US20160012750A1

US20160012750A1 - Welding simulator

Info

Publication number: US20160012750A1
Application number: US14/862,649
Authority: US
Inventors: Matthew Wayne WALLACE; Andrew Paul LUNDELL; David Anthony ZBORAY; Matthew Alan BENNETT
Original assignee: Lincoln Global Inc
Current assignee: Lincoln Global Inc
Priority date: 2008-08-21
Filing date: 2015-09-23
Publication date: 2016-01-14
Also published as: US20100048273A1; EP2329479A2; DE202009018950U1; CA2730545A1; BRPI0917273A2; US20170046982A1; WO2010020869A3; MX2011001223A; RU2011110478A; CN102171744A; US10762802B2; WO2010020869A2; CN102171744B; US9483959B2; BRPI0917273B1

Abstract

Embodiments of the present invention pertain to a computer program product and processor based computing system that provides processing means for executing coded instructions and input means for interacting with said processing means to create a virtual welding environment. The system establishes an objective to change a functional or operational state of a virtual article, and directs the end user to perform at least one virtual welding operation for changing its functional state. The system trains new users and inexperienced welders on the fundamental aspects of welding and other technical features.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is being filed as a continuation of U.S. non-provisional patent application Ser. No. 12/504,870 entitled WELDING SIMULATOR and filed on Jul. 17, 2009, which claims priority/benefit under 35 U.S.C. §119(e) from U.S. provisional patent application Ser. No. 61/090,794 entitled WELDING SIMULATOR and filed on Aug. 21, 2008, the entire disclosures of which are incorporated herein by reference.

FIELD

The present invention pertains to methods and systems for introducing potential new workers to the field of welding, and more particularly, to computer generated virtual environments that simulate welding processes.

BACKGROUND

In recent decades, welding has become a dominant process in the manufacture and construction of various products. Applications for welding are widespread and used throughout the world for the construction of ships, buildings, bridges, vehicles, and pipe lines, to name a few examples. Many welding tasks can be automated reducing the need for skilled labor. However, automated welding applications must be set up and managed by knowledgeable welders. Other welding applications aren't confined to a factory floor. Applications, including the construction of pipe lines or buildings, are welded in the field and require the mobility of an experienced welder. Accordingly, there is ongoing need for trained personnel who can adapt to the challenges of welding processes.
The demand for skilled welders remains high, despite reductions in manufacturing, in many regions of the world. In the United States, the average age of the welding professional is increasing, with many individuals approaching retirement age. Over the next decade, the number of available experienced welders is expected to significantly decline as workers retire from the welding profession. Many young people entering the workforce today are choosing advanced education over skilled trades and many of those workers entering the trades are dissuaded from a career in welding despite good working conditions. Programs and organizations promoting S.T.E.M. (Science Technology Engineering Math) and S.T.E. (Science and Technology/Engineering) education are valuable in revitalizing the interest of individuals in technology related fields.

SUMMARY

The embodiments of the present invention pertain to a computer program product and processor based computing system that provides processing means for executing coded instructions and input means for interacting with said processing means to create a virtual welding environment. The system establishes an objective to change a functional or operational state of a virtual article, and directs the end user to perform at least one virtual welding operation for changing its functional state.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a simulating device and end user according to the embodiments of the subject invention.

FIG. 2 is a close up perspective view of a simulating device depicting a virtual environment according to the embodiments of the subject invention.

FIG. 3 is an image of a virtual environment showing a virtual article according to the embodiments of the subject invention.

FIG. 4 is an image of a virtual environment showing a virtual article and user interface screen according to the embodiments of the subject invention.

FIG. 5 is an image of a virtual environment showing a user interface screen according to the embodiments of the subject invention.

FIG. 6 is a block diagram depicting a method of a game played on a processor based computing device executing coded instructions.

FIG. 7 is a block diagram depicting a method for training welding activity.

DETAILED DESCRIPTION

Referring now to the drawings wherein the showings are for purposes of illustrating embodiments of the invention only and not for purposes of limiting the same, FIGS. 1 and 2 show a simulator or simulating device depicted generally at 10. The simulating device 10 generates a virtual environment 9 that simulates a three dimensional setting, which may be an industrial or commercial setting utilizing one or more manufacturing processes. The virtual environment 9 may be depicted on an imaging device 22 as viewed by an end user 11. In particular, the simulating device 10 may depict a virtual environment 9 that facilitates interaction between the end user 11 and one or more virtual articles 16. An input device 13 may be included that senses activity when manipulated by the end user 11. Data from the input device 13 may be communicated to the simulating device 10 and is used to maneuver objects with the virtual environment 9 in or near real time. In one embodiment, the simulating device 10 functions to generate one or more virtual articles 16 that can be acted upon by virtual tools 26 generated in a similar manner. It follows that the virtual tools 26 may be employed in the virtual environment 9 when the input device 13 is maneuvered by the end user 11 in the real world.
The simulating device 10 may generate a virtual environment 9 having virtual articles 16 that resemble components of a particular manufacturing or construction process. In one embodiment, the virtual environment 9 may comprise a welding environment 9 a depicting one or more articles for assembly together via a welding process. Accordingly, the virtual tools 26 may comprise a welder 32 and welding torch 34. In this manner, the simulating device 10 displays virtual articles 16 being welded together by a virtual welder 32 as interactively controlled by the end user 11. The simulating device 10 may be realized as a training platform for exposing individuals to a particular manufacturing process, or may be realized as a game played to achieve a stated objective, both of which will be discussed further in a subsequent paragraph. It is expressly noted that while the embodiments of the present invention are described in the context of a virtual welding environment 9 a and one or more welding process, persons of skill in the art will understand its application to other industrial or commercial processes.
With continued reference to FIG. 1, the simulating device 10 may be constructed of electronic hardware comprising a processor based computing device 24 operable to run, i.e. execute, a computer program product. In one embodiment, the processor based computing device 24 comprises a microcomputer in any of various configurations including but not limited to: a laptop computer, a desktop computer, work station, server or the like. Alternatively, the processor based computing device 24 may comprise a gaming system like that manufactured by Nintendo®, Microsoft® or Sony®. In this manner, the processor based computing device 24 may be a commercially available system readily available for purchase by an end user 11. The processor based computing device 24 may include one or more logic processor based systems 25, or logic processors 25, such as a programmable microprocessor, although any type of logic processor 25 may be utilized in the simulating device 10 without departing from the intended scope of coverage of the embodiments of the subject invention. The processor based computing device 24 may further include support circuitry including electronic memory, such as RAM or ROM along with other peripheral support circuitry that facilitate operation of the logic processor(s) 25. Additionally, the processor based computing device 24 may include data storage, examples of which include hard disk drives, optical storage devices and/or flash memory for the storage and retrieval of data in a manner well known in the art. Thus, the processor based computing device 24 may be programmable and operable to execute coded instructions, as also referred to as programmed algorithms, which may be a computer program product written in a high or low level programming language. It is noted that any form of programming or type of programming language may be used to code algorithms as executed by the simulating device 10 for simulating the virtual environment 9, 9 a.
The simulating device 10 and, more particularly, the processor based computing device 24 may be communicated to and used in conjunction with other similarly or dissimilarly constructed systems. Input to and output from the simulating device 10, termed 1/0, may be facilitated in this embodiment by networking hardware including wireless as well as hard wired (directly connected) devices. Communication between simulating devices 10, or systems, may be accomplished remotely as through a network, like a wide area network (WAN) or local area network (LAN) via network hubs, repeaters, or by any means chosen with sound judgment. Communications may be established through, but are not limited to: direct connection of multiple simulating devices 10, web-based connectivity, virtual private networks, and/or SSL (Secure Sockets Layer) encrypted communication. It is noted that the relationship between simulating devices 10 may be peer-to-peer, client-server, or any hybrid combination thereof without departing from the scope of coverage of the embodiments of the subject invention. In this manner, information may be transmitted between systems 10 as is useful for simulating or interacting with the virtual environment 9, 9 a. In one embodiment, network communications may be used to download virtual articles 16 or virtual tools 26 for changing the game scenario. Alternatively, new environments may be downloaded for training a different manufacturing process, the details of which will be discussed further below. It is further contemplated in another embodiment that the simulating device 10 may generate a virtual environment 9, 9 a that may be acted upon by multiple end users 11 each working from the same system or separate systems networked together. Still, any manner of communicating one or more simulating devices 10 together may be utilized without departing from the intended scope of coverage of the embodiments of the subject invention.
With continued reference to FIGS. 1 and 2, the simulating device 10 may include an imaging device 22 for displaying the virtual environment 9, which may be a virtual welding environment 9 a. The imaging device 22 may comprise a display screen operable to display images generated by the processor based computing device 24 and the computer program product. In one embodiment, the display screen may include a computer monitor and/or television screen comprised of CRT (Cathode Ray Tube) or LCD (Liquid Crystal Display), although any type of monitor, screen, display, or projection device may be utilized as is appropriate for the embodiments of the subject invention. Information for generating the images on the display screen may be stored in memory within the processor based computing device 24. As memory is updated or changed during execution of the computer program product, images on the display screen may be dynamically changed in real time. Still any method or means for displaying the virtual environment 9, 9 a on the imaging device 22 may be chosen as is appropriate for use with the embodiments of the subject invention.
With reference now to FIGS. 2 and 3, the input device 13 may function to interface activity in the real world with the virtual environment 9. In particular, the input device 13 senses the actions of the end user 11 and translates those actions into data recognizable by the simulating device 10. The data is communicated to the logic processors 25 and may be used to interactively engage the virtual tools 26 and/or the virtual articles 16. In one embodiment, the computer program product processes the data and makes changes to the virtual environment 9 in real time. In this manner, as the end user 11 manipulates the input device 13 in three dimensional space, objects in the virtual environment 9, 9 a move in a corresponding manner, i.e. in direct relationship to movement of the input device 13. For example, the end user 11 may visualize one or more virtual objects on the imaging device 22, including a virtual representation of a real world tool. Accordingly, the end user 11 may move the input device 13 in a particular direction resulting in a corresponding movement of the virtual object. In the welding embodiment illustrated herein, the input device 13 may represent the welding torch 34. Movement of the input device 13 therefore translates into movement of the virtual welding torch 34 in the virtual environment 9 a. The input device 13 may include switches that activate the virtual welder thereby initiating the welding process. The end user 11 may then guide the input device 13 along a trajectory that coincides with the weld joint as depicted on the imaging device 22.
Still referring to FIG. 2, the input device 13 may include one or more sensors 37 that detect movement and/or orientation in three dimensional space. The sensors 37 may be integrated into the input device 13 and positioned at various locations for detecting different types of activity. For example, the sensor 37, or sensors, may detect spatial orientation, i.e. the direction that an object is pointing, as mentioned above. The sensors 37 may also detect motion in a particular direction. Additionally, the sensors 37 may detect velocity and/or acceleration, which may encompass not only the magnitude of change in position or speed, but also direction. However, any type of activity related to the input device 13 may be detected by the sensors 37 without departing from the intended scope of coverage of the embodiments of the subject invention. Examples of sensors 37 may include but are not limited to: inertial sensors like accelerometers, proximity sensors, infrared sensors, photoelectric and optical sensors, and the like. It is noted here that the input device 13 may further incorporate switching means 38 for interfacing with the virtual environment 9. The switching means 38 may include: pushbuttons, triggers or switches. In this way, virtual activity may be initiated, interrupted, or terminated as desired by depressing or releasing the switch respectively. Illustratively, the virtual welder 34 may be turned “on” or “off” by depressing or releasing a trigger switch. It is to be construed that any type, quantity or grouping of sensors 37 or switching means 38 may be integrated into the input device 13 as chosen with sound judgment. Still other means of tracking movement of the input device 13 may be included as a separate unit that resides in an adjacent region proximal to the coupon. Position and/or orientation data generated by the tracker, i.e. tracking means, may be used in conjunction with or in place of data generated by the input device 13.
In one embodiment, the input device 13 may be commercially available for purchase and use. One example may include a manually moveable device, like a computer mouse having an optical sensor for detecting movement along an adjacent surface. Another example of input device 13 may comprise a gaming joystick or controller, which may include a connector for plugging into an I/O port or may include wireless means for communication. The Wii wireless controller manufactured by Nintendo® is one exemplary type of input device, although other commercially available controller devices may be utilized as are suitable for use with a particle processor based computing device 24. Other embodiments contemplate customized controllers, which may be fashioned to physically look like a particular virtual tool 26, e.g. a welding torch 34. Interaction with the simulating device 10 is thereby enhanced by a physical object having a real world feel and look that resemble the virtual tools 26 depicted on the imaging device 22. It is noted that the customized controller may be substantially similar in size, shape and/or weight to the real world tool for which the controller is intended to resemble. Other embodiments include an attachment that connects to the commercially available input device 13 and resembles a particular virtual tool 26 to enhance the end user's experience in interacting with the virtual environment 9. In one embodiment, the attachment may be an overlaying component and/or a component that attaches to and extends from the input device 13. However, it is expressly noted that any configuration of customized controller or attachment may be chosen as is appropriate for use with the embodiments of the subject invention. Accordingly, at least part of the simulating device 10 may be packaged as a kit for use with any type of processor based computing device 24, commercially available or otherwise. In another embodiment of the subject invention, the kit may include a welding coupon that may resemble a virtual article 16 displayed in the virtual environment 9, 9 a. Accordingly, the welding coupon may function as a guide in the real world for assisting the end user in acting in the virtual environment 9, 9 a. The kit may also comprise tracking means like that mentioned above. In other words, a tracking unit may be provided in addition to the input device 13 for sensing the end user's 11 movement during play.
With reference to FIGS. 3, 4 and 6, the simulating device 10 may comprise a game having a stated objective to be accomplished by the end user 11. In one particular embodiment, the game may comprise a welding game where the objective is to weld one or more virtual articles 16 together. Achieving the objective may require the end user 11 to perform a number of welds each to a predetermined level of quality. That is to say that the game facilitates user interaction with processor based computing device 24 via the input device 13 for satisfactorily performing one or more virtual welds in the virtual welding environment 9 a. During play, the game presents the end user 11 with a scenario incorporating one or more themed virtual articles 16 a. Illustratively, the scenario may relate to motorized vehicles and may depict a number of virtual components that can be welded together to assemble a functioning motorcycle or racecar. In another exemplary scenario a jet aircraft is simulated that is in need of repairs, which may require welding before taxiing down the runway and taking off. Other examples include building structures or bridges that require repair or construction before people occupy the building or the train crosses the bridge respectively. However, any scenario theme may be chosen without departing from the intended scope of coverage of the embodiments of the subject invention. It will be realized that the game rewards successful completion of the objective, in one manner, by graphically displaying the themed article functioning in its environment, e.g. the motorcycle drives away or the train crosses the bridge. The simulating device 10 also takes in account the personal interests of the end user 11. In one embodiment, the game gives the end user 11 the option of selecting a scenario that is familiar increasing his or her level of interest. Accordingly, the game may be programmed with multiple scenario options for appeal to a broad range of individuals.
From the aforementioned description, it follows that the themed virtual article 16 a of the scenario has some deficiency that requires repair or assembly before becoming operational. During game initialization, i.e. game start up, the themed virtual article 16 a may be instantiated having an inoperative state or, in other words, is created not working properly or not working at all. In the present examples, the initial “inoperative” state may be represented and simulated by one or more broken brackets, a stack of unassembled I-beams, a cracked pipe, or any repairable element fitting the scenario theme. Accomplishing the game objective therefore requires the end user 11 to interact with the virtual environment 9 a to perform virtual welding that changes the operational state of the themed virtual article 16 a. It is noted here that accomplishing the game objective may require successful completion of multiple levels of play. That is to say winning the game requires successfully changing the operational state of each virtual article 16 a in every level of play.
At an introductory level, the game displays one or more virtual articles 16 that correspond to the scenario selected by the end user 11. The end user 11 is then instructed to perform a particular type of weld relating to the deficiency of the virtual article 16. It may be assumed that the end user 11 has little or no welding experience. Accordingly, a tutorial may be provided that presents information to the end user 11 about the welding process or welding techniques needed for achieving the objective for that level. Display of the tutorial may be initiated or controlled by the end user 11 via a graphical user interface (GUI), in one example, as selected by a “help” button. In the alternative, tutorial screens may automatically be presented if the end user's performance falls below a satisfactory level. In one exemplary manner, the instructions may be displayed in written form, an example of which may include a setup screen. Instructions may also be provided audibly and, more specifically verbally, to describe the process and/or motions needed to complete setup and a particular welding task. In either case, the instructions may be presented in one of a plurality of languages to accommodate individuals residing in different regions of the world. One embodiment is contemplated where the game graphically or pictorially presents tutorial information. In this instance, literacy of the end user 11 is not required to play the game.
Game play proceeds as the end user 11 engages the input device 13 to mimic movements characteristic of performing a weld. Progression through the game may depend on how well the end user 11 performs a virtual weld, which may relate to the level of virtual weld quality. In this manner, advancing to the next level, as will be discussed further in a subsequent paragraph, requires successful completion of the previous game stage. In making that determination, one or more parameters may be measured to determine the level of virtual weld quality. In processes well known in the real world, weld quality depends on many factors like the distance between the torch tip and the weld joint, which may vary with the type of welding process, the materials being welded, the welder settings, and the like. Corresponding real world parameters may be coded into the computer program product for judging the end user's 11 performance and for determining the quality of the virtual weld.
Completion of a particular game level may require the end user 11 to perform the one or more virtual welds to predetermined performance standards as determined by the computer program product. Performance parameters may be programmed into the computer program product that correlate to good welding practices and may consist of: weld torch 34 position, roll and pitch angles of orientation and travel speed. Sensor data from the input device 13 may be compared to preprogrammed parameters to determine whether or not the end user 11 has stayed within acceptable limits. In one particular embodiment, weld quality may be determined by monitoring the distance between the torch tip in relation to the center of the weld seam while maintaining proper pitch and roll angles during the virtual welding process. However, it is to be construed that other parameters may be utilized in determining if the end user 11 has successfully completed a virtual weld.
In one embodiment, the simulating device 10 provides or calculates a score resulting from game play. The score, which may also be a grade, may be derived from the performance data of the end user 11. Performance data may pertain to how well the end user 11 performs the virtual weld, that is to say how closely the end user 11 maintains the virtual tools 26 or welding torch 34 within limits for acceptable welding practices. Examples may include but should not be limited to, welding torch angle or distance to the virtual article 16 The score or grade may also be derived from end user selections made with respect to the problem-based scenarios as will be discussed further in a subsequent paragraph.
Simulating device 10 may provide feedback to help the end user 11 in performing the virtual welds. In the real world, a welder receives feedback by observing the weld bead as the torch travels along the weld joint. The simulating device 10 may similarly depict a virtual weld bead correlating to the end user's movement of the virtual welding torch 34. In one embodiment, the shape of the virtual weld bead is determined by factors including torch angle, travel speed and distance to the work piece, as well as welding power source settings, although other factors may be incorporated as is appropriate for use with the embodiments of the subject invention. In this manner, the end user 11 can make adjustments during the virtual welding process for laying down an acceptable weld bead thereby simulating real world activity.
Referencing FIG. 5, to further assist the end user 11, performance guides 41 may be included that provide quantitative feedback on the position and orientation of the virtual welding torch 34. In one particular embodiment, “indicating bars” 42 are included that show the pitch and roll angles of the virtual welding torch 34. Other types of performance guides 41 are contemplated that display the distance between the torch tip and the weld joint. Additional welding parameters incorporated into the performance guide 41 will become apparent to those skilled in the art.
The performance guides 41 may display the actual numerical values of the torch position, which in the current embodiment shows pitch and roll angles. The values displayed may show the angles as measured from an absolute reference like the vertical or horizontal plane. Alternatively, the performance guides 41 may display angle values that relate to offsets from the ideal torch position or orientation. The performance guide 41 may indicate which values are outside the range for achieving an acceptable weld. In one embodiment, the performance guides 41 may flash, changer color and play an audible sound that indicates when the welding torch 34 is out of position. In this way, the end user 11, through repeated use, learns correct welding techniques. As the end user 11 gains experience, he or she will naturally maintain the welding torch 34 at the proper orientation throughout the entire welding process. At one point, it may no longer be necessary to display the performance guides 41. Accordingly, the computer program product may be programmed to selectively turn the guides 41 “on” or “off ”
As previously mentioned, the game may incorporate different levels of play. The levels may be differentiated by scenario, i.e. by changes in the themed subject articles 16 a being welded. Alternatively, the levels of play in a particular scenario may differ by the types of weld joints and/or the number of virtual article pieces to be welded together. For example, a more fundamental level may simulate welding a single lap joint embodied by overlaid frame components of building structure. Another level of play may simulate performing a pipe weld as found on a motorcycle tailpipe or pipeline. Still, other examples are contemplated wherein overhead or vertical butt joints are to be welded for repairing the frame of motor vehicle. At each game level, the welding objectives must each be performed to within predetermined quality boundaries in succession, before proceeding to the next level. In this way, basic welding skills may be taught by progressively introducing increasingly complicated weld joint configurations and more advanced welding techniques.
The game objective may be accomplished when the end user 11 successfully performs, i.e. meets or exceeds predetermined limits of weld quality for, all of the virtual welds in a given scenario. That is to say that the end user 11 performs each weld on every level to a minimum standard for quality. Alternative game objectives may be included that are accomplished by exceeding a virtual weld performance average over the various levels. Consequently some levels of play may be performed below the performance minimums with others commensurately above. The game objective is met as long as the weighted average for the entire game exceeds a predetermined minimum.
In judging the end user's 11 performance, the simulating device 10 may track the movements of the end users 11 through the input device 13 and compare the data with parameters stored in memory, or coded into the computer program product. The data and/or parameters may be stored in a database, or by any means of data storage chosen with sound judgment. In one embodiment, the simulating device 10 records and stores information about the end user's 11 performance for comparison at a time subsequent to the virtual activity. In other embodiments, comparison with the welding quality parameters is performed in real time with the results being dynamically displayed or catalogued for subsequent review. In addition to the data collected via the input device 13, other types of data may be captured, which include: time and date data, user name, scenario, as well as game status data. It will be appreciated that any type of data may be tracked and stored as needed for determining and reporting the results of game play.
With reference now to FIG. 7, as mentioned above, the simulating device 10 may also comprise a system that facilitates training skills used in industrial or commercial settings. In one exemplary embodiment, the simulating device 10 may depict a virtual welding environment 9 a featuring scenarios having one or more themed articles 16 a consistent with that described above. The simulating device 10 may present the end user 11 with a problem to be solved, e.g. a building structure that needs assembled or a race car frame that needs repaired. The problem may be expressly stated whereby the end user 11 is directly tasked with solving the problem given a set of virtual tools 26. Instructions may be presented describing how the problem should be fixed including which welding techniques or processes should be used. The simulating device 10 may also indicate welder settings or ranges of settings that are needed to weld the virtual article(s) 16 for the given scenario. Additionally, the simulating device 10 may indicate what type of electrode is needed for a particular repair, and/or at what travel speed the weld should be made to make an acceptable virtual weld, which may correspond to a real world weld. However, any type of instruction may be presented to the end user 11 for assembling or repairing the virtual articles 16. It is once again noted that instructions may be displayed in text or audibly presented in any one of various languages, and/or graphically displayed with graphics as is appropriate for different training settings.
As the end user 11 advances, the level of instruction may be adjusted accordingly. At beginner levels, the level of instruction may focus on fundamentals relating to, for example, welding theory, basic welding practices and/or welder set up. Other training levels may provide tutorials related to various weld joint configurations and/or welding with different types of materials and electrodes. More advanced levels may concentrate on particular welding processes and techniques. Of course, each level may be enhanced by one or more scenarios simulating real world activity as described above.
In one embodiment, the welding training may include may be problem-based scenarios. The problem-based scenario may be characterized by incorporating an operational deficiency in a virtual article 16 that must be discovered, analyzed, and a solution formulated by the end user 11. Knowledge learned from a previous lesson or level of training may be relied on for solving the problem. In one example, a race car may be depicted and described as not functioning properly. The virtual environment 9 a may be programmed to present visual, and/or audible, clues that allow the end user 11 to discern the particular problem presented for the given scenario. After analyzing the problem, the end user 11 is directed to devise a solution that, in an exemplary manner, may incorporate: selecting the appropriate welding process, adjusting the welding power supply settings, choosing a particular electrode and then performing a virtual weld. A proper repair therefore requires not only the physical motion of implementing a suitable virtual weld, but also selecting the appropriate welding process and associated parameters. A successful repair or assembly may be indicated, whereby the virtual race car drives away or drives in a race. If an improper or incomplete repair has been made, the race car may perform poorly or not at all with further clues provided to the end user 11 as to what problems remain that need to be fixed. In this manner, welding training encompasses not only the training of muscle memory to successfully perform a particular weld, but also teaches the end user 11 how to properly analyze the virtual article(s) 16 for selecting the appropriate welding process needed to correct its operational deficiency. Welding training may also encompass learning that extends beyond the training of muscle memory by incorporating weld puddle modeling that teaches the end user 11 to make adjustments during the welding process.
As mentioned above, a grade may be derived from the end user's analysis of the problem-based scenario. In one embodiment, the end user 11 may be given information regarding the virtual article's 16 a base material and instructed to select an electrode appropriate for use with that base material. In the real world, selection of an electrode affects the integrity of a weld joint. Similarly selecting the right electrode in the virtual welding environment 9 a affects the score or grade of the end user's 11 performance. Additionally, the end user 11 may be required to calculate the heat input to ensure that the base material properties are not permanently altered by multi-pass welds. In another embodiment, the simulating device 10 may provide the end user 11 with information related to material thickness and/or joint configuration. Accordingly, the end user 11 may be required to determine the appropriate travel speed for the virtual welding power supply settings selected in order to properly make the virtual weld. It is noted here that the information may be expressly stated or indicated by virtual cues from which the end user 11 may infer important factors needed for analyzing the problem. A combination of the aforementioned is also contemplated by the embodiments of the subject invention. It will be recognized that the simulating device 10 therefore functions to educate and evaluate proficiency in learning for science, technology, engineering and/or math as promoted by various educational and governmental institutions.
It may be required that each level of training must be satisfactorily completed before advancing to subsequent levels. In one embodiment, tests may be given related to both welding knowledge and/or virtual welding performance. Data, i.e. test data or performance data, from the current scenario may be tracked, stored and compared against preprogrammed welding parameters in a manner consistent with that described above. In areas where minimum levels of achievement have not been reached, the end user 11 may be given opportunity to review tutorials and/or practice welding a particular weld joint. Once proficiency has been demonstrated, the end user 11 may advance to progressively more difficult levels teaching new skills.
The invention has been described herein with reference to the disclosed embodiments. Obviously, modifications and alterations will occur to others upon a reading and understanding of this specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalence thereof.

Claims

1. A welding training device comprising:

an input device which is manipulated by a user in three-dimensional space during a welding training exercise;

a tracking unit that tracks a position and orientation of said input device in said three-dimensional space, where said tracking unit includes at least one sensor which senses a movement of said input device, where said at least one sensor generates a sensor output which represents said position and orientation;

a processor based computing device which contains at least one predetermined welding performance parameter, said processor based computing device receives said sensor output and generates each of a visually represented weld bead and a visually represented welding tool based on said sensor output, and said processor based computing device uses said sensor output to generate a sensed welding parameter and compares said sensed welding parameter to said predetermined welding performance parameter to generate a performance guide for said user in real-time, where said sensed welding parameter is one of a pitch of said input device, a roll angle of said input device, a travel speed of said input device, or a contact tip to work distance of said input device;

a display coupled to said processor based computing device which displays said visually represented weld bead, said visually represented welding tool and said performance guide during said welding training exercise, where said performance guide is visually changed on said display device based on said comparison between said sensed welding parameter and said predetermined welding performance parameter; and

a weld coupon which is displayed on said display device as a visually represented workpiece for guiding said user during said welding training exercise while said user manipulates said input device in said three-dimensional space with respect to said welding coupon, and where said display device displays said visually represented weld bead on said visually represented workpiece during said welding training exercise.

2. The welding training device of claim 1, wherein said input device resembles a welding tool.

3. The welding training device of claim 1, wherein said input device comprises a switch that initiates and stops said welding training exercise.

4. The welding training device of claim 1, wherein said at least one sensor is an optical sensor.

5. The welding training device of claim 1, wherein said tracking unit is separate from said input device.

6. The welding training device of claim 1, wherein said at least one sensor is positioned on said input device.

7. The welding training device of claim 1, wherein said performance guide is visually changed in real-time based on said comparison.

8. The welding training device of claim 1, wherein said performance guide changes color based on said comparison.

9. The welding training device of claim 1, wherein said processor based computing device contains a plurality of predetermined welding performance parameters, said processor based computing device uses said sensor output to generate a plurality of sensed welding parameters and compares said sensed welding parameters to said predetermined welding performance parameters, respectively, to generate a plurality of performance guides in real-time, where said performance guides indicate, respectively, said pitch of said input device, said roll angle of said input device, said travel speed of said input device, and said contact tip to work distance of said input device.

10. The welding training device of claim 1, wherein said processor based computing device generates a score based on said comparison.

11. The welding training device of claim 1, wherein said display displays said visually represented workpiece in a completed weld state after said welding training exercise.

12. The welding training device of claim 1, wherein a shape of said visually represented weld bead is determined by said processor based computing device based on said sensor output.

13. The welding training device of claim 1, wherein said welding training device has a first mode of operation in which said at least one performance guide is visually displayed on said display and a second mode of operation where said performance guide is not display on said display during operation.

14. The welding training device of claim 1, wherein said welding training device has a first weld training capability where said weld coupon is a lap joint weld coupon and a second weld training capability where said weld coupon is a pipe joint weld coupon.

15. The welding training device of claim 1, wherein said processor based subsystem determines an overall score for said welding training exercise based on said comparison between said sensed welding parameter and said predetermined welding performance parameter.

16. The welding training device of claim 1, wherein said processor based computing device further comprises a predetermined acceptable range of performance for said at least one predetermined welding performance parameter and determines whether said sensed welding parameter is within said predetermined acceptable range, and wherein said processor based computing device calculates a score for said sensed welding parameter based on said determination.

17. The welding training device of claim 1, wherein said processor based computing device records and stores information regarding said welding training exercise, and associates said information to a specific user.

18. The welding training device of claim 1, wherein said user can input a plurality of weld settings for said weld training exercise prior to initiation of said weld training exercise.

19. The welding training device of claim 18, wherein said plurality of weld settings includes at least one of, or a combination of: electrode type, material type for said welding coupon, and weld joint type.

20. A welding training device comprising:

an input device which resembles a welding tool and which is manipulated by a user in three-dimensional space during a welding training exercise, said input device comprising a switch which initiates and stops said welding training exercise;

a tracking unit that tracks a position and orientation of said input device in said three-dimensional space, where said tracking unit includes at least one optical sensor which senses a movement of said input device, where said at least one optical sensor generates a sensor output which represents said position and orientation, and said tracking unit is separate from said input device;

a weld coupon which is displayed on said display device as a visually represented workpiece for guiding said user during said welding training exercise while said user manipulates said input device in said three-dimensional space with respect to said welding coupon, and where said display device displays said visually represented weld bead on said visually represented workpiece during said welding training exercise,

wherein said performance guide is visually changed in real-time based on said comparison.

21. The welding training device of claim 20, wherein said performance guide changes color based on said comparison.

22. The welding training device of claim 20, wherein said processor based computing device contains a plurality of said predetermined welding performance parameters, said processor based computing device uses said sensor output to generate a plurality of said sensed welding parameters and compares said sensed welding parameters to said predetermined welding performance parameters, respectively, to generate a plurality of said performance guides in real-time, where said performance guides indicate, respectively, said pitch of said input device, said roll angle of said input device, said travel speed of said input device, and said contact tip to work distance of said input device.

23. The welding training device of claim 20, wherein said processor based computing device generates a plurality of scores for each of said sensed welding parameters based on said comparisons.

24. The welding training device of claim 20, wherein said display displays said visually represented workpiece in a completed weld state after said welding training exercise is stopped with said switch.

25. The welding training device of claim 20, wherein a shape of said visually represented weld bead is determined by said processor based computing device based on said sensor output.

26. The welding training device of claim 20, wherein said welding training device has a first mode of operation in which said at least one performance guide is visually displayed on said display and a second mode of operation where said performance guide is not display on said display during operation.

27. The welding training device of claim 20, wherein said welding training device has a first weld training capability where said weld coupon is a lap joint weld coupon and a second weld training capability where said weld coupon is a pipe joint weld coupon.

28. The welding training device of claim 20, wherein said processor based subsystem determines an overall score for said welding training exercise based on said comparison between said sensed welding parameter and said predetermined welding performance parameter.

29. The welding training device of claim 20, wherein said processor based computing device further comprises a predetermined acceptable range of performance for said at least one predetermined welding performance parameter and determines whether said sensed welding parameter is within said predetermined acceptable range, and wherein said processor based computing device calculates a score for said sensed welding parameter based on said determination.

30. The welding training device of claim 20, wherein said processor based computing device records and stores information regarding said welding training exercise, and associates said information to a specific user.

31. The welding training device of claim 20, wherein said user can input a plurality of weld settings for said weld training exercise prior to initiation of said weld training exercise.

32. The welding training device of claim 31, wherein said plurality of weld settings includes at least one of, or a combination of: electrode type, material type for said welding coupon, and weld joint type.

33. The welding training device of claim 22, wherein said processor based subsystem determines an overall score for said welding training exercise based on said comparison between said sensed welding parameters and said predetermined welding performance parameters.