Welding training systems and devices

• US 9,713,852 B2
• Filed: 03/15/2013
• Issued: 07/25/2017
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Marcusen, David P., Becker, William J., Beeson, Richard
• Primary Examiner(s): Thanh, Quang D
• Assistant Examiner(s): ISKRA, JOSEPH W
• Application Number:
  US13/838,019
• Publication Number:
  US 20140263224A1
• Time in Patent Office: 1,593 Days
• Field of Search: 2191245, 219138, 2191372
• CPC Class Codes: B23K 35/0261 Rods, electrodes, wires
• CPC Class Codes: B23K 9/095 Monitoring or automatic control of welding parameters
• CPC Class Codes: B23K 9/0956 using sensing means, e.g. optical
• CPC Class Codes: B23K 9/124 Circuits or methods for feeding welding wire
• CPC Class Codes: B23K 9/235 Preliminary treatment
• CPC Class Codes: B23K 9/32 Accessories earthing connections H01R
• CPC Class Codes: G09B 19/24 Use of tools

Abstract

A welding tool includes a first handle and a second handle. The welding tool also includes a torch nozzle holder configured to hold a nozzle of a welding torch therein, and to block the nozzle from extending therethrough. The welding tool includes a blade assembly positioned a predetermined distance from the torch nozzle holder. The blade assembly is configured to cut welding wire extending through the blade assembly to calibrate wire stickout from the welding torch to the predetermined distance.

Claims

1. A welding consumable comprising:

a welding rod configured for a stick welding process, the welding rod comprising;

a first physical mark indicating a first location on the welding rod proximate to a first end of the welding rod; and

a second physical mark indicating a second location on the welding rod proximate to a second end of the welding rod;

wherein the first physical mark and the second physical mark are configured to be detected by a camera-based detection system to determine a remaining length of the welding rod, a consumed length of the welding rod, a rate of use of the welding rod, a dipping rate of the welding rod, or some combination thereof.

2. The welding consumable of claim 1, wherein the first physical mark and the second physical mark are laser etched.

3. The welding consumable of claim 1, wherein the first physical mark and the second physical mark are not within a visible spectrum.

4. The welding consumable of claim 1, wherein the first physical mark comprises a first bar code, and the second physical mark comprises a second bar code different from the first bar code.

5. The welding consumable of claim 1, comprising a third physical mark indicating a third location on the welding rod.

6. The welding consumable of claim 1, wherein the first physical mark comprises a first set of data corresponding to a first distance between the first physical mark and an end of the welding rod, and the second physical mark comprises a second set of data corresponding to a second distance between the second physical mark and the end of the welding rod.

7. A welding training system comprising:

a camera-based detection system; and

a welding rod configured for a stick welding process, the welding rod comprising;

a first physical mark indicating a first location on the welding rod offset by a first distance from a first end of the welding rod; and

a second physical mark indicating a second location on the welding rod offset by a second distance from a second end of the welding rod;

wherein the first physical mark and the second physical mark are configured to be detected by the camera-based detection system to determine a remaining length of the welding rod, a consumed length of the welding rod, a rate of use of the welding rod, a dipping rate of the welding rod, or some combination thereof.

8. A welding training system comprising:

a welding surface, wherein the welding surface is configured for live welds or simulated welds to be performed on the welding surface;

a sensor configured to sense a position of a welding torch, an orientation of the welding torch, or some combination thereof;

a first arm coupled to the welding surface, and extending vertically from the welding surface; and

a pivot assembly directly coupled to the first arm and directly coupled to the sensor, wherein the pivot assembly is disposed between the first arm and the sensor, and the pivot assembly enables adjustment of an angle between the first arm and the sensor.

9. The welding training system of claim 8, wherein the angle between the first arm and the sensor is manually adjusted to change a portion of the welding surface sensed by the sensor.

10. The welding training system of claim 8, comprising a control system configured to adjust the angle between the first arm and the sensor to change a portion of the welding surface sensed by the sensor.

11. The welding training system of claim 8, comprising a second arm coupled to the welding surface, and a rotatable bracket coupled to the second arm, wherein the second arm extends vertically from the welding surface.

12. The welding training system of claim 11, wherein the rotatable bracket is rotatable between a vertical position for vertical welding, and a horizontal position for overhead welding.