System and method of monitoring a welding environment

• US 9,724,787 B2
• Filed: 07/24/2015
• Issued: 08/08/2017
• Est. Priority Date: 08/07/2014
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Becker, William Joshua, Beeson, Richard
• Primary Examiner(s): SAAD, ERIN BARRY
• Application Number:
  US14/808,858
• Publication Number:
  US 20160039053A1
• Time in Patent Office: 746 Days
• Field of Search: 21913001, 21912164, 228 8, 228 12
• 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 9/0956 using sensing means, e.g. optical
• CPC Class Codes: G09B 19/24 Use of tools

Abstract

A welding system includes a first position detection system, a second position detection system independent of the first position detection system, and a controller coupled to the first and second position detection systems. The first position detection system is configured to generate a first output corresponding to a first position and a first orientation of a welding torch during a welding session for a weld. The second position detection system is configured to generate a second output corresponding to a second position and a second orientation of the welding torch during the welding session. The controller is configured to determine welding parameters during the welding session based at least in part on the first output, the second output, or any combination thereof. The welding parameters may include a work angle, a travel angle, a contact tip to work distance, a travel speed, an aim, or any combination thereof.

Claims

1. A welding system comprising:

a first position detection system configured to generate a first output corresponding to a first position and a first orientation of a welding torch during a welding session for a weld, wherein the first position detection system comprises a line-of-sight based position detection system configured to detect a portion of the welding torch, wherein the first output is based at least in part on the detected portion of the welding torch;

a second position detection system configured to generate a second output corresponding to a second position and a second orientation of the welding torch during the welding session for the weld, wherein the second position detection system is independent of the first position detection system; and

a controller coupled to the first position detection system and to the second position detection system, wherein the controller is configured to determine welding parameters during the welding session based at least in part on the first output, the second output, or any combination thereof, and the controller is configured to determine the welding parameters based only on the second output when the portion of the welding torch is obscured from the line-of-sight based position detection system, wherein the welding parameters comprise a work angle of the welding torch, a travel angle of the welding torch, a contact tip to work distance, a travel speed of the welding torch along a path of the weld, an aim of the welding torch, or any combination thereof.

2. The welding system of claim 1, wherein the first position detection system comprises an optical detection system comprising a camera, and the portion of the welding torch comprises a plurality of visual markers.

3. The welding system of claim 1, wherein the portion of the welding torch does not comprise a visual marker.

4. The welding system of claim 2, wherein the controller is configured to determine the welding parameters during the welding session based only on the second output when a visual marker of the plurality of visual markers is obscured from the optical detection system.

5. The welding system of claim 1, wherein the controller is configured to determine the welding parameters during the welding session based on the first output and the second output.

6. The welding system of claim 5, wherein the controller is configured to determine the welding parameters based at least in part on a weighted average of the first output and the second output.

7. The welding system of claim 1, wherein the first position detection system comprises a different type of position detection system than the second position detection system, wherein the second position detection system comprises one or more inertial sensors coupled to the welding torch.

8. The welding system of claim 1, wherein the first position detection system is partially integrated with a welding helmet, wherein the partial integration comprises integration of a receiver with the welding helmet, and the receiver is configured to detect the welding torch.

15. The welding system of claim 1, wherein the controller is configured to activate the second position detection system when the first position of the welding torch is near a welding joint, and the controller is configured to deactivate the second position detection system when the first position of the welding torch is not near the welding joint.

16. The welding system of claim 15, wherein the controller is configured to display a visual guide on a display of the welding torch when the welding torch is near the welding joint.

9. A welding system comprising:

a first position detection system comprising a line-of-sight based position detection system configured to detect a portion of a welding torch during a welding session for a weld, and the first position detection system is configured to generate a first output corresponding to detection of the portion of the welding torch;

a second position detection system configured to generate a second output corresponding to a position of the welding torch during the welding session when the portion of the welding torch is obscured from the line-of-sight based position detection system, wherein the second position detection system comprises one or more inertial sensors disposed on the welding torch; and

a controller coupled to the first position detection system and to the second position detection system, wherein the controller is configured to determine welding parameters of the welding torch during the welding session based at least in part on the first output and the second output, wherein the welding parameters comprise a work angle of the welding torch, a travel angle of the welding torch, a contact tip to work distance, a travel speed of the welding torch along a path of the weld, an aim of the welding torch, or any combination thereof, the controller is configured to detect if the welding torch is near a welding joint based on the first output, the controller is configured to activate the second position detection system when the welding torch is near the welding joint, and the controller is configured to deactivate the second position detection system when the welding torch is not near the welding joint.

10. The welding system of claim 9, wherein the line-of-sight based position detection system is configured to detect one or more markers coupled to the portion of the welding torch, the first position detection system is configured to generate the first output corresponding to detection of the one or more markers, and the second position detection system is configured to generate the second output when the one or more markers are obscured from the line-of-sight based position detection system.

11. The welding system of claim 9, wherein the second position detection system is configured to generate the second output when the portion of the welding torch is observable by the line-of-sight based position detection system, wherein the controller is configured to determine the welding parameters based on the first output and the second output.

12. The welding system of claim 9, wherein the second position detection system comprises a local positioning system, wherein the local positioning system comprises:

a plurality of beacons disposed about a welding environment comprising the welding system, wherein each beacon is configured to emit signals within a radio frequency range or an ultrasonic frequency range; and

a microphone disposed on the welding torch and configured to receive the signals from the plurality of beacons, wherein the second output comprises the signals received by the microphone, wherein the controller is configured to determine the welding parameters utilizing the second output via triangulation, trilateration, or multilateration.

13. The welding system of claim 9, wherein the one or more inertial sensors comprise an accelerometer, a gyroscope, or any combination thereof.

14. The welding system of claim 9, wherein the first position detection system is partially integrated with a welding helmet, wherein the partial integration comprises integration of a receiver with the welding helmet, and the receiver is configured to detect the welding torch.

17. The welding system of claim 9, wherein the welding torch is near the welding joint when both the contact tip to work distance and the aim of the welding torch are within less than 3 inches of the welding joint.

18. A welding system comprising:

a first position detection system configured to generate a first output corresponding to a first position and a first orientation of a welding torch during a welding session for a weld;

a second position detection system configured to generate a second output corresponding to a second position and a second orientation of the welding torch during the welding session for the weld, wherein the second position detection system is independent of the first position detection system, the second position detection system comprises a local positioning system comprising;

a plurality of beacons disposed about a welding environment comprising the welding system, wherein each beacon is configured to emit signals within a radio frequency range or an ultrasonic frequency range; and

a microphone disposed on the welding torch and configured to receive the signals from the plurality of beacons, wherein the second output is based at least in part on the signals received from the plurality of beacons during the welding session; and

a controller coupled to the first position detection system and to the second position detection system, wherein the controller is configured to determine welding parameters during the welding session based at least in part on the first output, the second output, or any combination thereof, wherein the welding parameters comprise a work angle of the welding torch, a travel angle of the welding torch, a contact tip to work distance, a travel speed of the welding torch along a path of the weld, an aim of the welding torch, or any combination thereof.

19. The welding system of claim 18, wherein the first position detection system comprises a line-of-sight based position detection system configured to detect a portion of the welding torch, the first output is based at least in part on the detected portion of the welding torch, and the controller is configured to determine the welding parameters during the welding session based only on the second output when the portion of the welding torch is obscured from the line-of-sight based position detection system.

20. The welding system of claim 18, wherein the controller is configured to activate the second position detection system when the first position of the welding torch is near the welding joint, and the controller is configured to deactivate the second position detection system when the first position of the welding torch is not near the welding joint.