Sound-based weld travel speed sensing system and method

• US 9,573,215 B2
• Filed: 01/10/2013
• Issued: 02/21/2017
• Est. Priority Date: 02/10/2012
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Pfeifer, Kyle Andrew, Becker, William Joshua, Watson, William Todd, Hutchison, Richard Martin
• Primary Examiner(s): Ratcliffe, Luke
• Application Number:
  US13/738,770
• Publication Number:
  US 20130208569A1
• Time in Patent Office: 1,503 Days
• Field of Search: 367/129
• US Class Current: 1/1
• 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: G01P 3/36 Devices characterised by the use of optical means, e.g. using infrared, visible, or ultraviolet light G01P3/68 takes precedence; gyrometers using the Sagnac effect, i.e. rotation-induced shifts between counter-rotating electromagnetic beams G01C19/64
• CPC Class Codes: G01P 3/38 using photographic means
• CPC Class Codes: G01S 11/12 using electromagnetic waves other than radio waves
• CPC Class Codes: G01S 11/14 using ultrasonic, sonic, or infrasonic waves
• CPC Class Codes: G01S 17/58 Velocity or trajectory determination systems; Sense-of-movement determination systems

Abstract

A weld travel speed sensing system includes at least one sound sensor configured to sense a sound generated to allow determination of a position of a welding torch. The weld travel speed sensing system is configured to determine a position of a point on the welding torch based on the sensed sound.

Claims

1. A weld travel speed sensing system, comprising:

at least one sound sensor configured to sense one or more sounds generated to allow determination of a position of a welding torch, wherein the one or more sounds comprises a welding arc sound;

wherein the weld travel speed sensing system is configured to determine a position of a point on the welding torch based on the one or more sensed sounds;

wherein the one or more sounds is identifiable by the travel speed sensing system based on a pulse pattern, a chirp, a delay, a waveform, a frequency content, a sound wave shape, or some combination thereof.

2. The weld travel speed sensing system of claim 1, comprising an array of sound sensors disposed about a weld area.

3. The weld travel speed sensing system of claim 1, wherein the at least one sound sensor is disposed on the welding torch.

4. The weld travel speed sensing system of claim 1, wherein the one or more sounds generated to allow determination of the position of the welding torch is emitted from one or more emitters disposed on the welding torch.

5. The weld travel speed sensing system of claim 1, wherein the one or more sounds generated to allow determination of the position of the welding torch is emitted from one or more emitters in an array of emitters disposed about a weld area.

6. The weld travel speed sensing system of claim 1, comprising a sensor disposed on the welding torch, wherein the sensor is configured to sense a parameter indicative of a torch angle of the welding torch, and wherein the travel speed sensing system is configured to determine the position of the point on the welding torch based on the sensed parameter.

7. The weld travel speed sensing system of claim 1, wherein the weld travel speed sensing system is configured to detect the position of the point on the welding torch based on a time of flight of the one or more sounds to the at least one sound sensor.

8. The weld travel speed sensing system of claim 1, wherein the one or more sounds is distinguishable, via the travel speed sensing system, from sounds associated with one or more additional welding systems.

9. The weld travel speed sensing system of claim 1, wherein the one or more sounds is identifiable by the travel speed sensing system based on a pulse pattern, a chirp, a delay, a waveform, a frequency content, a sound wave shape, or some combination thereof.

10. The weld travel speed sensing system of claim 1, comprising an array of sound sensors and/or sound emitters, wherein the travel speed sensing system is configured to self-calibrate a position of each sound sensor and/or sound emitter in the array.

11. The weld travel speed sensing system of claim 1, wherein the weld travel speed sensing system is configured to compare times of arrival of the one or more sounds sensed by the at least one sound sensor to determine the location of the point on the welding torch.

12. The weld travel speed sensing system of claim 1, wherein the weld travel speed sensing system is configured to determine a travel speed of the welding torch by determining a change in the position of the point on the welding torch with respect to time.

13. The weld travel speed sensing system of claim 1, wherein the weld travel speed system is configured to:

determine positions of two or more points on the welding torch based on the one or more sensed sounds; and

determine an orientation of the welding torch based on the determined positions.

14. A weld travel speed sensing system, comprising:

at least one sound sensor configured to sense a modulated sound emitted from a welding arc produced by a welding torch;

wherein the weld travel speed sensing system is configured to determine a position of the welding arc based on the sensed sound.

15. The weld travel speed sensing system of claim 14, wherein the sound emitted from the welding arc is identifiable based on natural fluctuations in the welding arc.

16. The weld travel speed sensing system of claim 14, wherein the sound emitted from the welding arc is modulated, based on an augmented current flow to the welding torch.

17. The weld travel speed sensing system of claim 14, wherein the weld travel speed sensing system is configured to determine a travel speed of the welding torch by determining a change in position of the welding arc with respect to time.

18. A method, comprising:

determining, via a sound sensor associated with a welding system, a sensor signal indicative of one or more modulated sounds emitted for determination of a position of a welding torch of the welding system, wherein the one or more modulated sounds comprises a welding arc sound; and

determining, via a processing system, a position of a point on the welding torch based at least in part on the sensor signal.

19. The method of claim 18, comprising:

comparing, via the processing system, times of arrival of the one or more sounds to one or more sound sensors based on sensor signals from the one or more sound sensors;

trilaterating, via the processing system, the position of the point on the welding torch based on the compared times of arrival; and

determining the travel speed by detecting a change in the position of the point on the welding torch with respect to time.

20. The method of claim 18, wherein determining the position of the point on the welding torch comprises processing the sensor signal to isolate the one or more sounds emitted from the welding system.