Welding training system
First Claim
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1. A handheld welding operator device for use by a welding operator while performing an actual or simulated weld, the handheld welding operator device comprising:
- a controller;
a position sensor; and
a stimulation device comprising a tactile feedback device providing directional feedback to an operator, the stimulation device operatively coupled to the controller, wherein the controller is programmed to receive position data from the position sensor, to compare the position data to stored position data defining a position of the handheld welding operator device for a stored weld to determine the position of the handheld welding operator device relative to the stored position data, and to activate the stimulation device to provide the directional feedback to the welding operator to correct the position of the handheld welding operator device to follow the stored position data during the actual or simulated weld.
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Abstract
A welding training system includes one or more welding operator device which provides positional feedback relevant to a quality weld. The positional feedback is analyzed and, when the positional feedback is outside of a predetermined range, a signal is provided to the welding operator. In one embodiment, tactile feedback is provided in a welding gun.
305 Citations
20 Claims
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1. A handheld welding operator device for use by a welding operator while performing an actual or simulated weld, the handheld welding operator device comprising:
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a controller; a position sensor; and a stimulation device comprising a tactile feedback device providing directional feedback to an operator, the stimulation device operatively coupled to the controller, wherein the controller is programmed to receive position data from the position sensor, to compare the position data to stored position data defining a position of the handheld welding operator device for a stored weld to determine the position of the handheld welding operator device relative to the stored position data, and to activate the stimulation device to provide the directional feedback to the welding operator to correct the position of the handheld welding operator device to follow the stored position data during the actual or simulated weld. - View Dependent Claims (2, 3, 4, 5, 16, 17, 18, 19, 20)
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6. A welding system, comprising:
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a welding power source for providing welding power to a simulated or actual weld, the welding power source comprising a welding power source controller and a power source communications device; and a handheld welding operator device in communications with the power source communications device in the welding power source, the handheld welding operator device comprising; a position feedback sensor; a stimulation device comprising a tactile feedback device; and a communications device operatively coupled to the position feedback sensor and the stimulation device, wherein the communications device provides position feedback data to the welding power source controller, and the welding power source controller is programmed to compare the position feedback data to stored position data to evaluate the position feedback data and to active the stimulation device to provide directional feedback to prompt a welding operator to adjust a position of the handheld welding operator device when the position feedback data is outside of a predetermined range during the simulated or actual weld to follow a weld path corresponding to the stored position data. - View Dependent Claims (7, 8, 15)
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9. A method for providing feedback to a welding operator to aid the welding operator to perform a quality weld, the method comprising the following steps:
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storing positional data relevant to a position of a welding gun during a predetermined weld sequence, the positional data including a height and an angle of the welding gun; acquiring positional data corresponding to an actual height of the welding gun and an actual angle of the welding gun during an actual or simulated weld performed by the welding operator; comparing the stored positional data to the acquired positional data during the actual or simulated weld; and providing a directional tactile signal to the welding operator indicating a direction of motion to guide the welding operator to reposition the welding gun toward a position specified in the stored positional data to direct the welding operator toward a consistent quality weld. - View Dependent Claims (10, 11, 12, 13, 14)
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Specification