Weld training system and method

• US 9,875,665 B2
• Filed: 08/18/2014
• Issued: 01/23/2018
• Est. Priority Date: 08/18/2014
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Beeson, Richard
• Primary Examiner(s): Utama, Robert J
• Application Number:
  US14/462,286
• Publication Number:
  US 20160049085A1
• Time in Patent Office: 1,254 Days
• Field of Search: 434234
• CPC Class Codes: B23K 10/00 Welding or cutting by means of a plasma
• CPC Class Codes: B23K 9/0956 using sensing means, e.g. optical
• CPC Class Codes: B23K 9/167 and of a non-consumable electrode
• CPC Class Codes: B23K 9/173 and of a consumable electrode
• CPC Class Codes: B23K 9/322 Head protecting means masks, shields or hoods for weldersp A61F9/06
• 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 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

Systems and methods for a weld training system are provided. In particular, components of the weld training system may be removably disposed within an interior volume of a portable enclosure. The portable enclosure may be easy to transport by a welding operator from various training and/or recruiting locations. In some embodiments, the components of the weld training system include a weld training device, a work surface, a sensing device, a virtual reality interface, and processing circuitry.

Claims

1. A weld training system, comprising:

a weld training device configured to perform a virtual welding procedure on a simulated weld joint via an interface, wherein the simulated weld joint is simulated on a work surface;

a portable enclosure comprising a body and a cover;

an internal display attached to the cover and configured to provide a visualization of the simulated weld joint, wherein the portable enclosure is configured to be opened to provide access to the weld training device, the work surface, and the internal display;

the virtual welding procedure on the simulated weld joint configured to be performed on the work surface when the work surface is coupled to the portable enclosure and the portable enclosure is open;

a sensing device configured to detect position or orientation information of the weld training device via processing circuitry; and

the body of the portable enclosure comprising an interior volume and configured to support the work surface during the virtual welding procedure, wherein at least one of the weld training device, the work surface, the sensing device, or the processing circuitry are removably disposed within the interior volume, and wherein the portable enclosure is configured to be transported by an operator of the weld training system.

2. The system of claim 1, wherein the portable enclosure is functionally self-contained and is configured to operate independent of an external computing system, an external display, an external power source, or a combination thereof.

3. The system of claim 1, wherein the interface comprises a wireless virtual vision device, wireless virtual gloves, wireless virtual audio features, or a combination thereof.

4. The system of claim 3, wherein the wireless virtual reality vision device is a virtual reality head piece worn by the operator of the weld training system, and wherein the wireless virtual vision device is configured to provide a visualization to the operator of the simulated weld joint within a virtual welding environment.

5. The system of claim 3, wherein the wireless virtual vision device comprises virtual goggles, virtual glasses, a virtual helmet, or a combination thereof.

6. The system of claim 1, wherein the weld training device comprises a virtual welding torch configured to simulate welding functions of a welding torch within a real welding operation.

7. The system of claim 6, wherein the virtual welding torch is configured with wireless capabilities.

8. The system of claim 6, wherein the virtual welding torch is configured with wired capabilities.

9. The system of claim 1, further comprising an external display operatively coupled to the portable enclosure, wherein the external display is configured to provide a visualization of the simulated weld joint.

10. The system of claim 1, further comprising a power source within the interior volume, wherein the power source is a rechargeable battery, a battery pack, a disposable battery, a replaceable battery, or a combination thereof.

11. The system of claim 10, wherein the power source is configured to power at least one of the weld training device, the sensing device, the processing circuitry, the virtual reality interface, or a combination thereof.

26. The system of claim 1, wherein the work surface is a flat surface configured as a welding surface.

12. A weld training system, comprising:

a weld training device configured to perform a virtual welding procedure on a simulated weld joint via an interface, wherein the simulated weld joint is simulated on a work surface;

a portable enclosure comprising a body and a cover;

an internal display attached to the cover and configured to provide a visualization of the simulated weld joint, wherein the enclosure is configured to be opened to provide access to the weld training device, the work surface, and the internal display;

the work surface comprising a coupon attachment, and the virtual welding procedure on the simulated weld joint configured to be performed on the work surface when the work surface is coupled to the portable enclosure and the portable enclosure is open;

one or more coupons configured to be operatively coupled to the coupon attachment disposed on the work surface within the portable enclosure during the virtual welding procedure;

a sensing device configured to detect position or orientation information of the weld training device based on the one or more coupons via processing circuitry; and

the body of the portable enclosure comprising an interior volume and configured to support the work surface during the virtual welding procedure, wherein at least one of the weld training device, the work surface, the sensing device, or the processing circuitry are removably disposed within the interior volume, and wherein the portable enclosure is configured to be transported by an operator of the weld training system.

13. The system of claim 12, wherein the portable enclosure is functionally self-contained and is configured to operate independent of an external computing system, an external display, an external power source, or a combination thereof.

14. The system of claim 12, wherein the weld training device comprises a virtual welding torch configured to simulate welding functions of a welding torch within a real welding operation, wherein the virtual welding torch is configured for wired or wireless communication with the processing circuitry.

15. The system of claim 12, wherein the position or orientation information is provided as sensor feedback to the virtual reality interface, and wherein the virtual reality interface utilizes the position or orientation information to generate a virtual reality simulated welding environment.

16. The system of claim 12, wherein the position or orientation information is utilized to determine one or more operating parameters of the virtual welding procedure.

17. The system of claim 16, wherein the one or more operating parameters comprise a work angle, a travel angle, a contact tip to work piece distance, a travel speed of the weld training device, a proximity of the weld training device to the simulated weld joint, a simulated welding voltage, a simulated welding current, an orientation of the weld training device, a position of the weld training device, or a combination thereof.

18. The system of claim 16, wherein the processing circuitry is configured to calculate a welding score based at least in part on the one or more operating parameters.

25. The system of claim 12, wherein the portable enclosure comprises a cover and a body coupled via a second hinge, wherein the second hinge is configured to position the cover in an open position or a closed position relative to the body, and the work surface forms an interior cover when the cover is in the open position relative to the body and the work surface is positioned horizontally within the portable enclosure via the first hinge.

19. A weld training method, comprising:

operating a weld training system within a portable enclosure, wherein the portable enclosure is configured to be transported by an operator of the weld training system, and wherein operating the weld training system comprises;

performing, via a weld training device, a virtual welding procedure on a simulated weld joint, wherein the weld joint is simulated on a work surface via an interface, the work surface is disposed within the portable enclosure, and the work surface is removably coupled to the portable enclosure via a first hinge configured to position the work surface vertically within the portable enclosure or horizontally within the portable enclosure;

receiving, via a sensing device, position or orientation information of the weld training device; and

determining, via processing circuitry, an updated position or orientation information of the weld training device based on the received position or orientation information of the weld training device, wherein the updated position or orientation information is utilized to determine one or more current operating parameters of the virtual welding procedure, and wherein at least one of the weld training device, the work surface, the sensing device, or the processing circuitry are removably disposed within an interior volume of the portable enclosure of the weld training system.

20. The method of claim 19, comprising operating the weld training system within the portable enclosure independently of an external computing system, an external display, an external power source, or a combination thereof, such that the portable enclosure is functionally self-contained.

21. The method of claim 19, comprising displaying the updated position or orientation information or the one or more current operating parameters of the virtual welding procedure on an internal display, and wherein the internal display is disposed within the interior volume of the portable enclosure.

22. The method of claim 19, comprising visualizing, via the interface, at least one of the weld training device, the simulated weld joint, the work surface, the virtual welding procedure, or a combination thereof.

23. A weld training system, comprising:

a weld training device configured to perform a virtual welding procedure on a simulated weld joint via an interface, wherein the simulated weld joint is simulated on a work surface;

the work surface configured to be coupled to a portable enclosure via a first hinge configured to position the work surface vertically within the portable enclosure or horizontally within the portable enclosure, wherein the virtual welding procedure on the simulated weld joint is configured to be performed on the work surface when the work surface is coupled to the portable enclosure;

a sensing device configured to detect position or orientation information of the weld training device via processing circuitry; and

the portable enclosure comprising an interior volume, wherein at least one of the weld training device, the work surface, the sensing device, or the processing circuitry are removably disposed within the interior volume, and wherein the portable enclosure is configured to be transported by an operator of the weld training system.

24. The system of claim 23, wherein the portable enclosure comprises a cover and a body coupled via a second hinge, wherein the second hinge is configured to position the cover in an open position or a closed position relative to the body, and the work surface forms an interior cover when the cover is in the open position relative to the body and the work surface is positioned horizontally within the portable enclosure via the first hinge.