. The markers are detected using one or more cameras. The method also includes blocking live welding using the welding torch while the one or more cameras are unable to detect at least one of the multiple markers on the welding torch.

Claims

1. A method comprising:

calibrating a weld joint, comprising;

detecting, using one or more cameras, a first position of the weld joint relative to the one or more cameras, wherein the first position corresponds to a first location of the weld joint that interfaces with a tip of a calibration tool;

detecting, using the one or more cameras, a second position of the weld joint relative to the one or more cameras, wherein the second position corresponds to a second location of the weld joint that interfaces with the tip of the calibration tool;

detecting, using the one or more cameras, a curved portion of the weld joint relative to the one or more cameras, wherein the curved portion extends between the first and second positions of the weld joint; and

storing a representation of the curved portion of the weld joint for determining a quality of a welding operation.

2. The method of claim 1, wherein detecting the first position of the weld joint comprises tracking, using the one or more cameras, a third position of the calibration tool, an orientation of the calibration tool, or some combination thereof.

3. The method of claim 1, wherein detecting the curved portion of the weld joint comprises tracking, using the one or more cameras, a third position of the calibration tool, an orientation of the calibration tool, or some combination thereof.

4. The method of claim 1, wherein detecting the first position of the weld joint comprises tracking, using the one or more cameras, a third position of a welding torch, an orientation of the welding torch, or some combination thereof, wherein the calibration tool comprises the welding torch.

5. The method of claim 1, wherein detecting the curved portion of the weld joint comprises tracking, using the one or more cameras, a third position of a welding torch, an orientation of the welding torch, or some combination thereof, wherein the calibration tool comprises the welding torch.

6. The method of claim 1, wherein detecting the first position of the weld joint comprises tracking, using the one or more cameras, a third position of a welding torch, an orientation of the welding torch, or some combination thereof, during a multi-pass welding operation.

12. The method of claim 1, comprising:

tracking, using the one or more cameras, a third position of a welding torch tip relative to the one or more cameras during the welding operation;

determining a weld path corresponding to the third position of the welding torch tip during the welding operation; and

comparing the weld path to the stored representation of the curved portion of the weld joint and a predetermined threshold.

13. The method of claim 6, wherein tracking, using the one or more cameras, the third position of a welding torch during the multi-pass welding operation on the weld joint comprises storing a representation of a first pass and a second pass of the multi-pass welding operation as a single welding operation.

7. A method comprising:

detecting, using one or more cameras, a first position of a circular weld joint relative to the one or more cameras, wherein the first position corresponds to a first location of the circular weld joint that interfaces with a tip of a calibration tool;

detecting, using the one or more cameras, a second position of the circular weld joint relative to the one or more cameras, wherein the second position corresponds to a second location of the circular weld joint that interfaces with the tip of the calibration tool;

detecting, using the one or more cameras, a third position of the circular weld joint relative to the one or more cameras, wherein the third position corresponds to a third location of the circular weld joint that interfaces with the tip of the calibration tool; and

determining a path of the circular weld joint using the first, second, and third positions, comprising calculating a best-fit circle that intersects the first position, the second position, and the third position.

8. The method of claim 7, wherein the circular weld joint comprises a pipe joint.

9. The method of claim 7, wherein detecting the first position of the circular weld joint comprises detecting the calibration tool that contacts the first position.

10. The method of claim 7, comprising touching the calibration tool to the circular weld joint in order to detect the first position, the second position, and the third position.

11. The method of claim 7, comprising storing a representation of the path.