Virtual testing and inspection of a virtual weldment

• US 9,911,359 B2
• Filed: 03/07/2016
• Issued: 03/06/2018
• Est. Priority Date: 07/10/2009
• Status: Active Grant

• Current Assignee: Lincoln Global Incorporated (Lincoln Electric Holdings Incorporated)
• Original Assignee: Lincoln Global Incorporated (Lincoln Electric Holdings Incorporated)
• Inventors: Wallace, Matthew Wayne, Peters, Carl
• Primary Examiner(s): Utama, Robert J
• Application Number:
  US15/062,469
• Publication Number:
  US 20160203732A1
• Time in Patent Office: 729 Days
• CPC Class Codes: B23K 9/095 Monitoring or automatic control of welding parameters
• CPC Class Codes: B23K 9/0953 using computing means
• CPC Class Codes: B23K 9/0956 using sensing means, e.g. optical
• CPC Class Codes: G06F 30/20 Design optimisation, verification or simulation optimisation, verification or simulation of circuit designs G06F30/30
• 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
• CPC Class Codes: G09B 5/02 with visual presentation of the material to be studied, e.g. using film strip
• CPC Class Codes: G09B 5/06 with both visual and audible presentation of the material to be studied
• CPC Class Codes: G09B 7/00 Electrically-operated teaching apparatus or devices working with questions and answers mechanically operated G09B3/00; computing arrangements G06F
• 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

Arc welding simulations that provide simulation of virtual destructive and non-destructive testing and inspection of virtual weldments for training purposes. The virtual testing simulations may be performed on virtual weldments created using a virtual reality welding simulator system (e.g., a virtual reality arc welding (VRAW) system). The virtual inspection simulations may be performed on “pre-canned” (i.e. pre-defined) virtual weldments or using virtual weldments created using a virtual reality welding simulator system. In general, virtual testing may be performed using a virtual reality welding simulator system (e.g., a virtual reality arc welding (VRAW) system), and virtual inspection may be performed using a standalone virtual weldment inspection (VWI) system or using a virtual reality welding simulator system (e.g., a virtual reality arc welding (VRAW) system). In accordance with certain enhanced embodiments of the present invention, virtual testing may also be performed on a standalone VWI system.

Claims

1. A system for virtual testing and inspecting of a virtual weldment, comprising:

a programmable processor-based subsystem;

a spatial tracker operatively coupled to the programmable processor-based subsystem;

a mock welding tool configured to be spatially tracked by the spatial tracker,

wherein the programmable processor-based subsystem is operable to execute coded instructions, the coded instructions cause the programmable processor-based subsystem to;

simulate formation of a three-dimensional (3D) virtual weldment via manipulation of the mock welding tool, by a user, which is spatially tracked by the spatial tracker such that the virtual weldment includes defects resulting from the manipulation of the mock welding tool by the user,

render at least one of the 3D virtual weldment before simulated testing, the 3D virtual weldment under simulated testing, or the 3D virtual weldment after simulated testing, and

perform a simulated test on the 3D virtual weldment by comparing data representing the defects of the virtual weldment to predefined welding standards, and

perform a virtual inspection of the 3D virtual weldment to identify at least one of pass/fail conditions or defect/discontinuity characteristics;

a display operatively coupled to the programmable processor-based subsystem and configured to display at least one of the 3D virtual weldment before simulated testing, the 3D virtual weldment under simulated testing, or the 3D virtual weldment after simulated testing; and

a user interface operatively connected to said programmable processor-based subsystem and configured for at least manipulating an orientation of the at least one of the 3D virtual weldment before simulated testing, the 3D virtual weldment under simulated testing, or the 3D virtual weldment after simulated testing on the display.

2. The system of claim 1, wherein the simulated test includes a simulated non-destructive test.

3. The system of claim 2, wherein the simulated non-destructive test includes at least one of a simulated x-ray test, a simulated ultrasonic test, a simulated liquid penetrant test, a simulated magnetic particle test, or a simulated time lapse test.

4. The system of claim 1, wherein the simulated test includes a simulated destructive test.

5. The system of claim 1, wherein the programmable processor-based subsystem executes coded instructions to further perform the virtual inspection through simulated interaction of one or more tools with the 3D virtual weldment, the one or more interactive tools are configured to be manipulated by a user via the user interface.

6. The system of claim 5, wherein the processor-based subsystem executes coded instructions to determine a score for the user based on how the user utilizes the one or more interactives tools to inspect the 3D virtual weldment.

7. The system of claim 5, wherein the one or more interactive tools includes at least one of a Palmgren gauge, a fillet gauge, a VWAC gauge, a sliding caliper, a micrometer, or a magnifying lens.

8. The system of claim 1, wherein the programmable processor-based subsystem executes coded instructions to generate an animation of the simulated test of the 3D virtual weldment.

9. The system of claim 1, wherein the 3D virtual weldment is tagged with metallurgical characteristics such that the programmable processor-based subsystem executes coded instructions to be further configured to utilize the metallurgical characteristics to perform the simulated test so as to transform the 3D virtual weldment in accordance with the simulated test.

10. The system of claim 1, wherein the processor-based subsystem executes coded instructions to:

generate questions for a user regarding the 3D virtual weldment;

receive input from the user via the user interface; and

generate a score based on the input received.

11. A system, comprising:

a virtual reality welding system, the virtual reality welding system comprising;

a programmable processor-based subsystem;

a spatial tracker operatively coupled to the programmable processor-based sub system;

a welding tool configured to be spatially tracked by the spatial tracker; and

a display device operatively coupled to the programmable processor-based subsystem,

wherein the programmable processor-based subsystem executes coded instructions, the coded instructions cause the programmable processor-based subsystem to simulate formation of a virtual weldment via manipulation of the welding tool, by a user, while being spatially tracked by the spatial tracker such that the virtual weldment includes defects resulting from the manipulation of the welding tool by the user; and

a virtual weldment inspection system, the virtual weldment inspection system comprising;

a second programmable processor-based subsystem operable to execute coded instructions, the coded instructions configure the programmable processor-based subsystem to;

render the virtual weldment,

perform a simulated test on the virtual weldment by comparing data representing the defects of the virtual weldment to predefined welding standards, and

perform a simulated inspection on the virtual weldment with one or more virtual inspection tools;

a second display device operatively coupled to the second programmable processor-based subsystem and configured to display the virtual weldment; and

a user interface operatively connected to the second programmable processor-based subsystem and configured for at least manipulating an orientation of the virtual weldment on the second display device.

12. The system of claim 11, wherein the virtual weldment includes metadata indicating the defects created during formation of the virtual weldment, the second programmable processor-based subsystem is further configured to perform the simulated test on the virtual weldment based on the metadata.

13. The system of claim 11, wherein the virtual weldment is the virtual weldment formed with the virtual reality welding system.

14. The system of claim 11, wherein the programmable processor-based system and the second programmable processor-based system constitute a single programmable processor-based system, and wherein the display device operatively connected to the programmable processor-based subsystem includes the second display device operatively coupled to the second programmable processor-based subsystem.

15. The system of claim 11, wherein the simulated test is a destructive test such that the programmable processor-based subsystem renders the 3D virtual weldment as transformed by the destructive test and the display device is configured to display the 3D virtual weldment transformed according to the destructive test.

16. The system of claim 11, wherein the simulated test is a non-destructive test and includes at least one of a simulated x-ray test, a simulated ultrasonic test, a simulated liquid penetrant test, a simulated magnetic particle test, or a simulated time lapse test.

17. The system of claim 11, wherein the programmable processor-based subsystem is further configured to:

generate a virtual environment for inspection of the 3D virtual weldment with one or more interactive tools, controllable via the user interface, to identify one or more defects in the virtual weldment; and

render the virtual weldment under inspection for display on the display device.