Stick welding electrode holders with real-time feedback features.

(54) Title: WELDING ELECTROD SUPPORTS WITH ROD WITH FEEDBACK FEATURES IN REAL TIME.

(54) Title: STICK WELDING ELECTRODE HOLDERS WITH REAL-TIME FEEDBACK FEATURES.

(57) Summary

The present embodiments include systems and methods for rod welding applications. In certain embodiments, simulation rod welding electrode holders may include rod electrode retraction assemblies configured to mechanically retract a simulation rod electrode toward the rod electrode retraction assembly to simulate consumption of the rod electrode. simulation during a simulated rod welding process. In addition, in certain embodiments, rod welding electrode holders may include various input and output elements that allow, for example, control inputs to be entered through the rod welding electrode holders, and which operating states are emitted through the rod welding electrode holders. In addition, in certain embodiments, a welding training system interface can be used to facilitate communication and cooperation of the various rod welding electrode holders with a welding training system.

(57) Abstract

Present implementations Include systems and methods for stick welding applications. In certain embodiments, simulation stick welding electrode holders may include stick electrode retraction assemblies configured to mechanically retract a simulation stick electrode toward the stick electrode retraction assembly to simúlate consumption of the simulation stick electrode during a simulated stick welding process. In addition, in certain embodiments, stick welding electrode holders may include various input and output elements that enable, for example, control inputs to be input via the stick welding electrode holders, and operational statuses to be output via the stick welding electrode holders. Furthermore, in certain embodiments, a welding training system interface may be used to facilitate communication and cooperation of various stick welding electrode holders with a welding training system.

PATENT TITLE No. 359249

<img file="MX359249B_D0001.tif" />

<td>Headlines):</td><td>ILLINOIS TOOL WORKS INC.</td>

<td>Home:</td><td>155 Harlem Avenue, Glenview, Illinois, 60025, USA</td>

Denomination:

WELDING ELECTRODE SUPPORTS WITH ROD WITH FEEDBACK FEATURES IN REAL TIME.

<td>Classification:</td><td>CIP: B23K9 / 095; B23K $ / 28; B23K9 / 32; G09B19 / 00; G09B19 / 24 CPC: B23K9 / 0953; tB23K9 / 32; B23K9 / 282; B23K9 / 0956; G09B5 / 02; G09B19 / 00; G09B19 / 003; G09B19 / 24</td>

<td>Inventor (s):</td><td>WILLIAM JÓSHUA BECKER; DgiVID PAUL MARCUSEN</td>

Number:

MX / a / 2016/010472

SpuClTUD

Date óe * qpentaciónc 11 0AgpÍBt0, c | » 2016 Time:

15:21

Country:

US US i

<img file="MX359249B_D0002.tif" />

July 15, 2016

Number:

62/204,241

15/211,770

Validity: Twenty years

Due date; August 11, 2036

Issue Date: September 20, 2018

The reference patent »e&gt; ® provides on the basis of articles 1", 2 "frafccAn V, β ° fraccsón ltl. and 59 «the Industrial Property Law.

In accordance with article 23 of the Property Law ΙηκΜύφΙ, the ^ rnaaente patent has a validity of twenty non-expendable years, counted from the filing date of the application and will be subject to the payment of the fee to keep the rights in force ..

Who subscribes to this title does so based on the provisions of * articles 6 'fraction * lll and 7 ° bis 2 of the Industrial Property Law (Official Gazette of the Federation (Q.QF,) 06/27/1991 , Reformed on 02'08 / 1994 25.10 / 1996, 12/26/1997, 05/17/1999, 01/26/2004, 06/16/2005, 01/25/2006, 05/06/2009, 01/06/2010. 06/18/2010, 06/28/2010, 01/07/2012 09 (04 / 2012,01 / 06/2016 and 03/13/2018) · articles 1 », 3rd section V clause A). 4 "and 12 'fractions I and lll of the Regulations of the MVMeano Institute of Indusáral Property (DO.F 14/12 / 1Ó99, amended on 07/01/2002, 07/15/2004, 07/28/2004 and 7 / 09/2007); articles Γ, 3 °, 4 ·, 5 ° fragcSq Vwiciso a). 16'Factions I and 1H and 30 of the Organic Statute of the Mexican Institute of Industrial Property (DO F. 12/27/1999 reformed gf'10 / 1W2Ótt ^ j¿07 / ®04, 08/04/2004 and 13 / 0p / 2007); 1, 3 'and 5' clause a) of the Agreement that delegates powers to the Deputy Directors General, CooidiifqpgrfilffectaM * # vieioneléá?! ISu | ee'ie the Regional Offices, Divisional Deputy Directors, Coordinators Departmental and other subordinates of the Mbxicehq mstitmo the Indtfstrial Property (DOF 12/15/1999, amended on 02/04/2000, 07/29/2004, 08/04/2004 and 09/13/2007).

This letter is signed with an advanced electronic signature (FIEL), based on articles 7 BIS 2 of the Industrial Property Law; 3rd of its Regulations, and 1 section III, 2 section V, 26 BIS and 26 TER of the Agreement establishing the guidelines for the use of the Electronic Payment and Services Portal (PASE) of the Mexican Institute of Industrial Property, in the procedures indicated.

THE DIVISIONAL DIRECTOR OF PATENTS

NAHANNY CANAL REYES

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Original string:

NAHANNY MARISOL CANAL REYES | 00001000000403252793 | Administration Service

Tax | 1695 || MX / 2018/79297 | MX / a / 2016/010472 | Normal patent title | 1027 | RGZ | Page (s) | 5l29P3hBIKvPznERVLSyNG8L3dc =

Digital stamp:

EQofFwYzcl3li6QJAfcwllOvQ9 + QLIZc8wRk3ePZY075ft2GUbdOkUZWHn3Mv1AM6epm48gBxucSLWw + gyuULQGAoSQ NSg8ZaYQziPPWv4q1woK2q + Jq7jNd4QIUNDmBcOI5nlqfJfMDk3LSyNvp / n7zM8ymN / YQT / HqNL1HVpz6soJARSRg1 qj + sQVyjMn6g4Ct3TPhZPhKruKULJEOENqGvlRYScLaA04LFKj1Cz / 9RQLxw7 / k50TUwPlvHv4 / vN5TyO5GQnfnKI4 NBYCOjuibimudT2yYPw3LMadFbjY90jtFqaLqXcXKWeTqLEírRPxw2OV4oDwtW / ufCccafHw ==

Arenal No, Pko 1, P.tebia Santa María lepepan, Xoe-'iniilco 160¿í; Mexico City

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MX / 2018/79297

IMPI ^&gt; 3

WELDING ELECTRODE STANDS'OTTWSC £ .A ^ 1S ^^

-------------------------------------------------- jubuí / ihiae— &lt;£ Elí&gt;

REAL-TIME FEEDBACK FEATURES

Cross reference to related requests

This application is a non-provisional US patent application of provisional application No. 62 / 204,241, entitled “Rod Welding Electrode Supports with Real-Time Feedback Characteristics,” filed on August 12, 2015, which is incorporated herein by reference in its entirety for all purposes.

Background of the Invention

The present invention relates generally to welding and, more particularly, to a welding system that can be used to monitor a welding environment and handle welding data associated with electrode supports for arc protected metal welding (SMAW) in the environment. data, such as weld data collected from the weld environments during and / or after welding.

Welding is a process that is increasingly used in various industries and applications. These processes can be automated in certain contexts, although there continue to be a large number of applications for manual welding operations. In both cases, such welding operations rely on a variety of equipment types to ensure that the supply of welding consumables (for example, wire feed, shielding gas, etc.) is provided to the weld in adequate amounts in the desired moment.

In preparation for manual welding operations, the

<img file="MX359249B_D0005.tif" />

(by welding operators can be trained using

<img file="MX359249B_D0006.tif" />

FROM INDUSTRIAL PROPERTY (example, a welding training system). The welding system can be designed to train welding operators with the proper techniques to carry out various welding operations. Certain welding systems can use various training methods. As can be appreciated, these training systems can be expensive to acquire and operate. Consequently, welding training institutions can only purchase a limited number of such training systems. Furthermore, certain welding systems may not adequately train welding operators to perform high-quality welds.

Brief description of the drawings

These and other features, aspects, and advantages of the present invention will be better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent similar parts throughout the drawings, wherein:

FIG. 1 is a block diagram of one embodiment of a welding system in accordance with aspects of the present invention.

Figure 2 is a block diagram of an embodiment of portions of the welding system of Figure 1 in accordance with aspects of the present invention.

Figure 3 is a perspective view of one embodiment of the weld base of Figure 1 in accordance with aspects of the present invention.

Figure 4 is a perspective view of one embodiment of a calibration device in accordance with aspects of the present invention.

FIG. 5 is a perspective view of one embodiment of a fastening assembly in accordance with aspects of the present invention.

<img file="MX359249B_D0007.tif" />

MEXICAN INSTITUTE OF INDUSTRIAL PROPERTY

<img file="MX359249B_D0008.tif" />

Figure 6 is a perspective view of one embodiment of a vertical arm assembly of the weldment of Figure 1 in accordance with aspects of the present invention.

Figure 7 is a perspective view of one embodiment of an overhead welding arm assembly in accordance with aspects of the present invention.

Figure 8 is a block diagram of a welding software embodiment having various training modes in accordance with aspects of the present invention.

FIG. 9 is a block diagram of one embodiment of a welding software virtual reality mode in accordance with aspects of the present invention.

Figure 10 is an embodiment of a method for integrating training result data in accordance with aspects of the present invention.

FIG. 11 is an embodiment of a graph illustrating various sets of welding data for a welding operator in accordance with aspects of the present invention.

FIG. 12 is an embodiment of a graph illustrating weld data for a welder compared to weld data for a class in accordance with aspects of the present invention.

FIG. 13 is a block diagram of one embodiment of a data storage system (eg, cloud storage system) for storing certification status data in accordance with aspects of the present invention.

Figure 14 is an embodiment of a screen illustrating data that

I jM. P1 correspond to a weld according to aspects of • NDUSTíial

Fig. 15 is a block diagram of one embodiment of a welding software instructor screen in accordance with aspects of the present invention.

Figure 16 is an embodiment of a method for welding training using augmented reality in accordance with aspects of the present invention.

Figure 17 is an embodiment of another method for welding training using augmented reality in accordance with aspects of the present invention.

FIG. 18 is a block diagram of one embodiment of a welding tool in accordance with aspects of the present invention.

FIG. 19 is an embodiment of a method of providing vibration feedback to a welding operator using a welding tool in accordance with aspects of the present invention.

FIG. 20 is a graph of an embodiment of two patterns each including a different frequency to provide vibration feedback to a welding operator in accordance with aspects of the present invention.

Figure 21 is a graph of an embodiment of two patterns each including a different modulation to provide vibration feedback to a welding operator in accordance with aspects of the present invention.

Figure 22 is a graph of an embodiment of two patterns each including a different amplitude to provide vibration feedback to a welding operator in accordance with aspects of the present invention.

Figure 23 is a perspective view of a welding tool having spherical markers that can be used to track the welding tool in accordance with aspects of the present invention.

IMPI

Figure 24 is a perspective view ^^^ Ui ^ EÍ ^ ility-f ^ j of the industrial welding tool, taken along line 24-24 of Figure 23 in accordance with aspects of the present invention.

Figure 25 is a top view of one embodiment of the welding tool and visual markers in accordance with aspects of the present invention.

Fig. 26 is an embodiment of a method for visually presenting to a visual presenter of a welding tool a welding parameter relative to a threshold according to aspects of the present invention.

Fig. 27 is an embodiment of a set of screenshots of a visual display of a welding tool to show a welding parameter relative to a threshold in accordance with aspects of the present invention.

Figure 28 is an embodiment of a method of tracing a welding tool in a welding system using at least four markers in accordance with aspects of the present invention.

FIG. 29 is an embodiment of a method for detecting the ability of a processor to communicate with a welding tool in accordance with aspects of the present invention.

Figure 30 is an embodiment of a method for calibrating a curved weld joint that can be used with a weld system in accordance with aspects of the present invention.

FIG. 31 is a diagram of one embodiment of a curved weld joint in accordance with aspects of the present invention.

Figure 32 is a diagram of one embodiment of a curved weld joint and a marking tool in accordance with aspects of the present invention.

Figure 33 is a modality of a method to trace a sw-M.-nís operation^-

IMPI multi-pass welding according to aspects of the?

Figure 34 is a perspective view of one embodiment of a welding base in accordance with aspects of the present invention.

FIG. 35 is a cross-sectional view of one embodiment of a weld surface of the weld mount of FIG. 34 in accordance with aspects of the present invention.

FIG. 36 is a cross-sectional view of one embodiment of a detection device having a removable cover in accordance with aspects of the present invention.

Figure 37 is a perspective view of one embodiment of a calibration tool in accordance with aspects of the present invention.

FIG. 38 is a perspective view of the calibration tool of FIG. 37 having an outer cover removed in accordance with aspects of the present invention.

FIG. 39 is a side view of one embodiment of a sharp tip of a calibration tool in accordance with aspects of the present invention.

FIG. 40 is a side view of one embodiment of a rounded tip of a calibration tool in accordance with aspects of the present invention.

FIG. 41 is a side view of one embodiment of a rounded tip of a calibration tool having a small sharp tip in accordance with aspects of the present invention.

Figure 42 is an embodiment of a method for detecting a calibration point in accordance with aspects of the present invention.

Figure 43 is an embodiment of a method for determining a

IMPI ¢ 31¾½ · weld score based on an afeniscIdaduwcde / áóuQrcIfflcon path ^{r 7} OF PROPERTY V?. ·. · · \ L^:J

INDUSTRIAL aspects of the present invention.

FIG. 44 is an embodiment of a method for switching between welding modes using a user interface of a welding tool in accordance with aspects of the present invention.

Figure 45 is an embodiment of a remote welding training system in accordance with aspects of the present invention.

Figure 46 is an embodiment of a dashboard page with weld data from different operators, in accordance with aspects of the present invention.

Figure 47 is an embodiment of a depth sensor welding system and a local placement system, in accordance with aspects of the present invention.

Fig. 48 is an embodiment of a method for controlling visual markers of the welding tool to track movement and position of the welding tool, in accordance with aspects of the present invention.

Figure 49 is a cross-sectional view of a base component with visual markers, in accordance with aspects of the present invention.

FIG. 50 is a perspective view of one embodiment of the assembly of arms and fastening of the welding support, according to aspects of the present invention.

Figure 51 is a top view of one embodiment of a clamp assembly of Figure 50, taken along line 51-51, in accordance with aspects of the present invention.

Figure 52 is a perspective view of one embodiment of a calibration block coupled to the clamp assembly of Figure 50, in accordance with aspects of the present invention.

<img file="MX359249B_D0009.tif" />

MEXICAN INSTITUTE OF INDUSTRIAL PROPERTY

<img file="MX359249B_D0010.tif" />

Figure 53 is an embodiment of a method for installing the arms of the weld bracket from an out-of-position weld allowance, in accordance with aspects of the present invention.

FIG. 54 is an embodiment of a method for selecting and executing a multi-pass weld assignment with the weld system, in accordance with aspects of the present invention.

Fig. 55 is an embodiment of a screen illustrating data, including arc parameters, corresponding to a weld in accordance with aspects of the present invention.

Figure 56 is an embodiment of a screen illustrating data corresponding to a weld test for which an arc has not been detected in accordance with aspects of the present invention.

Figure 57 is an embodiment of a screen illustrating allocation development routines in accordance with aspects of the present invention.

FIG. 58 is an embodiment of a screen illustrating properties that relate to a welding procedure in accordance with aspects of the present invention.

FIG. 59 is an embodiment of a display screen illustrating data corresponding to a simulated weld in accordance with aspects of the present invention.

FIG. 60 is an embodiment of a screen illustrating data corresponding to a weld prior to the start of the weld in accordance with aspects of the present invention.

Figure 61 is a modality of a screen illustrating a summary of welding test parameters according to aspXt ^ X ^ p ^ s ^ i ^ eWei ^ ióri.

MEXICAN INSTITUTE OF PROPERTY 1 ^ '

Figure 62 is an embodiment of a screen that^orSample Data - Including arc parameters, which correspond to a weld during a weld test in accordance with aspects of the present invention.

Figure 63 is an embodiment of a screen illustrating data, including heat input, corresponding to a weld in accordance with aspects of the present invention.

Figures 64A and 64B illustrate one embodiment of a simulation rod welding electrode holder in accordance with aspects of the present invention.

Figures 65A and 65B illustrate one embodiment of a real rod welding electrode holder in accordance with aspects of the present invention.

Figures 66A and 66B illustrate embodiments of a simulation rod welding electrode holder and a real rod welding electrode holder, respectively, in accordance with aspects of the present invention.

Fig. 67 is an embodiment of a rod electrode holder assembly of a simulation rod welding electrode holder in accordance with aspects of the present invention.

FIG. 68A is an embodiment of an actual rod welding electrode holder having a plurality of discrete rod electrode holder slots in accordance with aspects of the present invention.

FIG. 68B is an embodiment of a jaw of the actual rod welding electrode holder of FIG. 68A, illustrating the plurality of discrete rod electrode holder slots in accordance with aspects of the present invention.

Figure 68C is an embodiment of an on-screen indication referring to the use of the plurality of electrode support slots.

INDUSTRIAL figure 68B, in accordance with aspects of the present invention.

Figures 69A and 69B illustrate button panel arrangements of a simulation rod welding electrode holder and a real rod welding electrode holder, respectively, in accordance with aspects of the present invention.

Figure 70 is an embodiment of a rod welding electrode holder having a button panel on a handle in accordance with aspects of the present invention.

Figure 71 is an embodiment of a rod welding electrode holder having a button panel in an outer support structure in accordance with aspects of the present invention.

Figures 72A and 72B illustrate status indicator modalities of a simulation rod welding electrode holder and a real rod welding electrode holder, respectively, in accordance with aspects of the present invention.

Fig. 73 is an embodiment of a screen illustrating parameters corresponding to a rod welding process in accordance with aspects of the present invention.

Fig. 74 is an embodiment of a screen illustrating a selection graph (eg, visual guides) for a rod welding process in accordance with aspects of the present invention.

Fig. 75 is an embodiment of a screen illustrating the selection graph (eg, visual guides) just prior to the start of the rod welding process in accordance with aspects of the present invention.

Figure 76 is a modality of aIajb ^ a- ^ j¿if ^ tta^&gt;eL / a); iro del

INSTITUTO MEXICANO v - T. / 'ft Di LA reOMEDAD selection graph (for example, visual guides) during the performance of the welding process according to aspects of the prutídl lid invention ”

Figure 77A is an embodiment of a rod welding electrode holder having the selection chart (eg, visual guides) in accordance with aspects of the present invention.

Figure 77B is an embodiment of a handheld device having the selection chart (eg, visual guides) in accordance with aspects of the present invention.

Figure 77C is an embodiment of a rod welding electrode holder having a projection system configured to project the selection graph (eg, visual guides) onto a workpiece in accordance with aspects of the present invention.

Fig. 78 is an embodiment of a rod welding electrode holder having graphical interval gauges in accordance with aspects of the present invention.

FIG. 79 is an embodiment of a position calibration device configured to slide on a tip of a rod welding electrode in accordance with aspects of the present invention.

Figures 80A and 80B are display modalities illustrating assignment lists for an actual rod welding process and a simulated rod welding process, respectively, in accordance with aspects of the present invention.

Fig. 81 is an embodiment of a screen illustrating a calibration procedure for a rod welding electrode holder in accordance with aspects of the present invention.

Figure 82 is an embodiment of a pan

<img file="MX359249B_D0011.tif" />

e additional aids in accordance with aspects of the present invention.

Fig. 83 is an embodiment of a screen illustrating parameters corresponding to a rod welding process (including feed rate) in accordance with aspects of the present invention.

FIG. 84 is a schematic diagram of one embodiment of a junction box for use with the welding training system in accordance with aspects of the present invention.

FIG. 85 is a tabular summary of one embodiment of a state machine for the junction box of FIG. 84 in accordance with aspects of the present invention.

Detailed description of the invention

FIG. 1 is a block diagram of one embodiment of one or more welding systems 10. As used herein, a welding system can include any suitable welding related system, including, but not limited to, a welding training system, a live welding system, a remote welding training system (for example, helmet training system), a simulated welding system, a virtual reality welding system and so on. For example, the welding system 10 may include, but is not limited to, a LiveArc ™ welding performance management system, which is a welding training system available from Miller Electric of Appleton, Wl. The welding system 10 may include a welding base 12 to provide support for various training devices. For example, weld base 12 can be configured to support a weld surface, a

<img file="MX359249B_D0012.tif" />

IMPI workpiece 82, one installation, one or more braae ^^ 'g ^ J ^ gn

INDUSTRIAL on. Welding system 10 includes one or more welding tools 14 that can be used by a welding operator (eg, welding student) to carry out welding operations (eg, training operations). As described in greater detail below, in certain embodiments, the welding tools 14 can be configured with a user interface configured to receive inputs from the welding operator, control circuits configured to process the inputs, and a communication interface configured to provide inputs to another device. Furthermore, in certain embodiments, the welding tool 14 may include one or more visual displays and / or indicators to provide data to the welding operator. In certain embodiments, the welding tool 14 can be a fully functional welding torch or electrode holder capable of generating a live arc between the welding wire or a welding electrode and a workpiece 82. In contrast, in other embodiments, the welding tool 14 may be a simulation welding torch or electrode holder that is not capable of generating a live arc between the welding wire or a welding electrode and a workpiece 82, but rather it may be configured to simulate the generation of a live arc between the welding wire or a welding electrode and a workpiece 82.

Furthermore, in certain embodiments, the welding system 10 includes one or more detection devices 16 (eg, sensor, detection assembly, and so on) used to detect a position of one or more welding devices and / or to detect an orientation of one or more welding devices. For example, the detection device 16 can be used to detect a position and / or an orientation of the welding base 12, the welding tool 14, a surface of

<img file="MX359249B_D0013.tif" />

T · '- welding, workpiece 82, an installation, one or ¡j ^ eW ^ ámtéMO, el

OF INDUSTRIAL PROPERTY - operator, an identification card, and so on. The one or more detection devices 16 can include any suitable detection device, such as a motion detection device or a motion tracking device.

Furthermore, one or more detection devices 16 can include one or more cameras, such as one or more infrared cameras, one or more visible spectrum cameras, one or more high dynamic range (HDR) cameras, and so on. Alternatively, or in addition, the one or more detection devices 16 may include one or more depth sensors for determining relative distances between the respective depth sensors and an object (eg, welding tool 14, workpiece 82, operator , and so on). The one or more detection devices 16 can be placed at various locations around the welding environment of the welding system 10, thereby making it possible for certain detection devices 16 to monitor the welding environment (eg, track the movement of an object ) when other detection devices 16 are obscured. For example, a detection device 16 (eg, camera, depth sensor) integrated with a welding helmet 41 can facilitate tracking of the position, orientation and / or movement of the welding tool 14 with respect to the part of work 82 when the welding tool 14 is at least partially obscured from other detection devices 16 by the workpiece 82 or the operator. Furthermore, a detection device 16 (eg, accelerometer) integrated with the welding tool 14 can facilitate tracking the position, orientation and / or movement of the welding tool 14 relative to the workpiece 82 when the welding tool Weld 14 is at least partially obscured from other detection devices 16 (eg cameras, depth sensors) by the workpiece 82 or the operator.

The one or more detection devices [l ^^ o ^ afp ^ dós ^ - 'e ^ forñna

MEXICAN INSTITUTE S.

DJE TO PRORI AGES communicative to a computer 18. The one or more devices 09^orItem '^TOdete'Ccron '16 are configured to supply data (eg daios-de4megen7-data ^ cüstícos, data detected, six degree of freedom (6DOF) data, etc.) to computer 18. Furthermore, the one or more Detection devices 16 can be configured to receive data (for example, configuration data, programming data, commands, registry settings, etc.) from computer 18. Computer 18 includes one or more processors 20, memory devices 22, and storage devices 24. Computer 18 may include, but is not limited to, a desktop computer, a laptop, a tablet, a mobile device, a computer that can be carried, or any combination thereof. The processors or processor 20 can be used to run software, such as welding software, image processing software, detection device software, and so on. In addition, processors 20 may include one or more microprocessors, such as one or more "general purpose" microprocessors, one or more special purpose microprocessors and / or application specific integrated circuits (ASICS), or some combination thereof. For example, processors 20 may include one or more reduced instruction set (RISC) processors.

Storage device (s) 24 (eg, non-volatile storage) may include ROM, flash memory, a hard drive, or any other suitable solid state, magnetic or optical storage medium, or a combination thereof. The storage devices 24 can store data (for example, data corresponding to a welding operation, video data and / or parameters corresponding to a welding operation, data corresponding to an identity and / or a registration number of the operator, data corresponding to the execution of operad

<img file="MX359249B_D0014.tif" />

OF PROHEDAP

INDUSTRIAL

<img file="MX359249B_D0015.tif" />

(eg, software or firmware for the welding system, the one or more detection devices 16, etc.), and any other suitable data. As will be appreciated, data corresponding to a welding operation may include a video recording of the welding operation, a simulated video, an orientation of the welding tool 14, a position of the welding tool 14, a working angle , a displacement angle, a distance between a contact tip of the welding tool 14 and a workpiece, a displacement speed, a target, a voltage, a current, a traversed path, a discontinuity analysis, welding device configurations, and so on.

Memory devices 22 can include volatile memory, such as random access memory (RAM), and / or nonvolatile memory, such as read-only memory (ROM). Memory devices 22 can store a variety of information and can be used for various purposes. For example, memory devices 22 may store executable instructions per processor (eg, firmware or software) for processors 20 to execute, such as instructions for a welding training simulation, for the one or more detection devices 16 , and / or for an operator identification system 43. In addition, a variety of control regimes for various welding processes, along with associated settings and parameters, can be stored in storage devices 24 and / or memory devices 22, along with code configured to provide a specific output (for example, initiate wire feed, enable gas flow, capture weld current data, detect short circuit parameters, determine spatter amount, etc.) during operation. Welding power source 28 can be used to provide welding power to a

<img file="MX359249B_D0016.tif" />

live arc welding operation, and rse feeder

Ut LA rRVrtfclJALJ to provide solder wire to the soldering operation PVíSVrárcó ^ ffWÓ.

In certain embodiments, the welder system'tOinduyg-a visual presenter 32 to visually display data and / or displays associated with welding (eg, to visually display data that corresponds to welding software). For example, visual presenter 32 may provide a graphical user interface to a welding operator (eg, welding instructor, welding student). The graphical user interface can provide various screens to enable the welding instructor to organize a class, provide assignments to the class, analyze the assignments carried out by the class, provide assignments to an individual, analyze the assignments carried out by the individual, add, change, and / or delete parameters for a weld assignment, and so on. Furthermore, the graphical user interface can provide various screens to enable a weld operator (eg weld student) to perform a weld assignment, view results of previous weld assignments, and so on. In certain embodiments, the visual presenter 32 may be a touch screen visual presenter configured to receive touch inputs, and to provide data corresponding to the touch inputs to computer 18.

In certain embodiments, an external visual presenter 34 may be coupled to the computer 18 to enable an individual who is located away from the welding system 10 to view data that corresponds to the welding system 10. Furthermore, in certain embodiments, a device Network 36 can be coupled to computer 18 to enable computer 18 to communicate with other devices connected to the internet or another network 38 (for example, to provide results

<img file="MX359249B_D0017.tif" />

test to another device and / or to receive test results

INDUSTRIAL example, network device 36 may enable computer 18 to be, | -r — y — r ~ ri&gt; t ~ r ~ ~ .i - ι. ··· ιιιιι · τυι · τ iirri. * 'Rrm :

communicate with an external welding system 40, a production welding system 42, a remote computer 44 and / or a data storage system (eg, cloud storage system) 318. As can be seen, the Solder 10 described here can be used to train welding students in an economical way. In some embodiments, the one or more welding systems 10 may include a helmet 41 having a visual presenter 32 and one or more detection devices 16, such as optical or acoustic detection devices. As described in detail below, helmet 41 communicatively couples to computer 18, and helmet 41 can facilitate welding training and / or welding monitoring without weld base 12. In some embodiments, the one or more detection devices 16 integrated with the helmet 41 can facilitate welding training and / or welding monitoring without separate detection devices 16 external to the helmet 41. In addition, the welding system 10 is configured to integrate real welding with simulated welding in a way that prepares welding students for high-quality production welding.

In certain embodiments, an operator identification system 43 can be coupled to computer 18 to enable an operator using the welding system 10 to be identified. The operator identification system 43 uses one or more types of operator information (eg identifiers) to identify the operator. Operator information may include, but is not limited to, a resettable identifier 45 (eg, password, motion sequence, action performed by operator), a biometric identifier 47 (eg, retinal scan, fingerprint, printout of palm, facial profile, voice profile, operator traits

<img file="MX359249B_D0018.tif" />

Inherent IMPIfi), information based on at least part of a token 49 (for example, key, key fob, radio frequency identification (RFID) tag, access card, barcode, physical identifier), or any combination thereof . Alternatively, or in addition, an instructor or manager may provide an input to the operator identification system 43 to identify the identity of the operator, thereby authorizing the operator for the welding session (eg, welding assignment) and welding data. associates. That is, the identification of an operator may involve one or more steps, such as identification of the operator through information received from the operator, and verification of the operator through information received from the instructor and / or manager of the operator. In some embodiments, the operator identification system 43 can use the one or more detection devices 16 to facilitate operator identification. For example, a camera or microphone of the welding system 10 may receive the biometric identifier 47. In addition, the operator identification system 43 may have an input device 51 (eg, keyboard, touch screen, retinal scanner, fingerprint sensor). digital, camera, microphone, barcode scanner, radio transmitter, and so on) configured to receive the one or more types of operator identification information.

The operator identification system 43 can identify the operator before carrying out a welding process (for example, live process, training process, simulated process, virtual reality process) or after carrying out the welding process . In some embodiments, the operator identification system 43 can enable or block an operator to use the welding system 10 based on the one or more identifiers received through the input device 51. For example, the operator identification system operator 43 can block a first operator (eg student) from using the system

<img file="MX359249B_D0019.tif" />

operator identification system 43 receives a first first operator input that can identify the first operator. In some embodiments, the welding system 10 may enable the first operator to carry out a welding session with the welding system 10 without verification of the identity of the first operator; however, the welding system 10 can store and / or transmit the welding data associated with such a welding session only after verification of the identity of the first operator based at least in part on a second input by a second operator ( for example, instructor, administrator). That is, the operator identification system 43 can disable the storage or transmission of the welding data associated with a welding session until the identity of the first operator who carried out the welding session is verified by the second operator. Furthermore, some modalities of the welding system 10 may block the first operator from using the welding system until a second input is received from the second operator verifying the identity of the first operator, which was preliminarily determined based on the first input of the first operator. In some embodiments, the operator identification system 43 can identify the operator during a welding process, such as through an operator identification feature during the welding process. For example, a first operator may hold welding tool 14 differently than a second operator, and a detection device 16 (eg, camera) coupled to operator identification system 43 may facilitate distinguishing the first operator from the second operator. . As an alternative, or in addition, the operator identification system 43 may include a sensor (eg, fingerprint scale, camera, microphone) in the welding tool 14 and / or helmet 41. In some embodiments, an instructor and /or

<img file="MX359249B_D0020.tif" />

a manager can confirm after the conclusion of an identified operator carried out the welding process

The operator identification system 43 can communicate with the computer 18 to determine the identity of the operator using the received identification information. In some embodiments, computer 18 may communicate with network 38 and / or a remote computer 44 to determine the identity of the operator. Computer 18 can control visual presenter 32 to visually display at least a portion of the information associated with the operator after operator identification. For example, the visual presenter 32 may present the name, a photograph, registration number, experience level, or any combination thereof. In some embodiments, the operator identification system 43 can be used with one or more welding systems 10.

Computer 18 can receive weld data (eg, weld parameters, arc parameters) that correspond to a weld session (eg, weld assignment) during and / or after the respective weld session is brought to performed by the operator. Computer 18 can receive welding data from network 38, one or more detection devices 16, welding tool 14, welding power source 28, wire feeder 30 or helmet 41, or any combination thereof. Alternatively, or in addition, the computer 18 may associate the received weld data with the identity of the operator, such as through a unique registration number for the operator, the operator's name and / or a photograph of the operator. Furthermore, computer 18 can transmit the associated weld data and operator identity (eg, registration number to a data storage system within weld system 10 or located far through network 38. The association of the welding data with the identity of the operator (for example,

Say THE PROPERTY

INDUSTRIAL

<img file="MX359249B_D0021.tif" />

«.

istro) makes significantly more possible than connecting unassociated weld data from operators. That is, associating weld data with a unique operator registration number makes it possible for someone (eg operator, instructor, manager) who is either local or remote from the operator to track performance, progress and capabilities. operator over time through the registration number.

FIG. 2 is a block diagram of one embodiment of portions of the welding system 10 of FIG. 1. As illustrated, in certain embodiments, a power distribution assembly 46 provides power to the welding tool 14 and the computer. 18. In addition, the welding tool 18 includes control circuits 52 configured to control the operation of the welding tool 14. In the illustrated embodiment, control circuits 52 include one or more processors 54, memory devices 56, and storage devices 58. In other embodiments, control circuits 52 may not include processors 54, memory devices 56, and / or or storage devices 58. Processors 54 can be used to run software, such as solder tool software.

Furthermore, the processors 54 may be similar to the processors 20 described above. Furthermore, memory devices 56 may be similar to memory devices 22, and storage devices 58 may be similar to storage devices 24.

In certain embodiments, the welding tool 14 includes a user interface 60 to enable a welding operator (eg, welding student, welding instructor, etc.) to interact with the welding tool 14 and / or provide inputs to the soldering tool 14. For example, user interface 60 may include buttons, switches, touch screens, alphanumeric keyboards, scanners, and so on.

Inputs proportfflSoaí ^^^ í ^ ffamtghfe from welding 14 by the welding operator can be supplied to the computer. 18.

For example, the inputs provided to the welding tool 14 can be used to control welding software being executed by the computer 18. In this way, the welding operator can use the user interface 60 on the welding tool 14 to navigate the welding software screens, setup procedures, data analysis, welding courses, make selections within the welding software , configure the welding software, and so on. In this way, the welding operator can use the welding tool 14 to control the welding software (for example, the welding operator does not have to lower the welding tool 14 to use a different input device). In certain embodiments, the welding tool 14 also includes visual indicators 61, such as a visual presenter 62 and LEDs 64. Visual indicators 61 can be configured to visually indicate or display data and / or images corresponding to a weld, weld training and / or weld software. For example, visual indicators 61 can be configured to indicate a welding tool orientation, a welding tool travel speed, a welding tool position, a contact tip to workpiece distance, a tool target 14, a training information for the welding operator, and so on. Furthermore, the visual indicators 61 can be configured to provide visual indications before a weld, during a weld and / or after a weld. In certain embodiments, LEDs 64 may be illuminated to facilitate detection by the one or more detection devices 16. In such embodiments, LEDs 64 may be positioned to enable the one or more detection devices 16 to determine a ^ o ^ uíOOec ^ ion of the

MEXICAN INSTITUTE

PROPERTY 14 position based welding tool is ^ ciaTcle LEDs 64.

Returning to Figure 2, in cieilUS friodahdades, the ™ welding tool 14 includes power conversion circuits 66 configured to receive power from the power distribution assembly 46, the computer 18 or other device, and to convert the received power to power the welding tool 14. In certain embodiments, the welding tool 14 may receive power that has already been converted and / or not use power conversion. Furthermore, in some embodiments, the welding tool 14 can be powered by a battery or any suitable energizing mechanism. In certain embodiments, the welding tool 14 also includes a communication interface 68 (eg, RS-232 controller) to facilitate communication between the welding tool 14 and computer 18.

In embodiments where the welding tool 14 is a welding torch, the welding tool 14 may include a trigger 70 configured to mechanically actuate a trigger switch 72 between an open position (as illustrated) and a closed position. Trigger 70 provides a lead 71 to carry a signal to control circuits 52 to indicate whether trigger switch 72 is in the open or closed position. Wire feeder 30, welding power source 28 and / or computer 18 can determine if there is continuity through welding tool 14 through a first trigger lead 74 and a second trigger lead 76. The Trigger switch 72 is electrically coupled between the first trigger lead 74 and the second trigger lead 76. Continuity across first trigger lead 74 and second trigger lead 76 can be determined by applying a voltage across leads 74 and 76,

<img file="MX359249B_D0022.tif" />

<img file="MX359249B_D0023.tif" />

apply a current through conductors 74 and ⁷ INDUSTRIAL conductors 74 and 76, and so on. In certain embodiments, portions of the first, trigger lead 74 and / or portions of the second trigger lead 76 may be arranged within a connector of the welding tool 14. In addition, in certain embodiments, the arrangement of switches and / or leads inside the welding tool 14 may be different than that illustrated in figure 2.

Welding power source 28 can determine whether it allows welding power to flow through welding tool 14 based on whether there is continuity across conductors 74 and 76. For example, the welding power source 28 can allow welding power to flow through the welding tool 14 as long as there is continuity across the conductors 74 and 76, and the welding power source 28 can block that power solder flow through the soldering tool 14 as long as there is an open circuit through conductors 74 and 76. Furthermore, wire feeder 30 can provide solder wire to solder tool 14 as long as there is continuity across conductors 74 and 76, and can block solder wire from being supplied to solder tool 14 as long as there is a circuit open through conductors 74 and 76. Additionally, computer 18 can use continuity across leads 74 and 76 and / or the position of trigger 60 or trigger switch 72 to start and / or stop a welding operation, a simulation of welding, recording data, and so on.

With trigger switch 72 in the open position, there is an open circuit through leads 74 and 76, thus, the open position of trigger switch 72 blocks the flow of electrons between leads 74 and 76. Accordingly , the welding power source 28 can block welding power from flowing to

IMPI e '^ J ^ ajedelock through the soldering tool 14 and the

<img file="MX359249B_D0024.tif" />

that welding wire is provided to the welding tool 1A_. Depressing trigger 70 directs trigger switch 72 to the closed position where trigger switch 72 remains as long as trigger 70 is depressed. With trigger switch 72 in the closed position, there is continuity between the first trigger lead 74 and a lead 77 electrically connected to trigger switch 72 and a training switch 78.

Training switch 78 is electrically coupled between first trigger lead 74 and second trigger lead 76. Furthermore, training switch 78 is electrically controlled by control circuit 52 to an open or closed position. In certain embodiments, training switch 78 can be any suitable electrically controlled switch, such as a transistor, relay, etc. Control circuit 52 can selectively control training switch 78 to the open or closed position. For example, while the welding software of the welding system 10 is operating in a live arc mode, the control circuit 52 can be configured to control the training switch 78 to the closed position to enable a live arc weld. while trigger 70 is depressed. In contrast, while the welding software of the welding system 10 is operating in any mode other than live arc mode (eg simulation, virtual reality, augmented reality, etc.), control circuit 52 can be configured to control training switch 78 to the open position to block a live arc (by blocking the flow of electrons between conductors 74 and 76).

In certain modalities, training switch 78 can return to the open position in a preset manner, thereby establishing a circuit

IMPI

MEXICAN INSTITUTE

<img file="MX359249B_D0025.tif" />

open across leads 74 and 76. As training switch 78 is in the open position, there will be an open circuit across leads 74 and 76 regardless of the position of trigger switch 72 (eg, flow of Electrons between conductors 74 and 76 is blocked by the open position of training switch 78). However, while training switch 78 is controlled to the closed position, and trigger switch 72 is in the closed position, conductivity is established between conductors 74 and 76 (for example, flow of electrons between conductors 74 and 76 is enabled). Accordingly, the welding power source 28 can enable welding power to flow through the welding tool 14 only while the training switch 78 is in the closed position and while the trigger switch 72 is in the closed position. . For example, welding energy can flow from the welding energy source 28, through a welding cable 80, the welding tool 14, a workpiece 82, and back to the welding energy source 28 through from a work cable 84 (for example, negative electrode or direct polarity). Conversely, welding energy can flow from the welding power source 28, through the work cable 84, the workpiece 82, the welding tool 14, and back to the welding power source 28 through the welding cable 80 (eg, positive electrode, or reverse polarity).

As can be appreciated, the training switch 78 can be physically located in any suitable portion of the welding system 10, such as computer 18, and so on. Furthermore, in certain embodiments, the functionality of the training switch 78 can be replaced by any suitable hardware and / or software in the welding system 10.

Figure 3 is a perspective view of one embodiment of the base of

IMPI7Í

MEXICAN INSTITUTE í 'includes H ^^ S ^ rftefesoidadura' IV weld 12 of figure 1. The weld base 12 in which live welds can be carried out (by exerpojo- soidariiiras.raaias_;true welds) and / or simulated welds. Feet 90 provide support to weld surface 88. In certain embodiments, weld surface 88 may include slots 91 to assist a weld operator in positioning and orienting workpiece 82. In certain embodiments, the position and orientation of Workpiece 82 can be provided to the welding software of the welding system 10 to calibrate the welding system 10. For example, a weld operator can provide an indication to the weld software that it identifies which slot 91 of the weld surface 88 the workpiece 82 is aligned with. Furthermore, a predefined weld assignment can direct the weld operator to align workpiece 82 with a particular slot 91. In certain embodiments, workpiece 82 may include an extension 92 configured to extend within one or more of grooves 91 for alignment of workpiece 82 with one or more grooves 91. As can be appreciated, each of grooves 91 can be placed in a location corresponding to a respective location defined in the welding software.

In certain embodiments, the weld surface 88 includes a first opening 93 and a second opening 94. The first and second openings 93 and 94 can be used together to determine a position and / or orientation of the weld surface 88. As You can see, in certain embodiments, at least three openings can be used to determine the position and / or orientation of the weld surface 88. In some embodiments, more than three openings can be used to determine the position and / or orientation of the weld surface 88. The first and second openings 93 and 94 can be placed in any suitable location on the weld surface 88, and can be of any suitable size. In certain embodiments, the position and / or orientation of the weld surface

<img file="MX359249B_D0026.tif" />

detection devices 16 can be calibrated using the first and second openings 93 and

93. For example, as described in greater detail below, a calibration device configured to be detected by one or more detection devices 16 may be inserted into the first opening 93, or touched to the first opening 93. As the calibration device is inserted into, or touches, the first opening 93, a user input provided with the welding software (or other calibration software) may indicate that the calibration device is inserted into the first opening 93. As a result, the welding software can establish a correlation between a first set of data (eg, calibration data) received from the one or more detection devices 16 (eg, position and / or orientation data) at first. and the location of the first opening 93. The calibration device can then be inserted into the second opening 94, or touched to the second opening 94. As the calibration device is inserted into, or touches, the second opening 94, a user input provided with the welding software may indicate that the calibration device is inserted into the second opening 94. As a result, the welding software can establish a correlation between a second data set (eg, calibration data received from the one or more detection devices 16 at a second time and the location of the second opening 94). Thus, the welding software may be able to calibrate the position and / or orientation of the welding surface 88 with respect to one or more detection devices 16 using the first data set received at the first time and the second data set received in the second moment.

In certain embodiments, the weld surface 88 also includes a first marker 95 and a second marker 96. The first and second markers 95 and 96 can be used together to determine a position and / or orientation of the weld surface 88.

MEXICAN INSTITUTE OF PROPERTY As can be seen, in certain modafldawe,

<img file="MX359249B_D0027.tif" />

Markers can be used to determine the position and / or orientation of the weld surface 88. In some embodiments, more than three markers can be used to determine the position and / or orientation of the weld surface 88. The first and second markers 95 and 96 can be formed from any suitable material. Furthermore, in certain embodiments, the first and second markers 95 and 96 may be integrated into the weld surface 88, while in other embodiments, the first and second markers 95 and 96 may be attached to the weld surface 88. By For example, the first and second markers 95 and 96 may be affixed to the weld surface 88 using an adhesive and / or the first and second markers 95 and 96 may be decals. The first and second markers 95 and 96 can have any suitable shape, size and / or color. Furthermore, in certain embodiments, the first and second markers 95 and 96 may be a reflector formed from a reflective material. The first and second markers 95 and 96 can be used by the welding system 10 to calibrate the position and / or orientation of the welding surface 88 relative to one or more detection devices 16 without a separate calibration device. Accordingly, the first and second markers 95 and 96 are configured to be detected by one or more detection devices 16. In certain embodiments, the first and second markers 95 and 96 can be placed at predetermined locations on the weld surface 88. Furthermore, the welding software can be programmed to use the predetermined locations to determine the position and / or orientation of the welding surface 88. In other embodiments, the location of the first and second markers 95 and 96 can be provided to the welding software during calibration. With the first and second markers 95 and 96 on the weld surface 88, one or more detection devices 16 can

Ι ^ Ι detect the position and / or orientation of the first one and follow it ^ íiáSíá ^ iÍíbr ^^^^^ B in relation to the one or more detection devices 16. Using these detected data together with the location of the first and second markers 95 and 96 at the weld surface 88, the weld software may be able to calibrate the position and / or orientation of the weld surface 88 with respect to one or more detection devices 16. In some embodiments, the weld surface 88 may be removable and / or reversible. In such embodiments, the weld surface 88 can be flipped, as if the weld surface 88 were to wear out.

In the illustrated embodiment, workpiece 82 includes a first marker 98 and a second marker 99. The first and second markers 98 and 99 can be used together to determine a position and / or orientation of workpiece 82. As It can be appreciated, at least two markers are used to determine the position and / or orientation of the workpiece 82. In certain embodiments, more than two markers can be used to determine the position and / or orientation of workpiece 82. The first and second markers 98 and 99 can be formed from any suitable material. Furthermore, in certain embodiments, the first and second markers 98 and 99 can be constructed on workpiece 82, while in other embodiments, the first and second markers 98 and 99 can be attached to workpiece 82. For example, the first and second markers 98 and 99 can be affixed to the workpiece 82 using an adhesive and / or the first and second markers 98 and 99 can be decals. As a further example, the first and second markers 98 and 99 can be clamped or pressed onto the workpiece 82. The first and second markers 98 and 99 can have any suitable shape, size, and / or odor. Furthermore, in certain embodiments, the first and second markers 98 and 99 may be a reflector formed from a reflective material. The first and second markers 98 and 99 'it siGi0 &amp; .y7u Orientation can be used by the welding system 10 to calibrate ^ ot THE PROPERTY

INDUSTRIAL workpiece 82 relative to one or more detection devices 16 without a separate calibration device. Accordingly, the first and second markers and 99 are configured to be detected by one or more detection devices.

16. In certain embodiments, the first and second markers 98 and 99 can be placed at predetermined locations on workpiece 82. Furthermore, the welding software can be programmed to use the predetermined locations to determine the position and / or orientation of workpiece 82. In other embodiments, the location of the first and second markers 98 and 99 can be provided to the welding software during calibration. With the first and second markers 98 and 99 on the workpiece 82, one or more detection devices 16 can detect the position and / or orientation of the first and second markers 98 and 99 relative to the one or more detection devices 16. Using this detected data in conjunction with the location of the first and second markers 98 and 99 on workpiece 82, the welding software may be able to calibrate the position and / or orientation of workpiece 82 relative to one or more detection devices 16. Although markers 95, 96, 98, and 99 have been described herein as being detected by one or more detection devices 16, in certain embodiments, markers 95, 96, 98, and 99 may include locations where a calibration device goes to be touched for calibration using the calibration device, as previously described.

In certain embodiments, weld base 12 includes a first arm 100 extending vertically from weld surface 88 and configured to provide support for one or more sensing devices 16 and visual presenter 32. A knob 101 is attached to the first arm 100 and can be used to adjust an orientation of the one or more detection devices 16 relative to the first arm 100.

ΙΜΡΙ ^&gt; χ

For example, by adjusting the knob 101, components ^ FrJ ^ mtó ^^ u ^ séFíe ^ éhdan through the first arm 100 can adjust an angle of the one or more detection devices 16. In certain embodiments, the display 32 includes a cover 102 to protect visual presenter 32 from weld emissions that may arise during an in vivo weld operation. Cover 102 can be made of any suitable material, such as a transparent material, a polymer, and so on. By using a transparent material, a welding operator can view visual presenter 32 while cover 102 is positioned in front of visual presenter 32, such as before, during, and / or after a welding operation. In certain embodiments, the one or more detection devices 16 may include a camera 104 coupled to the first arm 100 to record welding operations. In certain embodiments, camera 104 may be a high dynamic range (HDR) camera. Furthermore, in certain embodiments, the one or more detection devices 16 may include one or more emitters 105 coupled to the first arm 100. Emitters 105 can be used to calibrate the position and / or orientation of weld surface 88 relative to one or more detection devices 16. For example, one or more emitters 105 can be configured to emit a visible pattern on the surface of weld 88, workpiece 82, weld tool 14 or operator, or any combination thereof. That is, the patterns emitted by the one or more emitters 105 are visible to camera 104. Emitter 105 can emit the visible pattern at a desired wavelength, such as a wavelength in the infrared, visible, or ultraviolet spectrum (eg, about 1mm at 120nm). Visible patterns can be displayed on weld surface 88 and / or workpiece 82. In addition, visible patterns can be detected by one or more detection devices 16 to calibrate the position and / or orientation of the surface. welding 88

IMPI owrrrvromexicano in relation to the one or more detection devices 16. in particular characteristics of the visible pattern, the ^ 'innaftií'n ?? and / ·· nrifíntrWH ?? ΡΙ '^^ρηdetermined by the one or more detection devices 16 and / or the welding software. Furthermore, the visible patterns emitted by the one or more emitters 105 can be used to facilitate the placement of the workpiece 82 on the welding surface 88. As described in greater detail below, visible patterns can be detected by the one or more detection devices 16 (eg, cameras 104) to determine a shape (eg, tube, S-shape, I-shape, U) of the workpiece 82, the operator, or the position of the welding tool 14 before welding. In some embodiments, the visible pattern may be detected by the one or more detection devices 16 during welding to detect the workpiece 82, the operator, the welding tool 14, or any combination thereof.

In some embodiments, the one or more detection devices 16 of the weld base 12 may include a second chamber 109 coupled to a third arm 107 to record welding operations in a similar manner to camera 104. In addition, a second emitter 113 coupled to the third arm 107 it can emit a visible pattern on the welding surface 88, the workpiece 82, the welding tool 14, or the operator, or any combination thereof. The second emitter 113 can emit the visible pattern at a desired wavelength, such as a wavelength in the infrared, visible, or ultraviolet spectrum. The visible pattern emitted from the second emitter 113 can be approximately the same wavelength or a different wavelength as the visible pattern emitted by the emitter 105. As can be seen, the second chamber 109 and the second emitter 113 can be positioned to have a different orientation (for example, perpendicular) with respect to the workpiece 82 than the chamber 104 and the emitter 105, thus making the determination possible

MEXICAN INSTITUTE of the shape of workpiece 82, the position of the op ^ l ^ tá ^ f ^ Lla'13® ^ wSftⁱof the welding tool 14 in case the device Πρ rWorrión ir ría nlaiguier arm 100,107 is obscured from the view of a portion of the welding environment. In some embodiments, detection devices 16 may include multiple sets of cameras and emitters arranged at various points around the welding environment inside or outside of the welding base 12 to facilitate monitoring of the position and movement of targets in the environment if one or more detection devices 16 are obscured from view of the welding environment. As described in greater detail below, chamber 104 and emitter 105 can be integrated with welding helmet 41, then making it possible for welding system 10 to monitor the position and / or orientation of welding tool 14 and part working relative to the welding helmet 41.

In certain embodiments, weld base 12 also includes a second arm 106 extending vertically from weld surface 88 and configured to provide support for a weld plate 108 (eg, a vertical weld plate, horizontal weld plate , aerial welding plate, etc.). The second arm 106 can be adjustable to facilitate aerial welding at different heights. Furthermore, the second arm 106 can be manufactured in a number of different ways to facilitate aerial welding at different heights. Weld plate 108 is coupled to second arm 106 using mounting assembly 110. Mounting assembly 110 facilitates rotation of welding plate 108 as illustrated by arrow 111. For example, weld plate 108 may be rotated from generally extending in the horizontal plane (eg, for overhead welding), as illustrated, to generally extending in the vertical plane (eg, for vertical welding). . Weld plate 108 includes a weld surface 112.

In certain embodiments, the weld surface 11

<img file="MX359249B_D0028.tif" />

assisting a welding operator to position workpiece 82 on weld surface 112, similar to grooves 91 in weld surface 88. In certain embodiments, the position of workpiece 82 can be provided to 10 welding system welding software to calibrate welding system 10. For example, a weld operator can provide an indication to the weld software that identifies which groove 114 of the weld surface 112 is aligned with the workpiece 82. In addition, a predefined weld assignment can direct the weld operator to align workpiece 82 with a particular groove 114. In certain embodiments, workpiece 82 may include an extension configured to extend within one or more of grooves 114 for alignment of workpiece 82 with one or more grooves 114. As can be appreciated, each of the Slots 114 can be placed in a location that corresponds to a respective location defined in the welding software.

In certain embodiments, the weld surface 112 also includes a first marker 116 and a second marker 118. The first and second markers 116 and 118 can be used together to determine a position and / or orientation of the weld surface 112. As You can see, at least two markers are used to determine the position and / or orientation of the weld surface 112. In certain embodiments, more than two markers can be used to determine the position and / or orientation of the weld surface 112. The first and second markers 116 and 118 can be formed from any suitable material. Furthermore, in certain embodiments, the first and second markers 116 and 118 can be integrated into the weld surface 112 (or other part of the weld plate 108), while in other embodiments, the first and second markers 116 and 118 can be fixed to the

IMPI welding surface 112 (or other part of the welding plate?

MEXICAN INSTITUTE

<img file="MX359249B_D0029.tif" />

the first and second markers 116 and 118 can be affixed to the weld surface 112 using an adhesive and / or the first and second markers 116 and 118 can be decals. As a further example, the first and second markers 116 and 118 can be clamped or affixed to the weld surface 112. In some embodiments, the first and second markers 116 and 118 can be integrated into a retaining clamp that is clamped onto a ingot of solder. The first and second markers 116 and 118 can be of any suitable shape, size and / or color. Furthermore, in certain embodiments, the first and second markers 116 and 118 may be a reflector formed from a reflective material.

The first and second markers 116 and 118 can be used by the welding system 10 to calibrate the position and / or orientation of the welding surface 112 relative to the one or more detection devices 16 without a separate calibration device. Consequently, the first and second markers 116 and 118 are configured to be detected by the one or more detection devices 16. In certain embodiments, the first and second markers 116 and 118 can be placed at predetermined locations on the weld surface 112. In addition, the welding software can be programmed to use the predetermined locations to determine the position and / or orientation of the weld surface. Welding 112. In other embodiments, the location of the first and second markers 116 and 118 can be provided to the welding software during calibration. With the first and second markers 116 and 118 on the weld surface 112, one or more detection devices 16 can detect the position and / or orientation of the first and second markers 116 and 118 relative to the one or more detection devices 16. Using these detected data in conjunction with the location of the first and second markers

116 and 118 on the weld surface 112, the software ^^ c ^ dJU ^ üldérsgr ^ apaz

MEXICAN INSTITUTE

FROM PROPERTY to calibrate the position and / or orientation of the welding surfaceTT ^ relative to one or more detection devices 16. In addition, the one onTra§^rDetection devices 16 can detect and / or track the first and second markers 116 and 118 during a weld to compensate for any movement of the weld plate 108 that may occur during the weld, although markers 116 and 118 have been described herein as being detected by the one or more detection devices 16, in certain modalities, Markers 116 and 118 can Indicate locations where a calibration device is to be touched or inserted for calibration using a calibration device, as described above.

Figure 4 is a perspective view of one embodiment of a calibration device 120. In some embodiments, the calibration device 120 is configured as a welding tool and can be used to calibrate the position and / or orientation of the surfaces of weld 88 and 112 relative to the one or more detection devices 16. In other embodiments, the calibration device 120 can be used to calibrate the position and / or orientation of a weld joint. Calibration device 120 includes a handle 122 and a nozzle 124. Nozzle 124 includes a sharp end 126 that can be used to touch a location for calibration and / or to be inserted into a calibration opening. Calibration device 120 also includes a user interface 128 which makes it possible for the welding operator to provide input that corresponds to a time when calibration device 120 is touching a location for calibration and / or is being inserted into an opening for calibration. Furthermore, in certain embodiments, the calibration device 120 includes markers 130 configured to be detected by the one or more detection devices 16. As illustrated, markers 130 extend

<img file="MX359249B_D0030.tif" />

<img file="MX359249B_D0031.tif" />

from calibration device 120. However, markers 130 may not extend from calibration device 120. Markers 130 may be any suitable marker configured to be detected by the one or more detection devices 16. (eg cameras). Furthermore, the markers 130 can be of any suitable shape, size and / or color.

During calibration, detection devices 16 can detect a position of calibration device 120 and / or an orientation of calibration device 120. The position and / or orientation of the calibration device 120 can be used by the welding software to determine a position and / or orientation of one or more of the welding surfaces 88 and 112 relative to the detection devices 16, a position and / or orientation of the workpiece 82 relative to the detection devices 16, a position and / or orientation of an installation relative to the detection devices 16, and so on. In this way, the calibration device 120 can facilitate the calibration of the welding system 10. In some embodiments, a tray can be placed below the welding surface 88 to store the calibration device 120. In addition, in certain embodiments, live welding can be disabled if the calibration device 120 is capable of being tracked by detection devices 16 (eg, to prevent spatter from contacting calibration device 120).

FIG. 5 is a perspective view of one embodiment of a clamp assembly 132. Clamp assembly 132 may be placed on weld surface 88 and / or weld surface 112, and may secure workpiece 82 on the same. In certain embodiments, clamp assembly 132 can be configured to align with one or more of slots 91 and 114. In other embodiments, clamp assembly 132 can be placed at any location on the surface of

<img file="MX359249B_D0032.tif" />

it includes a first marker 134 and a second marker 136. The first and second markers 134 and 136 can be used together to determine a position and / or an orientation of the clamp assembly 132. As can be appreciated, at least two markers are used to determine the position and / or orientation of the clamp assembly 132. The first and second markers 134 and 136 can be formed from any suitable material. Furthermore, in certain embodiments, the first and second markers 134 and 136 can be integrated into clamp assembly 132, while in other embodiments, the first and second markers 134 and 136 can be attached to clamp assembly 132. For example , the first and second markers 134 and 136 may be affixed to the fastening assembly 132 using an adhesive and / or the first and second markers 134 and 136 may be decals. The first and second markers 134 and 136 can be of any suitable shape, size and / or color.

Furthermore, in certain embodiments, the first and second markers 134 and 136 may be a reflector formed from a reflective material. The first and second markers 134 and 136 can be used by the welding system 10 to calibrate the position and / or orientation of the clamp assembly 132 relative to the one or more detection devices 16 without a separate calibration device. Accordingly, the first and second markers 134 and 136 are configured to be detected by detection devices 16. In certain embodiments, the first and second markers 134 and 136 may be placed at predetermined locations in clamp assembly 132. In addition, the Welding software can be programmed to use predetermined locations to determine the position and / or orientation of fixture assembly 132. In other embodiments, the location of the first and second markers 134 and 136 can be provided to the welding software during calibration. With the first and

ΡΙ.ΡΙ second markers 134 and 136 in the fixation-assembly3i® | ^ poM®fe! ^ J0ositives ^M Industrial detection 16 can detect the position and / or orientation of the first and second markers 134 and 136 relative to the detection devices 16. Using these detected data in conjunction with the location of the first and second markers 134 and

136 In fixture assembly 132, the welding software may be able to calibrate the position and / or orientation of fixture assembly 132 relative to detection devices 16. Although the first and second markers 134 and 136 have been described herein as being detected by detection devices 16, in certain embodiments, the first and second markers 134 and 136 may indicate locations where a calibration device is to be touched or inserted. for calibration using calibration device 120, as described above.

In the illustrated embodiment, clamp assembly 132 is configured to secure a lower portion 138 of workpiece 82 to an upper portion 140 of workpiece 82 to perform a lap weld. In other embodiments, clamp assembly 132 may be configured to secure portions of workpiece 82 to perform a butt weld, a fillet weld, and so on, to assist a weld operator to perform a weld. Attachment assembly 132 includes vertical arms 142 extending from a base 143. A traverse 144 extends between vertical arms 142, and is secured to vertical arms 142. Adjustment mechanisms 146 (for example, knobs can be adjusted to direct locking devices 148 towards workpiece 82 to secure workpiece 82 between locking devices 148 and base 143 of installation assembly 132. Otherwise, the adjusting mechanisms 146 can be adjusted to direct the securing devices 148 away from the workpiece 82 to remove the workpiece 82 from being between the securing devices 148 and the base 143. Accordingly, they are

FROM raoratMD

INDUSTRIAL selectively secured to fixture assembly 132.

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FIG. 6 is a perspective view of one embodiment of an assembly of the vertical arm 223 of the weld base 12 of FIG. 3. As illustrated, one or more detection devices 16 are attached to the first arm 100. In addition, the detection devices 16 include one or more cameras 224, and one or more infrared emitters 226. However, in other embodiments, detection device 16 may include any suitable number of cameras, emitters, and / or other detection devices. A pivot assembly 228 is coupled to the first arm 100 and to the one or more detection devices 16, and enables an angle of the one or more detection devices 16 to be adjusted while the one or more detection devices 16 rotate as desired! Shine down arrow 229. As can be appreciated, adjusting the angle of the one or more detection devices 16 relative to the first arm 100 changes the field of view of the one or more detection devices 16 (eg, to change the portion of the weld surface 88 and / or the welding surface 112 detected by the detection device 16). In some embodiments, the one or more detection devices 16 may be arranged to observe at least a portion (eg, hands, face) of the operator before and / or after the completion of a welding process. Observation of the operator by the one or more detection devices 16, such as by a camera, can facilitate operator identification and verification that the identified operator carried out the observed welding process.

In certain embodiments, ropes 230 extend between knob 101 and one or more detection devices 16. Rope 230 is routed through a pulley 232 to facilitate rotation of one or more detection devices 16. Thus, an operator weld can rotate knob 101 to manually adjust the angle of one or more

<img file="MX359249B_D0033.tif" />

<img file="MX359249B_D0034.tif" />

detection devices 16. As can be seen, the T6¡5 ^ Oíj $ § INDUSTRIAL and pulley 232 is an example of a system for rotating the one or more detection devices 16. It should be noted that any suitable system can be used to facilitating rotation of the one or more detection devices 16. Although an embodiment of a knob 101 is illustrated, it can be appreciated that any suitable knob can be used to adjust the angle of the one or more detection devices 16. Furthermore, the angle of the one or more detection devices 16 can be adjusted using a motor 234 coupled to the rope 230. Accordingly, a welding operator can operate the motor 234 to adjust the angle of the one or more detection devices 16. Furthermore, in certain embodiments, a control circuit may be coupled to motor 234 and may control the angle of the one or more detection devices 16 based on a desired field of view of the one or more detection devices 16 and / or with based on tracking an object within a field of view of one or more detection devices 16.

FIG. 7 is a perspective view of one embodiment of an aerial weld arm assembly 235. The aerial weld arm assembly 235 illustrates an embodiment of a manufacturing design that enables the second arm 106 to be height adjustable. . Consequently, as can be seen, the second arm 106 can be manufactured to have an adjustable height in a number of ways. As illustrated, the aerial weld arm assembly 235 includes handles 236 used to vertically raise and / or lower the second arm 106 as illustrated by arrows 238. The aerial weld arm assembly 235 includes a belay device 240 to secure the second arm 106 to a desired height. For example, latch device 240 may include a button that is depressed to disengage a latch configured to extend into openings 242, thereby unlocking second arm 106 from being latched to rails.

Side FITTINGS 243. With the second arm 106 unsecured laCggBlésyBfe, the handles 236 can be vertically adjusted to a desired height, thus adjusting the welding surface 112 to a desired height. As can be appreciated, releasing the button can result in the latch extending into openings 242 and securing second arm 106 to side rails 243. As can be appreciated, the belay device 240 can operate manually as described and / or the belay device 240 can be controlled by a control system (eg, automatically controlled). Furthermore, the second arm 106 can be raised and / or lowered vertically using the control system. For example, in certain embodiments, the welding software can control the second arm 106 to move to a desired position automatically. Thus, the welding surface 112 can be adjusted to a desired height for aerial welding.

Fig. 8 is a block diagram of a welding software mode 244 (eg, welding training software) of the welding system 10 having various modes. As illustrated, the welding software 244 may include one or more than one live arc mode 246 configured to make training possible using a live (eg, real) arc weld, a simulation 248 welding mode configured to make training possible using a welding simulation, a virtual reality (VR) welding mode 250 configured to make training possible using a VR welding simulation, and / or an augmented reality welding mode 252 configured to make training possible using augmented reality welding simulation.

Welding software 244 can receive signals from audio input 254. Audio input 254 can be configured to allow a welding operator to operate welding software 244 using audible commands.

IMPI

MKICANO INSTITUTE (for example, voice activation). Furthermore, the software "ifewSSfiíSd

<img file="MX359249B_D0035.tif" />

It can be configured to provide a 256 audio output and / or a non-volatile output 258. For example, welding software 244 can provide audible information to a welding operator using audio output 256. This audible information may include instructions for configuring (eg, programming) the welding system 10, a real-time feedback provided to a welding operator during a welding operation, instructions to a welding operator before carrying out an operation. welding, instructions to a welding operator after carrying out a welding operation, alerts, and so on.

Fig. 9 is a block diagram of a modality of the VR 250 welding mode of the welding software 244. The VR 250 welding mode is configured to provide a welding operator with a VR 260 simulation. The VR 260 simulation can be presented Visually to a welding operator through a VR headset, glasses, VR, a VR visual presenter, or any suitable VR device. In some embodiments, the visual presenter 32 of the helmet 41 of the welding system 10 can facilitate the VR 260 simulation. The VR 260 simulation can be configured to include a variety of virtual objects that enable interaction between a welding operator and a virtual object selected from the variety of virtual objects within the VR 260 simulation. For example, virtual objects can include a virtual workpiece 262, a virtual soldering base 264, a virtual soldering tool 266, virtual wire cutters 268, virtual software setup 270, virtual training data results 272 and / or or a virtual glove 274.

In certain modes, the weld operator can interact with virtual objects without touching a physical object. For example, the one or more devices in

IMPI

INSTITUTO MEXICANO detection 16 can detect the movement of the operated? *

<img file="MX359249B_D0036.tif" />

result in similar movements occurring in the VR 260 simulation based on real-world welding operator movements. In other embodiments, the welding operator can use a glove or welding tool 14 to interact with the virtual objects. For example, the glove or welding tool 14 may be detected by detection device 16, and / or the glove or welding tool 14 may correspond to a virtual object in the VR 260 simulation. Furthermore, the welding operator You may be able to operate the welding software 244 within the VR 260 simulation using virtual software configuration 270 and / or the results of virtual training data 272. For example, the welding operator may use his hand, glove, or welding tool 14 to select items within the welding software 244 that are virtually visually presented within the VR 260 simulation. In addition, the welding operator You can perform other actions such as picking wire cutters and cutting virtual weld wire extending from virtual weld tool 266, all within the VR 260 simulation.

Figure 10 is an embodiment of a method 276 for integrating training result data, non-training result data, simulation result data, and so on. Method 276 includes welding software 244 from computer 18 that receives a first set of welding data from a storage device (eg, storage device 24) (block 278). The first set of weld data may include weld data corresponding to a first weld session (eg weld assignment). Method 276 also includes welding software 244 that receives a second set of welding data from the storage device (block

280).

In certain modalities, the first set

<img file="MX359249B_D0037.tif" />

INDUSTRIAL welding can be received from a network storage device. The networked storage device can be configured to receive welding data from and / or to provide welding data to the welding system 10 and / or the external welding system 40. Welding software 244 can integrate the first and second weld data sets into a graph to enable a visual comparison of the first weld data set with the second weld data set (block 282). As you can see, the graph can be a bar graph, a pie graph, a line graph, a histogram, and so on. In certain embodiments, integrating the first weld data set with the second weld data set includes filtering the first weld data set and the second weld data set to visually present a subset of the first weld data set, and a subset of the second weld data set. The welding software 244 can provide the graph to a display device (eg, display presenter 32) (block 284). In certain embodiments, providing the graph to the display device includes providing selectable elements on the graph that when selected visually display data that corresponds to a respective selected element of the selectable elements (eg, Selecting wire speed from the graph can change the screen to visually present the wire speed history for a particular weld session (eg weld assignment).

The first weld data set and / or the second weld data set may include a weld tool orientation, a weld tool travel speed, a weld tool position,: &lt;»»: ν.ΛΧΛΤ * V - ·&gt; ί ··:

a distance from contact point to workpiece * íi0S¿ ^^ 8i ^^ Feel

INDUSTRIAL welding, a welding score, a welding grade, and so on.

Furthermore, the first weld data set and the second weld data set may correspond to training carried out by a weld operator and / or by a class of weld operators. In addition, the first welding session (for example, welding assignment) and the second welding session (for example, welding assignment) may correspond to training carried out by a welding operator and / or by a class of operators. welding. In certain embodiments, the first weld assignment may correspond to training performed by a first weld operator, and the second weld assignment may correspond to weld performed by a second weld operator. Furthermore, the first assignment and the second assignment may correspond to the same welding scenario, in addition, or alternatively, the first welding data set and the second welding data set may correspond to welding sessions (for example, assignments ) performed by a welding operator and / or a class of welding operators outside of a training environment (eg, production floor).

FIG. 11 is an embodiment of a graph 285 illustrating various weld data sets for a weld operator. Graph 285 may be produced by welding software 244 and may be provided to visual presenter 32 for use by a welding instructor to review welding operations performed by a welding student, and / or may be provided to the visual presenter 32 to be used by a welding student to review welding operations carried out by that welding student. Graph 285 illustrates a bar graph comparison between different sessions (eg, assignments)

IMPig ^ of a first set of weld weld assignments. The first set of welding sessions (eg, weld assignments) includes sessions (eg, assignments) 286, 288, 290, 292, and 294. Graph 285 also illustrates a bar graph comparison between different one-second assignments. set of welding sessions (for example, welding assignments) carried out by the welding operator. The second set of welding sessions (eg, weld assignments) includes sessions (eg, assignments) 296, 298, 300, 302, and 304. Accordingly, the weld sessions (eg, weld assignments) can be compared each other for analysis, instruction, certification and / or training purposes. As illustrated, weld sessions (eg weld assignments) can be compared to each other using any of a number of criteria, such as a total score, a working angle, an offset angle, an offset speed , a contact distance to work, a target, a mode (for example, live arc mode, simulation mode, etc.), a completion state (for example, complete, incomplete, partially complete, etc.), a type of joint (eg fillet, butt, tee, flap, etc.), a weld position (eg flat, vertical, aerial, etc.), a type of metal used, a type of filler metal , and so on.

The welding software 244 can associate an operator with welding data (for example, arc parameters, welding parameters) acquired during a welding session (for example, live arc welding assignment, simulated welding assignment, and so on). For example, welding software 244 can identify the welding operator by an operator name 291, an operator registration number 293, an operator photograph 295, and so on. For example, the operator identification system 43 described above

IΜ Ρ1 «Mexican Nsrnvro with figure 1 can be used to determine the regtstfb dehbpeicraor number 293. That is, each operator registration number 293 can be e-ipüncler to the iiuiiTbrede operator 291 and a set of identification information (for example, resettable information 45, biometric information 47, record 49). In some embodiments, registration number 293 may be reset or reassigned to another operator after a period (eg 1,3,5,10 or more years) of inactivity associated with registration number 293. Registration number 293 It can be unique for each operator. In some embodiments, registration number 293 may be retained by the operator for an extended period of time (eg, career, life) regardless of the level of activity associated with registration number 293. That is, registration number 293 it can be a permanent identifier associated with each operator through a welding system 10 or a network of welding systems 10 coupled through network 38. Welding data associated with registration number 293 can be maintained locally or within one or more data storage systems, such as a cloud storage system or network database 38 coupled to the welding system 10. The data storage system 318 (eg, cloud storage system) of network 38 can be maintained by the manufacturer or other party, then making it possible for the weld data associated with a given registration number 293 to be independently retained of a state of employment of the operator with the registration number 293 determined. For example, operator registration number 293 and the data storage system (eg cloud storage system) can facilitate the retention of welding data associated with the operator from welding processes carried out during training , during a simulation, during a first job, during a second job, during personal time, or any combination thereof. In some

ΤΟυΤΟ MEXICANO modalities, welding data stored within the¹* Jí ^ tosSiws chíJlOroria 22 or the storage devices 24 of the computer-lA-ctel welding system-10 for a particular welding operator (for example, operator registration number 293) can be selectively or automatically synchronized with the data storage system (eg cloud storage system).

Weld history data, such as data in graph 285, is associated with each record number 293. In some embodiments, weld history data is automatically acquired and stored in the data storage system (for example , cloud storage system) by the welding software 244 of the welding system 10. Alternatively, or in addition, weld history data may be uploaded directly to the data storage system (eg, network cloud storage system 38 through a remote computer 44). Welding software 244 can facilitate access to weld history data through a 297 weld history control. Furthermore, welding software 244 can make it possible for the operator to associate personal information with registration number 293 through a personal user control 299. The operator associated with registration number 293 can enter one or more organizations (eg training center, school, employer, business organization) with which the operator is affiliated, experienced, certified for various welding processes and / or positions welding, a resume, or any combination thereof. Furthermore, registration number 293 may remain associated with the operator despite changes in affiliated organizations, experience, certifications, or any combination thereof.

FIG. 12 is an embodiment of a graph 305 that illustrates weld data for a welder compared to weld data for a class. By

IMPI ^ Tá ·

MEXICAN INSTITUTE &amp; * J. ν'-_rexample, graph 305 illustrates a score 306 of a^D^ Sffl ^ L of ^ fiíiftSéffra compared to a 308 score (for example, average ^. Median, ixalgunauatra score) of a class for a first assignment. Furthermore, a welder operator score of 310 is compared to a class score of 312 (for example, average, median, or some other score) for a second assignment. Additionally, a weld operator score of 314 is compared to a class score of 316 (for example, average, median, or some other score) for a third assignment. As can be appreciated, scores from one or more welding operators can be compared to scores from the entire class. This comparison makes it possible for a welding instructor to assess the progress of individual welding students compared to the welding student class. Furthermore, the scores of one or more welding operators can be compared with scores of one or more of other welding operators. In certain modalities, the scores of one class can be compared to the scores of another class. Furthermore, the scores of the first assignment, the second assignment and / or the third assignment can be selected for comparison.

FIG. 13 is a block diagram of one embodiment of a data storage system 318 (eg, cloud storage system) for storing weld data 327, such as certification status data 326. Data storage system 318 may include, but is not limited to, the computer 18 of the welding system 10, a remote computer 44 (eg, server) coupled to the welding system 10 via the internet or a network 38, or any combination thereof. Certification status data can occur when a welding operator completes multiple assignments in the welding system 10. For example, a default set of assignments can

<img file="MX359249B_D0038.tif" />

" me

IMPI certify a welding operator for a device &amp; Teeros ^^^ rál ^ gl industrial welding process. Data storage system 318 (eg, cloud storage system includes control circuit 320, one or more memory devices 322, and one or more storage devices 324. Control circuit 320 may include one or more processors, which may be similar to processors 20.

Also, memory devices 322 can be similar to memory devices 22, and storage devices 324 can be similar to storage devices 24. Memory devices 322 and / or storage devices 324 can be configured to store 326 certification status data that corresponds to a welding certification (for example, welding training certification from a welding operator).

Weld data 327 may include any data acquired by welding system 10 associated with weld operator registration number 293 (eg, any data that is related to assignments to certify the weld operator, weld data from training, simulated welding data, virtual reality welding data, live welding data, any data related to a real certification (for example, certified, uncertified, qualified, unqualified, etc.), an amount of one or more welds carried out by the welding operator, a time stamp for one or more welds carried out by the welding operator, a location and / or installation in which the welding operator performs the one or more welds, the components of the welding system used by the welding operator for the one or more welds, the organization with which the welding operator is affiliated, the organization for which the welding operator is performing the one or more welds, welding data and parameters for one or more welds carried out by the welding operator, a Clasification of

<img file="MX359249B_D0039.tif" />

<img file="MX359249B_D0040.tif" />

welding operator quality level, a history of welds performed by the welding operator, a history of production welds carried out by the welding operator, a certification status of first welding process (for example, a metal inert gas (MIG) welding process, a tungsten inert gas (TIG) welding process, a rod welding process, etc.) (for example, if the welding operator is certified for the first welding process, if the welding operator is not certified for the first welding process), a second welding process certification status (for example, if the welding operator is certified for the second welding process, if the welding operator is not certified for the second welding process), a certification status of the first welding device (for example, a wire feeder, a power source, a model number, etc.) (for example, if the welding operator is certified for the first welding device, if the welding operator is not certified for the first welding device ), and / or a second welding device certification status (for example, if the welding operator is certified for the second welding device, if the welding operator is not certified for the second welding device).

Control circuit 320 can be configured to receive a request for the first weld process certification status, the second weld process certification status, the first weld device certification status, and / or the second welding certification status Welding device of the welding operator. Furthermore, control circuit 320 can be configured to provide a response to the request. The response to the request may include the certification status of the first welding process, the certification status of

IMPI

INSTITUTO MEXICANO second welding process, the certification status *

<img file="MX359249B_D0041.tif" />

welding and / or the certification status of the second welding operator qualification. In certain embodiments, the welding operator may be authorized to use a first welding process, a second welding process, a first welding device, and / or a second welding device based at least partially on the response. Furthermore, in some embodiments, the first welding process, the second welding process, the first welding device, and / or the second welding device of a welding system may be enabled or disabled based at least partially on the response. Furthermore, in certain embodiments, the first welding process, the second welding process, the first welding device and / or the second welding device of a welding system can be automatically activated or deactivated. Thus, the identification data of a welding operator can be used to enable and / or disable the ability of that welding operator to use a particular welding system, welding device and / or welding process. For example, a welding operator may have a certification for a first welding process, but not for a second welding process. Accordingly, in certain modalities, a welding operator can verify their identity in a welding system (for example, by logging in, using operator identification system 43, providing registration number 293, or some other form of authentication. ). Once the identity of the welding operator is verified, the welding system can review the welding operator's certification status. The welding system can make it possible for the welding operator to carry out operations using the first welding process based on the welding operator's certification status, but can block the welding operator from carrying out the second process welding based on the state of certification of the operator of solids ϊμ flwfiwTO MEXICANO

OF INDUSTRIAL PROPERTY

<img file="MX359249B_D0042.tif" />

The storage device 324 of the data storage system 318 (eg, cloud storage system) may have weld data 327 from various operators. Data storage system 318 may be a database containing 327 weld data associated with record numbers 293 to enable analysis and tracing of the operator's weld history for extended durations (eg, stroke, lifetime) ), including through one or more organizations. As can be seen, the data storage system

318 (eg, cloud storage system) can facilitate aggregation of 326 certification status data and / or 327 weld data to identify usage trends, anticipate supply or maintenance issues, and so on. Furthermore, coupling data storage system 318 to the internet or other network 38 enables instructors or managers to monitor and analyze welding data away from the operator and welding system 10.

FIG. 14 is an embodiment of a screen illustrating data corresponding to a weld by an operator identified on the screen by registration number 293. In some embodiments, at each welding session (eg, test, weld assignment) Carried out by an operator and monitored by the welding system 10 it is assigned a unique serial number 329. Serial number 329 may be associated with registration number 293 within one or more local and / or remote data storage systems, such as a cloud storage system or network database 38 coupled to the Weld 10. Serial number 329 can be used to associate the physical weld sample with the captured weld test results. The serial number 329 format can include, but is not limited to a decimal number, a hexadecimal number, or a string of

<img file="MX359249B_D0043.tif" />

vr

<img file="MX359249B_D0044.tif" />

characters. Furthermore, the serial numbers 329 for lar

IN be

OF THE PROPERTY

INDUSTRIAL different for each operator. In some embodiments, serial number 329 is affixed to workpiece 82. For example, serial number 329 may be affixed to, stamped, engraved, embossed, or printed on work surface 82. In some embodiments, the serial number 329 is encoded as a barcode attached to workpiece 82. Alternatively, or in addition, the operator may write serial number 329 on workpiece 82.

As described below, a search feature makes it possible for an instructor to enter serial number 329 to retrieve test results for the associated welding session (for example, welding test, assignment) without the instructor having to know the user (for example, registration number 293), the assignment or any other details about the weld. Consequently, the instructor can review the data that corresponds to each 329 serial number, then provide feedback to the respective operator. Furthermore, an inspector or technician may review the serial number 329 of a workpiece 82 to assist in a weld quality review carried out against welding procedure specifications (WPS) and / or to determine a maintenance program related to workpiece 82. That is, serial number 329 can be used to track work piece 82, weld data, arc data, and operator (eg, record number 293) through a life of work piece 82 respective. In some embodiments, serial number 329 may be stored within one or more local and / or remote data storage systems, such as a cloud storage system or network database 38 coupled to the welding system 10 . The screen can be produced by welding software 244 and can be displayed visually on visual presenter 32. The screen illustrates parameters that can be displayed

<img file="MX359249B_D0045.tif" />

welding operator before, during and / or after carrying out a welding operation. For example, parameters may include a working angle 328, a displacement angle 330, a contact tip to work piece distance 332, a welding tool travel speed 334, a target of the welding tool in relation with the junction of the workpiece 336, a welding voltage 337, a welding current 338, a welding tool orientation, a welding tool position, and so on.

As illustrated, the graphically illustrated parameters may include an indication 339 of a current value of a parameter (eg, while conducting a welding session). In addition, a graph 340 can show a history of the parameter value, and a score 341 can show a total percentage corresponding to how long during the welding session the weld operator was within a range of acceptable values. In certain embodiments, a video repeat 342 of a welding session can be provided on the screen. Video Replay 342 can display live video of a welding operator performing a real weld, live video of the welding operator performing a simulated weld, live video of the welding operator performing a weld virtual reality, live video of the welding operator performing an augmented reality weld, live video of a welding arc, live video of a welding pit and / or simulated video of a welding operation.

In certain embodiments, the welding system 10 can capture video data during a welding session (eg, weld assignment), and store the video data in storage device 24 and / or data storage system 318 (for example, cloud storage system) a

<img file="MX359249B_D0046.tif" />

IMPI over the network 38. Furthermore, the soldaduwe ^ M ^ guede software

INDUSTRIAL configure video data from storage device 24 or data storage system 318, to retrieve weld parameter data from the factory for storage device 24 or data storage system 318, to synchronize data from video with welding parameter data, and to provide synchronized video and welding parameter data to visual presenter 32.

In some embodiments, the welding system 10 can receive previously performed weld test data. Test results 343 based at least in part on test data can be visually displayed on the screen. The test data may include properties of the welding session carried out (for example, welding assignment), such as strength, porosity, penetration, hardness, heat affected zone size, appearance and contamination, or any combination of the themselves. Test data can be obtained through destructive or non-destructive tests carried out after the conclusion of the welding session. For example, the strength of a weld can be determined through a destructive test, while the porosity and penetration can be obtained through non-destructive tests, such as X-ray or ultrasonic inspection.

In some embodiments, the weld system 10 can determine test data (eg, weld mapping properties) based at least in part on weld parameter data. Alternatively, or in addition, the welding system 10 may use arc parameter data to determine the test data. Test data (for example, weld mapping properties) can be associated with weld parameter data and

IMPI any arc parameter data such as *^NK5 ^ '$ ^^ $ g INDUSTRIAL

<img file="MX359249B_D0047.tif" />

Welding parameters and arc parameter data that correspond to the same welding session (for example, welding assignment) are stored together.

When the welding session (for example, welding assignment) is a live welding assignment, the arc parameters (for example, welding voltage, welding current, wire feed speed) can include measured arc parameters and / or fixed arc parameters. When the welding session is a simulated welding session, in virtual reality or in augmented reality, the arc parameters can include simulated arc parameters. In some embodiments, the arc parameters associated with non-live welding sessions (eg simulated, virtual reality, augmented reality) may include a null set stored in the data store.

In some embodiments, the determined properties of the weld session (eg, weld assignment) are based at least in part on a comparison with weld data (eg, weld parameters, arc parameters) that correspond to welding sessions. previously carried out welding. Welding data corresponding to previously conducted welding sessions can be stored in data storage system 318. Welding system 10 can determine (eg, estimate, extrapolate) properties of a simulated weld allowance, a virtual reality weld allowance, or an augmented reality weld allowance through a comparison with weld data (eg. , welding parameters, arc parameters) and associated test data corresponding to a previously performed live welding session (for example, live welding assignments). For example, the welding system 10 can determine the penetration of a weld allowance into

IMPI virtual reality through a comparison of the parameters lg ^ gj ^ j ^

INDUSTRIAL

<img file="MX359249B_D0048.tif" />

example, contact tip to work distance, travel speed) of the VR weld assignment with the weld parameters associated with previously performed live weld assignments. Accordingly, the welding system 10 can facilitate operator training by providing one or more determined properties of the welding assignment despite the fact that the welding assignment (eg simulated, virtual reality, augmented reality) is you are performing without a tangible workpiece produced to test.

The computer 18 of the welding system 10 can determine one or more properties of the welding session (for example, welding assignment) by executing executable instructions per processor to compare the received weld data with corresponding weld data to previously performed welding sessions. In some embodiments, the one or more properties of the welding session are determined remotely from the welding system 10, such as in a remote computer 44 or data storage system 318 coupled to the welding system 10 through network 38. As Alternatively, or in addition, the one or more determined properties may be transmitted to the data storage system 318, such as through network 38. In some embodiments, computer 18 can determine properties of the weld session (eg, weld mapping, while receiving the weld data associated with the weld session. That is, computer 18 can determine properties (eg, penetration , porosity, strength, appearance) in substantially real time while the operator is conducting the welding session. The determined properties can be visually presented through visual presenter 32 as results

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adjusted after obtaining test results (for example, destructive tests, non-destructive tests) of the welding session (for example To?

<td>welding).</td><td>The 244 welding software can analyze parameter data from</td>

weld to determine a path traveled 344 that can be displayed on display 32. In some embodiments, a time during a weld can be selected by a weld operator, as shown by a gauge 346. By adjusting the selected time indicator 346, the welding operator can view the video stream 342 and / or the path traveled 344 in conjunction with the welding parameters as they were at the selected time in order to establish a correlation between the parameters welding, video replay 342 and / or path traveled 344. As an alternative, or in addition, the welding operator may select (eg, via a cursor on visual display 32) a visually displayed location of traveled path 344 to review welding data 327 corresponding to one or more times the welding tool 14 passed through the selected location. Furthermore, video loop 342 may display video frames (eg, captured images, illustrations) corresponding to selected time 346 and / or selected location. As can be appreciated, a selected location may correspond to several frames or images captured when the welding operator used an interleaving or beating technique and / or when the welding session includes several passes. Accordingly, the visual presenter 32 may display the various frames (eg, captured images, illustrations), and the welding operator may select one or more for further review. In some modes, test results 343 (for example, one or more properties

<img file="MX359249B_D0049.tif" />

FROM THE PRO ?! * DAD

INDUSTRIAL determined from the weld allowance) pre-correspond to the selected moment shown by indicator 346 and / or to one or more locations along the path traveled 344. That is, the test results

343 they may visually exhibit proven characteristics (eg, porosity, weld penetration corresponding to the selected time indicator 346 and / or the selected location along the traveled path 344. Welding software 244 can be configured to recreate weld data based at least partially on weld parameter data, to synchronize 342 video replay with the recreated weld data, and to provide synchronized 342 video replay and weld data. recreated weld to visual presenter 32. In certain embodiments, the recreated weld data may be weld hole data and / or a simulated weld. In some embodiments, the welding software 244 can correlate various aspects (eg, determined properties, video, non-destructive test results, destructive test results) of the acquired welding data for positions along the path traveled 344 from welding and / or for selected times during the welding process. Welding software 244 can facilitate correlation of welding parameters (for example, working angle 328, offset angle 330, CTWD 332, travel speed 334, and target 336 of the welding tool relative to the joint of the workpiece, an orientation of the welding tool, a position of the welding tool) with arc parameters (for example, voltage 337, current 338, wire feed speed), 342 video replay and 343 test results, or any combination thereof. The welding data associated with registration number 293 for an operator can enable the operator, instructor, or manager to review welding parameters, arc parameters,

<img file="MX359249B_D0050.tif" />

determined) corresponding to the selected time indicator 346 and / or position along the path 344 of the welding process. For example, the operator can review weld data to identify relationships between changes in weld parameters (eg, working angle 328, CTWD 332) and changes to arc parameters (eg, current, voltage) at the selected moment shown by indicator 346 or a selected position. Furthermore, the operator can review weld data to identify relationships between changes in weld parameters and changes in weld 343 test results.

In some embodiments, the welding tool 14 (for example, MIG welding torch, rod welding electrode holder, TIG welding torch) can be used as a pointer, when pointing the welding tool 14 to a specific location of The weld visually presents weld data 327 in the visual presenter that corresponds to the specific location. In some embodiments, the welding tool 14 can contact the workpiece 82 at the specific location. Furthermore, welding software 244 can determine the specific location from the operator based on the point along the weld that is closest to where the operator is pointing welding tool 14 (eg, electrode). Welding software 244 can produce a location bar 346 (eg pointer) that will be displayed visually along with weld data 327 when weld tool 14 is pointed to locations along the weld after the conclusion of the session. That is, the location bar can be extended through the graphs of the welding parameters (for example, working angle 328, displacement angle 330, CTWD 332, displacement speed 334 and objective 336 of the welding tool in

IMPI

<img file="MX359249B_D0051.tif" />

po

ΤΟυΤΟ MEXICAN relationship to workpiece bonding) in a selected selected manner 346 described above. The welding software 244 can be configured to visually display the video clip 342 (eg, one or more video frames, captured images) that was captured when the welding tool 14 was at the specific location. For example, welding software 244 may visually display 0 to 30 frames before and / or after when welding tool 14 was at the specific location. Alternatively, or in addition, welding software 244 may visually present a cross-sectional view of the weld at the specific location. The cross-sectional view may be based on one or more data sets that include, but are not limited to, an X-ray scan, ultrasonic scan, a model generated based at least in part on weld data 327, or any combination of the same. Furthermore, the cross-sectional view may make it possible for the weld operator or instructor to review various weld quality characteristics at the specific location, including, but not limited to, porosity, undercut, spatter, incomplete fill, and overfill. Although the soldering tool 14 can easily be used to target and select specific solder locations before the workpiece 82 is moved after the conclusion of the session, the soldering tool 14 can be used as a pointer for pre-sessions completed with workpieces 82 moved after re-calibration of respective workpieces 82.

In certain embodiments, the storage device 24 can be configured to store a first set of data corresponding to several welds performed by a welding operator, and to store a second set of data corresponding to various non-training welds carried to performed by the welding operator, furthermore, the 320 control circuit can

IMPI be configured to retrieve at least part of the first set ^ g ^^ l

<img file="MX359249B_D0052.tif" />

storage 24, to retrieve at least part of the second data set from storage device 24, to synchronize at least part of the first data set with at least part of the second data set, and to provide the at least part of the first set data and at least part of the second data set synchronized to visual presenter 32.

FIG. 15 is a block diagram of one embodiment of a welding instructor screen 368 of the welding software 244. The welding software

244 It is configured to provide training simulations for many different welding configurations. For example, welding configurations can include a MIG 370 welding process, a TIG 372 welding process, a rod welding process 374, live arc welding mode 346, simulation welding mode 248, the 250 virtual reality welding mode and / or 252 augmented reality welding mode.

Welding instructor display 368 can be configured to make it possible for a welding instructor to restrict the training of a weld operator 376 (for example, to one or more selected weld settings), restrict the training of a class of weld operators 378 (for example, to one or more selected welding configurations), and / or restrict the training of a portion of a class of welding operators 380 (for example, to one or more selected weld settings). In addition, welding instructor display 368 can be configured to enable the welding instructor to assign selected training assignments to weld operator 382, ​​assign selected training assignments to a class of weld operators 384, and / or assign training assignments selected to a portion of

IMPI

<img file="MX359249B_D0053.tif" />

of

INSTITUTO MEXICANO a class of 386 welding operators. Furthermore, the^Dba $$ ^^TO$ e weld 368 can be configured to allow the weld instructor to automatically advance the weld operator (or a class of weld operators) from a first assignment to a second assignment 388. For example, the weld operator can advance from one first assignment to a second assignment based at least partially on a performance quality of the first assignment. Furthermore, the welding instructor display 368 can be configured to verify the identity of an operator (eg, to ensure that welding data is associated with the proper registration number 293). In some embodiments, the operator identification system 43 identifies the operator, and the instructor verifies the identity of the operator through the welding instructor display 368. For example, the instructor may provide a verification entry (eg, resettable identifier, biometric identifier, physical identifier) ​​to the operator identification system 43 to authorize that the identity of the operator be properly recognized by the operator identification system 43. In some embodiments, the instructor (eg, second operator provides a second identifier entry (eg, resettable identifier, biometric identifier, token) to the welding system 10, such as through the operator identification system 43, verifying from this way the identity of the operator that provided a first identifier entry to the operator identification system 43. The second identifier entry may be stored with the welding data (eg, identity of the operator who performs the welding session), such as memory device 56 of computer 18 or data storage system 318). As an alternative, or in addition, the welding instructor can verify the identity of an operator through a two-step identification process in which the

<img file="MX359249B_D0054.tif" />

IMPI INSTITUTO Mexican Operator Identification 43 separately identify both the prior to ensuring weld data is associated with the proper 293 registration number.

Figure 16 is an embodiment of a method 389 for welding training using augmented reality. A welding operator can select a mode from the welding software 244 (block 390). Welding software 244 determines if augmented reality mode 252 has been selected (block 392). If the augmented reality mode 252 has been selected, the welding software 244 runs an augmented reality simulation. You should notice that the welding operator may be wearing a welding helmet and / or some other head gear configured to position a visual display device within sight of the welding operator. Furthermore, the display device can generally be transparent to enable the welding operator to see real targets; however, a virtual welding environment can be displayed in portions of the display device. As part of this augmented reality simulation, the welding software 244 receives a position and / or an orientation of the welding tool 14, such as from detection device 16 (block 394). The welding software 244 integrates the virtual welding environment with the position and / or orientation of the welding tool 14 (block 396). In addition, welding software 244 provides the integrated virtual welding environment to the display device (block 398). For example, welding software 244 can determine where a weld bead should be placed within the field of view of the welding operator, and welding software 244 can visually present the weld bead on the display device in such a manner. the weld bead appears to be on a workpiece. After the conclusion of the

IMPI welding, augmented reality simulation can

INDUSTRIAL welding deletes a portion of the virtual welding environment (for example, the weld bead (block 400), and the welding software 244 returns to block 390.

If the augmented reality mode 252 has not been selected, the welding software 244 determines whether the live arc mode 246 has been selected (block 402). If live arc mode 246 has been selected, welding software 244 enters live arc mode 246 and the weld operator can perform live arc welding (block 404). If live arc mode 246 has not been selected and / or after executing block 404, welding software 244 returns to block 390. Accordingly, welding software 244 is configured to enable a welding operator practice welding in the 252 augmented reality welding mode, erase at least a portion of the virtual welding environment from the practice weld, and perform a live weld in live arc mode 246. In certain embodiments, the welding operator may practice welding in the augmented reality 252 welding mode consecutively a multiple number of times.

Figure 17 is an embodiment of another method for welding training using augmented reality. A welding operator can select a mode from the welding software 244 (block 408). Welding software 244 determines if augmented reality mode 252 has been selected (block 410). If the augmented reality mode 252 has been selected, the welding software 244 runs an augmented reality simulation. It should be mentioned that the welding operator may be wearing a welding helmet and / or some other head gear configured to place a display device in front of the welding operator's view. In addition, the visual display device can completely block the field of view of the welding operator MEj ^ tJ ^^ gná ^^^^^ the images observed by the welding operator have been captured by a camera and visually displayed on the display device visual. As part of this augmented reality simulation, the welding software 244 receives an image of the welding tool 14, such as the detection device 16 (block 412). The welding software 244 integrates the virtual welding environment with the image of the welding tool 14 (block 414), In addition, the welding software 244 provides the virtual welding environment integrated with the image of the welding tool 14 to the device of visual presentation (block 416). For example, welding software 244 can determine where a weld bead should be placed within the field of view of the welding operator, and welding software 244 visually displays the weld bead on the display device with the image of the welding tool 14 and other objects in the welding environment. After welding is complete, augmented reality simulation can make it possible for the welding operator to delete a portion of the virtual welding environment (for example, weld bead) (block 148), and welding software 244 returns to block 408 .

If the augmented reality mode 252 has not been selected, the welding software 244 determines whether the live arc mode 246 has been selected (block 420). If live arc mode 246 has been selected, welding software 244 enters live arc mode 246 and the weld operator can perform live arc welding (block 422). If live arc mode 246 has not been selected and / or after executing block 422, the welding software 244 returns to block 408. Accordingly, the welding software 244 is configured to enable a welding operator practice welding in the

IMPIí 252 augmented reality welding, erase at least urwr ^ ügij ^^ 'jgel INDUSTRIAL

<img file="MX359249B_D0055.tif" />

virtual welding of the practice weld, and perform a live weld in live arc mode 246. In certain modes, the welding operator can practice welding in 252 augmented reality welding mode consecutively a number multiple times.

FIG. 18 is a block diagram of one embodiment of the soldering tool 14. The soldering tool 14 includes the control circuit 52, the user interface 60, and the display 62 previously described. Furthermore, the welding tool 14 includes a variety of sensors and other devices. Soldering tool 14 may include a temperature sensor 424 (eg, thermocouple, thermistor, etc.), a motion sensor 426 (eg, accelerometer, gyroscope, magnetometer, etc.), a vibration device 428 (for eg, vibration motor), a microphone 429, one or more visual indicators 61 (eg LEDs 64), or any combination thereof. Furthermore, in certain embodiments, the welding tool 14 may include a voltage sensor 425 and / or a current sensor 427 for detecting voltage and / or current, respectively, of the arc produced by the welding tool 14. As described in detail below, one or more sets of LEDs 64 can be arranged around the welding tool 14 to enable the one or more detection devices 16 to detect the position and orientation of the welding tool 14 relative to weld base 12 and work piece 82. For example, sets of LEDs 64 can be arranged on an upper side, a left side and a right side of the welding tool 14 to enable the one or more detection devices 16 to detect the position and orientation of the welding tool 14 regardless of which side of the welding tool 14 is facing the one or more detection devices 16. In certain embodiments, the ^ fPBflgde welder tool of a temperature sensor 424, motion sensor 426, vibration device 428, voltage sensor 425, current sensor 427 and / or microphone 429.

During operation, the soldering tool 14 can be configured to use the temperature sensor 424 to detect a temperature associated with the soldering tool 14 (eg, a temperature of electronic components of the soldering tool 14, a temperature of the presenter 62, a temperature of a light-viewing device, a temperature of the vibrating device, a temperature of a body portion of the welding tool 14, etc.). Control circuit 52 (or control circuit of another device) can use the detected temperature to carry out various events. For example, control circuit 52 may be configured to disable the use of live arc mode 246 (eg, live weld) by welding tool 14 if the sensed temperature reaches and / or exceeds a predetermined threshold (for example, such as 85 ° C). Furthermore, the control circuit 52 can also be configured to deactivate various heat producing devices of the welding tool 14, such as the vibration device 428, light emitting devices and so on. Control circuit 52 can also be configured to display a message on display 62, such as "Waiting for the tool to cool down. Sorry for the inconvenience". In certain embodiments, control circuit 52 can be configured to disable certain components or features if the sensed temperature reaches a first threshold and to disable additional components or features if the sensed temperature reaches a second threshold.

In addition, during operation, the welding tool 14 can be configured to use motion sensor 426 to detect movement (eg, acceleration, etc.) associated with the welding tool.

IMPI

INDUSTRIAL

<img file="MX359249B_D0056.tif" />

The control 52 (or control circuit of another device) can use the detected acceleration to carry out various events. For example, control circuit 52 may be configured to activate visual presenter 62 (or other visual presenter) after motion sensor 426 detects that welding tool 14 is moved. Accordingly, control circuit 52 can direct visual presenter 62 to "wake up", such as from a sleep mode and / or exit to a screen saver mode to facilitate a welding operator of welding tool 14 use a graphical user interface (GUI) on visual presenter 62. Furthermore, control circuit 52 can use feedback from one or more motion sensors 426 to determine the position of the welding tool 14 in the welding environment and / or the movement of the welding tool 14 within the welding environment . As described in detail below, detection devices 16 (eg, cameras) can use markers on welding tool 14 to determine the position, orientation, and / or movement of welding tool 14 in the welding environment. In some embodiments, the control circuit 52 (a control circuit from another device) may use feedback from the one or more motion sensors 426 to increase the determination with the detection devices 16 of the position, orientation and / or movement of the welding tool 14. That is, control circuit 52 can determine the position and orientation of welding tool 14 based on feedback from one or more motion sensors 426 when workpiece 82 or operator obscures (eg, locks) one or more markers of the welding tool 14 from the detection device 16.

In certain embodiments, control circuit 52 can be configured to

IMPIég ^ .ItWTITVTO MEXICANO determine that a high impact event (eg, fall, etc.) to the welding tool 14 is presented based at least partially on the detected motion. After determining that a high impact event has occurred, control circuit 52 can store (eg, record) an indication that the welding tool 14 has been impacted. Along with the indication, the control circuit 52 can store other corresponding data, such as a date, a time of day, an acceleration, a user name, welding tool identification data, and so on. Control circuit 52 may also be configured to display a warning on display 62 to a welding operator requesting that the operator refrain from impacting welding tool 14. In some embodiments, control circuit 52 can be configured to use motion detected by motion sensor 426 to enable the weld operator to navigate and / or make selections within a software user interface (eg, software welding, welding training software, etc.). For example, control circuit 52 can be configured to receive acceleration and to make a software selection if acceleration matches a predetermined pattern (for example, acceleration indicates jerky movement in a certain direction, acceleration indicates that the tool 14 is being shaken, etc.).

Vibration device 428 is configured to provide feedback to a welding operator by directing welding tool 14 to vibrate and / or shake (eg, providing haptic vibration or feedback). Vibration device 428 can provide vibration feedback during live welding and / or simulated welding. As can be seen, the vibration feedback during live welding can be tuned to a specific frequency to enable an operaloJ ^ ísIidJ ^rr r t- INSTITUTO MFXICANí

<img file="MX359249B_D0057.tif" />

between

OF THE PROPERTY

INDUSTRIAL vibration that occurs due to live welding and vibration feedback. For example, for example, vibration feedback may be prbvistá ~ at approximately 3.5 Hz during live welding. Using such a frequency it can be made possible for a welding operator to detect when vibration feedback is occurring at the same time that natural vibration occurs due to live welding. Conversely, vibration feedback can be provided at approximately 9 Hz during live welding. However, the 9 Hz frequency can be mistaken for natural vibration that occurs due to live welding.

The one or more microphones 429 are configured to facilitate determination of the position of the welding tool 14 with a local positioning system. The one or more microphones 429 of the welding tool 14 receive emitted signals (eg, ultrasonic, RF) from beacons arranged at known locations around the welding environment. As can be seen, a local positioning system makes it possible to determine the location of an object when the object receives the signals emitted (that is, through an unobstructed line of sight) from three or more beacons in known positions. The control circuit 52 (or control circuit of another device) can determine the position of the welding tool 14 from the signals received by triangulation, trialteration or multi-alteration. In some embodiments, microphones 429 can facilitate determination of the position of the welding tool 14 during welding when one or more of the detection devices 16 (eg cameras) are obstructed by the workpiece 82 and / or the operator.

Fig. 19 is an embodiment of a method 430 for providing vibration feedback to a welding operator using the welding tool 14. Control circuit 52 (or

<img file="MX359249B_D0058.tif" />

parameter (eg working angle, displacement angle, speed of tvm——¹ i »· *» - »» »- displacement, distance from tip to work surface, objective, etc.) corresponding to a welding operation (block 432). As can be appreciated, the welding operation can be a live welding operation, a simulated welding operation, a virtual reality welding operation and / or an augmented reality welding operation. Control circuit 52 determines if the parameter is within a first predetermined range (block 434). As can be appreciated, the first predetermined interval may be an interval that is just outside an acceptable range. For example, the parameter may be a working angle, the acceptable range may be 45 to 50 degrees, and the first default range may be 50 to 55 degrees. Accordingly, in such an example, control circuit 52 determines whether the working angle is within the first predetermined range of 50 to 55 degrees.

IF the parameter is within the first predetermined range, control circuit 52 vibrates welding tool 14 to a first pattern (block 436). The first pattern may be a first frequency, a first frequency modulation, a first amplitude, and so on. Furthermore, if the parameter is not within the first predetermined interval, control circuit 52 determines whether the parameter is within a second predetermined interval (block 438). The second predetermined interval can be an interval that is just outside the first predetermined interval. For example, continuing with the example described above, the second default range may be 55 to 60 degrees. Accordingly, in such an example, control circuit 52 determines whether the working angle is within the second predetermined range of 55 to 60 degrees. If the parameter is within the second predetermined range, control circuit 52 vibrates welding tool 14 at a

TPT second pattern (block 440). The second pattern can {j ^ Woü &amp; fl®púfRiáfréqj | nc¡a, a^OF ^ INDUSTRIAL second frequency modulation, a second amplitude, and so on. It should be mentioned that the second pattern is typically different from the first pattern. In certain modalities, the first and second patterns may be the same. Furthermore, audible cues may be provided to the welding operator to indicate whether the parameter is within the first predetermined range or within the second predetermined range. Additionally, audible cues can be used to indicate a parameter that is not within an acceptable range. In such modalities, vibration can be used to indicate that a welding operator is doing something wrong, and audible indications can be used to identify what the welding operator is doing wrong and / or how to fix it. The parameter can be any suitable parameter, such as a working angle, a displacement angle, a displacement speed, a tip-to-work surface distance, and / or a target. Figures 20-22 illustrate modalities of various patterns.

FIG. 20 is a graph 442 of an embodiment of two patterns each including a different frequency to provide vibration feedback to a welding operator. A first pattern 444 is separated from a second pattern 446 by time 448. In the illustrated mode, the first pattern 444 is a first frequency and the second pattern 446 is a second frequency that is different from the first frequency. The first and second frequencies can be any suitable frequency. As can be appreciated, the first and second frequencies can be configured to be different than a natural frequency produced during live welding to facilitate a welding operator to differentiate between the natural frequency and the first and second frequencies. Although the illustrated mode shows that the first frequency is lower than the second

IMPIé frequency, in other modalities, the second industrial frequency first frequency.

<img file="MX359249B_D0059.tif" />

FIG. 21 is a graph 450 of a two-pattern embodiment, each including one different modulation to provide vibration feedback to a welding operator. A first pattern 452 is separated from a second pattern 454 by time 456. In the illustrated mode, the first pattern 452 is a first modulation and the second pattern 454 is a second modulation that is different from the first modulation. The first and second modulations can be any suitable modulation. For example, the first modulation may include a first number of vibration pulses (eg, two pulses) and the second modulation may include a second number of vibration pulses (eg, three pulses). Furthermore, modulation can vary a number of pulses, a time between pulses, etc. In certain embodiments, a number of vibrating pulses and / or a time between pulses can be set to gradually increase or decrease as your parameter is moved to or away from acceptable parameter values. Although the illustrated mode shows the first modulation as having fewer pulses than the second modulation, in other modes, the second modulation may have fewer pulses than the first modulation.

FIG. 22 is a graph 458 of an embodiment of two patterns each including a different amplitude to provide vibration feedback to a welding operator. A first pattern 460 is separated from a second pattern 462 by time 464. In the illustrated embodiment, the first pattern 460 is a first amplitude and the second pattern 462 is a second amplitude that is different from the first amplitude. The first and second amplitudes can be any suitable amplitude. Although the illustrated modality shows that the first amplitude is lower than the second amplitude, in other modalities, the second am | idr®wecto. ^ r &lt;í OF A PROPERTY

INDUSTRIAL

<img file="MX359249B_D0060.tif" />

It was the first amplitude.

Welding tool 14 can provide varying levels of vibration and visual feedback to the operator during simulated welding or live welding. For example, a first mode of feedback from welding tool 14 can provide visual feedback (eg, via visual presenter 62) and vibration feedback to the operator until the operator initiates a simulated or live welding process, and the welding tool 14 may not provide visual feedback or vibration during the simulated or live welding process. A second mode of feedback from the welding tool 14 can provide visual feedback and vibration to the operator both before and during the simulated or live welding process. A third mode of weld tool feedback can provide visual feedback and vibration to the operator both before and during simulated welding processes only. As can be appreciated, some modes may provide only visual feedback prior to or during a simulated welding process, and other modes may provide only vibration feedback prior to or during a simulated welding process. In some modalities, an instructor can specify the level of feedback that can be provided to the operator during simulated or live welding sessions that will be evaluated. Furthermore, the operator can selectively disable the vibration and / or visual feedback provided by the welding tool before and during simulated or live welding.

Fig. 23 is a perspective view of one embodiment of the welding tool 14 having markers that can be used to track the welding tool 14. In some embodiments, the position of the welding tool 14

IMPI weld 14 can be traced before welding

INDUSTRIAL

<img file="MX359249B_D0061.tif" />

cir, calibrate) the shape of the weld joint. For example, welding tool 14 can be used to trace the shape of a workpiece 82 in various positions including, but not limited to, welding positions 1G, 2G, 3G, 4G, 5G, 6G, 1F, 2F,

3F, 4F, 5F or 6F. The determined shape of the weld joint can be stored in data storage system 318 for comparison with a subsequent live weld process along the weld joint. In some embodiments, the position of the welding tool 14 can be tracked during live welding and compared to the shape of the weld joint stored in the data storage system 318. The control circuit 52 of the welding tool 14 and / or any other component of the welding system 10 can provide approximately real-time feedback to the operator regarding the position (eg location) and / or orientation of the welding tool weld 14 relative to the weld joint. The welding tool 14 includes a housing 466 that encloses the control circuit 52 of the welding tool 14 and / or any other component of the welding tool 14. Visual presenter 62 and user interface 60 are incorporated in an upper portion from accommodation 466.

As illustrated, a neck 470 extends from the housing 466 of the welding tool 14. Markers for tracing the welding tool 14 can be provided on the neck 470. Specifically, a mounting bar 472 is used to engage markers 474. to neck 470. Markers 474 are spherical markers in the illustrated manner; however, in other embodiments, the markers 474 can have any suitable shape (eg, such as a shape of an LED). Markers 474 are used by the one or more detection devices 16 to

IMPI track the position and / or orientation of the tool ^J INDUSTRIAL appreciate, three of the 474 markers are used to define a foreground. Furthermore, markers 474 are arranged such that a fourth marker 474 is in a different background from the foreground. Accordingly, the detection device can be used to track the position and / or orientation of the welding tool 14 using the four markers 474. It should be noted that although the illustrated mode shows four 474 markers, the mounting bar 472 can have any suitable number of 474 markers.

In certain embodiments, markers 474 can be reflective markers, while in other embodiments markers 474 can be light emitting markers (eg, light emitting diodes LEDs). In embodiments where markers 474 are light-emitting markers, markers 474 can be powered by electrical components within housing 466 of welding tool 14. For example, markers 474 can be powered by a connection 476 between mounting bar 472 and housing 466. In addition, control circuit 52 (or control circuit of another device) can be used to control on and / or off (eg illumination) of markers 474. In certain embodiments, markers 474 can be individually turned on and / or off based on the position and / or orientation of the welding tool 14. In other embodiments, markers 474 can be turned on and / or off in groups based on the position and / or orientation of the soldering tool 14. It should be noted that in embodiments that do not include mounting bar 472, the connection 476 can be replaced with another marker 468 on a separate plane than the illustrated 468 markers. The modalities of the welding tool 14 are described here in relation to a consistent set of axes of the coordinate 780. An X-axis 782 is a horizontal direction to

IMPI »

MEXICAN INSTITUTE.

&gt; íanaax&gt; &amp;&gt; tth&gt; ^ | e IpuotSK ^to INDUSTRIAL **, _ A * £ J of the welding tool 14, a Y axis 784 is the vertical direction relative to the longitudinal axis, and a Z axis 186 is a horizontal direction extending laterally from the welding tool 14.

Figure 24 is an embodiment of a neck 800 of welding tool 14, taken along line 24-24 of Figure 23. Visual markers 802 are arranged at predefined locations in neck 800 to facilitate detection of the position and orientation of the welding tool 14 by the one or more detection devices 16. In some embodiments, the visual markers 802 are LEDs 64. As an alternative, or in addition, the 802 visual markers are directional, such that the one or more detection devices 16 detect 802 visual markers that are oriented towards the one or more detection devices 16 more easily than the 802 visual markers that are less oriented towards the one or more detection devices 16. For example, LEDs 64 arranged on a surface may be directed to emit light primarily along an axis substantially perpendicular to the surface. In some embodiments, multiple sets of visual markers 802 are arranged in neck 800.

The visual markers 802 in each set can be oriented in substantially the same direction as the other visual markers 802 in the respective set. In some embodiments, a first set 804 of visual markers 802 is directed substantially vertically along the Y axis 784, a second set 806 of visual markers 802 is directed in a second direction 808, and a third set 810 of visual markers 802 is directed in a third direction 812. That is, the visual markers 802 in each set are oriented to emit light in directions substantially parallel to other visual markers 802 in the respective set.

The second address 808 is

<img file="MX359249B_D0062.tif" />

X-axis 782 along the welding tool 14, and is off-center at a second angle 814 of the Y-axis 784. The third direction 812 is substantially perpendicular to the X-axis 782 along the welding tool 14, and is off-center to a third angle 816 of the Y axis 784. In some embodiments, the second angle 814 and the third angle 816 are approximately the same magnitude. For example, the second set 806 of visual indicators 802 may be off-axis from the Y axis 784 by 45 °, and the third set 810 of visual indicators 802 may be off-axis from the Y axis 784 by 45 °, such that the second angle 814 is substantially perpendicular to the third angle 816. The second angle 814 and the third angle 816 may each be between approximately 5^or at 180 °, 15 ° to 135 °, 25 ° to 90 ° or 30 ° to 75 °. As can be appreciated, the neck 800 may have 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more sets of 802 visual markers, with each set oriented in a particular direction to facilitate detection by the one or more detection devices 16.

The visual markers 802 of each set can be arranged on the same or substantially parallel planes. For example, the first set 804 of visual markers 802 may be arranged in a foreground 818 or a plane substantially parallel to foreground 818 that is perpendicular to the Y axis 784. The second set 806 of visual markers 802 can be arranged in a second plane 820 or a plane substantially parallel to the second plane 820 that is perpendicular to the second direction 808. The third set 810 of visual markers 802 can be arranged in a third plane 822 or a plane substantially parallel to the third plane 822 that is perpendicular to the third direction 812. As used herein, the term "substantially parallel" includes orientations within 10 ° (or 5 degrees, or 1 degree, or less) of parallel, and the term "substantially perpendicular includes

IMMPIO ^.

orientations within 10 degrees (or 5 degrees, or 1 degree¹,

Furthermore, as used herein, the term "substantially different", when referring to orientations, includes angles that differ by more than 10 degrees, more than 15 degrees, more than 20 degrees, more than 30 degrees, more than 45 degrees, or more. The visual marker arrangements 802 of each set can facilitate tracing of the welding tool 14 during simulated and / or live out-of-position welding processes including, but not limited to, vertical or aerial welding positions.

Neck structures 824 800 may facilitate orientation of sets of visual markers 802. For example, a mounting surface of each structure 824 may be substantially parallel to a respective plane for the corresponding set of visual markers 802. Furthermore, structures 824 can reduce or eliminate detection of the respective 802 visual marker by the one or more detection devices 16 when the respective 802 visual marker is oriented relative to the one or more detection devices 16 at an angle greater than an angle threshold. For example, the second set 806 of visual markers 802 can be configured to be detected by the one or more detection devices 16 when the operator holds the welding tool 14 with the one or more detection devices 16 to the left of the operator ( i.e. a left-handed operator), and the third set 810 of visual markers 802 can be configured to be detected by the one or more detection devices 16 when the operator holds the welding tool 14 with the one or more detection devices 16 to the operator's right (i.e. , a right-handed operator). Neck 800 and / or structures 824 for second set 806 of visual markers 802 can reduce or eliminate detection of second set 806 of visual markers 802 when a right-handed operator uses welding tool 14, and vice versa for third set 810 of visual markers when a left-handed operator uses the welding tool 14.

IMPI iNSTtHjTOMEXia ^ g oe THE tfíblrtTMIAL rtOmDAD

<img file="MX359249B_D0063.tif" />

FIG. 25 is a top view of an arrangement of visual markers 802 in the neck 800 of the welding tool 14, similar to the embodiment of the neck 800 illustrated in FIG. 24. The visual markers 802 of the first set 804 (for example "A"), the second set 806 (for example "B") and the third set 810 (for example, "C") are arranged in different predefined positions in the neck 800 which make it possible for the detection device 16 to determine which side of the welding tool 14 is most directed towards the one or more detection devices 16 through the detection of a different pattern or arrangement corresponding to each side (for example, top, left 826, right 828, bottom, front) of the welding tool 14. As an alternative, or in addition, the visual markers 802 (eg LEDs 64) of each set can be colored respectively, thus making it possible for the one or more detection devices 16 to determine which side of the welding tool 14 is most directed to the one or more detection devices 16 through color detection.

The one or more detection devices 16 can track the position and orientation of the welding tool 14 relative to the welding base 12 and the workpiece 82 when the one or more detection devices 16 detect a threshold amount of visual markers 802 one set. The threshold number of visual markers 802 in a set may be less than or equal to the number of visual markers 802 in the respective set. For example, the one or more detection devices 16 can detect the right side of the welding tool 14 when the four visual markers 802 of the third set 810 are detected, the one or more detection devices 16 can detect the upper side of the welding tool 14 when the five 802 visual markers in the first set are detected

804, and the one or more detection devices 16 can

<img file="MX359249B_D0064.tif" />

welding tool when the four 802 visual markers in the second set are detected. In some embodiments, each set of 802 visual markers may have redundant visual markers, such that the one or more detection devices 16 can track the position and orientation of the welding tool 14 when one or more of the redundant visual markers be obscured from vision. The one or more detection devices 16 can track position and orientation with substantially the same precision, regardless of which array has been detected by the one or more detection devices 16.

Visual markers 802 may be disposed on neck 800 of welding tool 14 at positions relative to the X-axis 782 along the welding tool 14, and relative to a baseline 830. For example, the first set 804 may have five 802 visual markers: two 802 visual markers along baseline 830 near a first end 832 of neck 800 and spaced at a first displacement 831 from X-axis 782, a visual marker 802 spaced at a first distance 834 from baseline 830 in a middle section 836 of the neck 800 and separated in a second displacement 838 of the X axis 782 of the left side 826, a visual marker 802 separated at a third distance 840 from the baseline 830 in the middle section 836 and separated from the second offset 838 to the right side 828, and a visual marker 802 near a second end 842 of the neck 800 along the X axis 782 and spaced a fourth distance 844 from baseline 830. The second set 806 may have four 802 visual markers: one 802 visual marker along baseline 830 and separated to a third X axis offset 846 782 on the left side 826, one 802 visual marker separated a fifth distance 848 from baseline 830 along X axis 782 and in mid section 836, a marker

IMPI ^ ggl visual 802 separated at a sixth distance 850 from the line (Ma | ^ ep6n media 836 and separated to the second displacement 838 of the X axis 782 to the right side 828, and a visual marker 802 near the second end 842 of the neck 800 separated fourth distance 844 from baseline 830 and separated second offset 832 on left side 826. The third set 810 can have four 802 visual markers: a visual marker 802 along baseline 830 and spaced third offset 846 from X-axis 782 on right side 828, visual marker 802 spaced a seventh distance 852 from baseline 830 along axis X 782 in the middle section 836, a visual marker 802 separated an eighth distance 854 from the baseline 830 in the middle section 836 and separated the second offset 838 from the X axis 782 on the left side 826, and a visual marker 802 near the second end 842 of the neck 800 separated the fourth distance 844 from the baseline 830 and separated the second offset 838 on the right side 828.

The arrangements (eg, distances and offsets relative to baseline 830 and X-axis 782) of visual markers 802 for each set 804, 806, 810 can be stored in a memory of the welding system 10. For example, the Arrangements can be stored in a memory as calibrations corresponding to a particular welding tool 14 coupled to the welding system 10. As described in detail below, the welding system 10 can detect the arrangement of the visual markers 802 directed to the one or more detection devices 16, and determine the position and orientation of the welding tool 14 with respect to the welding base 12 and workpiece 82 based at least in part on a comparison of the detected arrangement and the arrangements stored in memory. Each set of 802 visual markers can be calibrated, such as before initial use, after reconnecting welding tool 14, or at a

IMPI

-TO. ul τ _a_ jjl jx INSTITUTO MEXICANO default maintenance interval. To calibrate

<img file="MX359249B_D0065.tif" />

visors 802, the welding tool 14 can be mounted to the welding base 12 in a predetermined position and orientation such that the respective set of visual markers 802 is directed substantially towards the one or more detection devices 16. For example, the first set 804 can be calibrated when the welding tool 14 is mounted such that the Y axis 784 of the welding tool 14 is generally directed towards the one or more detection devices 16, the second set 806 can be calibrated when the welding tool 14 is mounted in such a way that the second direction 808 is generally directed towards the one or more detection devices 16, and the third set 810 can be calibrated when the welding tool 14 is mounted such that the third direction 812 is generally directed toward the one or more detection devices 16. In some embodiments, the visual marker sets 802 are calibrated when a calibration tool (for example, the 610 calibration tool described below) is attached to the welding tool 14. The operator can verify the calibrations by moving the welding tool 14 around the welding environment relative to the welding base 12 and the one or more detection devices 16.

In certain embodiments, the visual markers 802 described herein, which are detected by the one or more detection devices 16, may include passive markers (eg, decals, reflectors, patterns) and / or active markers (eg, lights, LEDs). Accordingly, the visual markers 802 can be configured to either emit light that is detected by the one or more detection devices 16 or reflect light that is detected by the one or more detection devices 16. Furthermore, as described in more detail here, the

IMPI 802 visual bookmarks can include bookmarks

INDUSTRIAL

<img file="MX359249B_D0066.tif" />

mo non-visible spectrum markers such as infrared markers or some combination thereof, in certain embodiments. Furthermore, it should be noted that although the modalities illustrated in Figures 24 and 25 refer to 802 visual markers configured to be detected by the one or more detection devices 16, in other embodiments, the 802 markers may be other types of markers. configured to facilitate tracking the position, orientation and / or movement of the welding tool 14. For example, in certain embodiments, the markers 802 may include electromagnetic, acoustic, microelectromechanical (MEMS) components, or other types of components that can effectively function as markers on the welding tool 14 to facilitate tracking of position, orientation, and / or or movement of the welding tool 14 by the one or more detection devices 16.

FIG. 26 is an embodiment of a method 478 for displaying visually on a display 62 of a welding tool 14 a welding parameter relative to a threshold. In the illustrated mode, the control circuit 52 (or control circuit of another device) receives a selection made by a welding operator of a welding parameter associated with a position, orientation and / or movement of the welding tool. solder 14 (block 480). For example, the welding operator may select a button on the user interface 60 of the welding tool 14 to select a welding parameter. The weld parameter can be any suitable weld parameter, such as a working angle, an offset angle, an offset speed, a tip-to-work surface distance, a target, and so on. As can be seen, the welding system 10 can select the parameter of

IMPIOS weld automatically without operator input n ^ YesOCíff ^ e

INDUSTRIAL makes the selection, the visual display 62 of the welding tool 14 visually displays or displays a representation of the welding parameter in relation to a predetermined threshold range and / or target value for the welding parameter (block

482). The visually displayed welding parameter is configured to change by changing the position of the welding tool 14, by changing the orientation of the welding tool 14 and / or by changing the movement of the welding tool 14. Thus, the welding operator may use the welding tool 14 to properly position and / or orient the welding tool 14 while performing (for example, before starting, starting, stopping, etc.) a welding operation, thereby making it possible for the welding operator to carry out the welding operation with the welding parameter within the predetermined threshold range or at the target value.

For example, the welding operator may wish to start the welding operation at a suitable working angle. Accordingly, the welding operator can select "working angle" on the welding tool 14. Once "working angle" is selected, the welding operator can set the welding tool 14 at a desired working angle. When the welding operator moves the welding tool 14, a current working angle is visually displayed relative to a desired working angle. Thus, the welding operator can move the welding tool 14 around until the current working angle coincides with the desired working angle and / or is within a desired range of working angles. As can be appreciated, the display 62 can be turned off and / or darkened such that it is blank during a welding operation. However, a welding operator can select a desired welding parameter before carrying out the operation.

<img file="MX359249B_D0067.tif" />

Blank visual presenter 62, control circuit 52 can be configured to monitor the weld parameter and provide feedback to the weld operator during the weld operation (eg, vibration feedback, audio feedback, etc.).

Fig. 27 is an embodiment of a set of screen captures of visual presenter 62 of welding tool 14 to show a welding parameter relative to a threshold. The set of screenshots illustrate various ways in which welding parameters are visually presented for a welding operator to perform a welding operation. As can be appreciated, in certain embodiments, the welding parameters can be visually presented to the welding operator before, during and / or after the welding operation. Display 484 illustrates a working angle that is not within a predetermined threshold range. A parameter portion 486 of visual presenter 62 indicates the selected parameter. Furthermore, an interval section 488 indicates whether the selected parameter is within the predetermined threshold interval. In addition, a parameter value section 490 indicates the value of the selected parameter. On screen 484, the working angle of 38 is out of range as indicated by the arrow extending outward from the center circle. Display 492 illustrates a working angle of 45 that is within the predetermined threshold range as indicated by no arrows extending from the center circle.

As can be appreciated, the one or more detection devices 16 can be configured to detect whether the displacement angle is a drag angle (eg, the displacement angle is ahead of the welding arc) or a thrust angle (eg , if the displacement angle is behind the welding arc.

IMPI

Consequently, the screen 494 illustrates an angle of the &amp; ienk&gt; ¡of ^R Dt INDUSTRIAL PROPERTY

<img file="MX359249B_D0068.tif" />

it is outside a predetermined threshold range as indicated by an arrow extending outward from a center circle. Conversely, display 496 illustrates a thrust displacement angle of 15 that is within the predetermined threshold range as indicated by no arrows extending from the center circle. In addition, display 498 illustrates a travel speed of 12 that is within a predetermined threshold range as indicated by a vertical line aligned with the center circle. Conversely, display 500 illustrates a scrolling speed of 18 that is outside (ie, greater than) the predetermined threshold range as indicated by the vertical line to the right of the center circle. As can be appreciated, a travel speed that is less than a predetermined threshold interval may be indicated by a vertical line to the left of the center circle. The travel speed indicator can move dynamically relative to the center circle in real time during a welding process based at least in part on the determined travel speed, thereby guiding the operator to carry out the welding process with a travel speed within the predetermined threshold range.

Display 502 illustrates a tip-to-work distance of 1.5 that is greater than a predetermined threshold interval as indicated by a small circle within an outer band. In addition, display 504 illustrates the tip-to-work distance of 0.4 that is less than a predetermined threshold interval as indicated by the circle outside the outer band. Furthermore, display 506 illustrates the tip-to-work distance of 1.1 that is within the predetermined threshold range as indicated by the circle that substantially fills the area within the outer band. In addition, display 508 illustrates a target of 0.02 that is within a predetermined threshold range as indicated

IMPIOS

MEXICAN INSTITUTE

FROM THE ΓΚΟΗΕΛΑ ΐώ ^ ΒΓ ^ ΐβ ^ by a line 509 aligned with a central circle. Inversely ^ Efpafitan ^ SlWtüstra a target of 0.08 that is not within the threshold interval · 'predetermined ceme- is indicated by line 509 towards the top of the central circle. In some embodiments, line 509 of screens 508 and 510 represents the bond with respect to the tip of the welding tool 14. For example, screens 508 and 510 illustrate the objective of the welding tool 14 when the welding tool 14 is oriented substantially perpendicular to the joint (as illustrated by line 509). Screen 510 illustrates the objective of the welding tool 14 when the welding tool is at least partially angled relative to the joint, as indicated by line 509 and the tilted orientation of the welding tool 14. That is, although the positions of the welding tool 14 relative to the joint (eg, line 509) corresponding to displays 508 and 511 are substantially the same, the orientation of line 509 of screen 508 in the visual presenter corresponds to a perpendicular orientation of the welding tool 14 relative to the joint and the orientation of line 509 of screen 511 in visual presenter 62 corresponds to an orientation not perpendicular to the welding tool 14 relative to the joint. The orientation of the interval section 488 (eg, target indicator, angle indicator, CTWD indicator) can be rotated in the visual presenter by a rotation angle defined as the angle difference between a front edge 513 of the visual presenter 62 and the union. The graphical representations in visual presenter 62 may correspond to the orientation of the welding tool 14 to the joint rather than to the orientation of visual presenter 62 with respect to the operator. For example, when the welding tool 14 is placed near a vertical joint such that the welding tool 14 is substantially parallel to the joint, line 509 in visual display 62 may be

The vertically oriented joint indicator line.

IMPIOS * W $ ji ^^ er ^^^ § ^ mind perpendicular to the scroll speed indicator described above with displays

498 and 500.

Although specific graphical representations have been shown in display 62 in the illustrated mode to show a weld parameter relative to a threshold, other modes can use any suitable graphical representation to show a weld parameter relative to a threshold. Furthermore, in certain embodiments, visual guides of individual parameters may be combined such that various parameters are visually presented together.

Furthermore, in certain embodiments, the welding system 10 can detect whether the welding tool 14 is near and / or far from a weld joint. Being close to the weld joint is a function of the target to contact work distance (CTWD) and target parameters. When both the CTWD and target parameters are within suitable predetermined ranges, the welding system 10 may consider the welding tool 14 to be close to the welding joint. Furthermore, the control circuit 52 of the welding tool 14 or other device can determine the working angle, the angle of displacement and the speed of displacement based at least in part on the position of the welding tool 14 relative to to a known (eg, calibrated) weld joint of workpiece 82 when the CTWD and target are substantially constant along the weld joint. As can be appreciated, the position and orientation of the welding tool 14 can be determined through the detection devices 16 and markers on the welding tool 14, the one or more motion sensors 426 and / or the one or more microphones 429 of the soldering tool 14. Furthermore, when the soldering tool 14 is close to the solder joint, the visual guides can be visually displayed in

<img file="MX359249B_D0069.tif" />

14.

When the welding tool 14 is close to the live ion weld and weld weld diode, a message (eg alert message) may be visually displayed on a visual display indicating that suitable welding equipment ( for example, welding helmet, etc.) should be in place as a safety precaution for spectators. However, an external visual presenter can continue to visually present the data in real time at a safe distance from the welding operation. Furthermore, in some embodiments, when the welding tool 14 is close to the welding junction and in live welding mode, the visual display of the welding tool 14 can be changed (for example, to substantially white and / or transparent, non-distracting vision, predetermined image, etc.) while a welding operator pulls the trigger of the welding tool 14. When the soldering tool 14 is away from the solder joint, pulling the trigger of the soldering tool 14 will not carry out (eg initiate) a test activity. Also, when the welding tool 14 is away from the welding joint, actuation of the welding tool 14 will have no effect in a non-live welding mode, and it can feed the welding wire in the live welding mode without starting a test run.

FIG. 28 is an embodiment of a method 512 for tracing welding tool 14 in welding system 10 using at least four markers. One or more cameras (eg, such as one or more cameras of the one or more detection devices 16) are used to detect the markers of the welding tool 14 (block 514). As described above, the markers can be reflective markers and / or light emitting markers. Furthermore, the markers may include four or more markers to facilitate

<img file="MX359249B_D0070.tif" />

FROM INDUSTRIAL PROPERTY precise orientation of the welding tool 14. One or more processors 20 of the computer 18 (or other processors) can be used with the detection devices to track the position of the welding tool 14 and / or the orientation of the welding tool 14 based on the detected markers (block 516). If the one or more cameras are unable to detect one or more of the markers, the one or more processors 20 (or control circuit, such as control circuit 52) ​​can be configured to block the live weld while the one or more cameras are unable to detect the markers (block 518). However, in some embodiments of the welding system 10, one or more cameras integrated with the helmet 41 may make it possible to detect four or more parameters to facilitate determining an accurate position and / or orientation of the welding tool 14 with respect to the welding helmet 41. Thus, one or more cameras integrated with the helmet 41 can facilitate the detection of the position and / or orientation of the welding tool 14 for welding processes that would otherwise obscure the one or more camera markers mounted to the welding base. 12. As can be appreciated, the position and / or orientation of the welding helmet 41 in the welding environment can be determined through the one or more detection devices 16 of the welding system 10 in a manner similar to that described above for the welding tool. solder 14 when the markers are observable. In some embodiments, the visual display 62 of the welding tool 14 can be configured to visually display a message indicating that the markers are not detected while the one or more cameras are unable to detect the welding tool 14 markers (block 520). Consequently, live welding using the welding tool 14 can be blocked if the welding tool 14 is unable to be tracked by the one or more detection devices 16.

IMPI

MEXICAN INSTITUTE OF INDUSTRIAL NONEDAD

<img file="MX359249B_D0071.tif" />

Some embodiments of the welding system 10 can track the welding tool 14 in the welding environment during periods when one or more of the markers 474 are obscured and undetected. As described above, the welding system 10 can track the position and / or orientation of the welding tool 14 based at least in part on feedback from one or more motion sensors 426 (eg, accelerometers, gyroscopes) of the welding tool 14. Furthermore, modalities of the welding system 10 with beacons of a local positioning system and one or more microphones 429 in the welding tool 14 can determine a position of the welding tool 14 within the welding environment when the portions (for example , markers 474) of the welding tool 14 are obscured from the line of sight of some detection devices 16 (eg cameras). Accordingly, method 512 block 518 (for blocking live welding while markers are not detected) may be optional at intervals when control circuit 52 may otherwise determine the position of the welding tool 14 within the environment. welding. Alternatively, or in addition, the welding system 10 can track the welding tool 14 in the welding environment when the welding tool 14 does not have markers 474 as described above. Therefore, in some embodiments, the control circuit 52 allows live welding while the markers are not detected or are not present in the welding tool 14.

FIG. 29 is an embodiment of a method 522 for detecting the ability of processor 20 (or any other processor) to communicate with welding tool 14. Welding tool 14 is configured to detect a signal from processor 20 (block 524). ).

<img file="MX359249B_D0072.tif" />

Dropper 20 to the welding tool 14 at a predetermined interval. In certain embodiments, the signal may be a pulsed signal provided from the processor to the welding tool 14 at the predetermined interval. Furthermore, the signal is provided to the welding tool 14 such that the welding tool 14 is capable of determining that the welding tool 14 is capable of communicating with processor 20. If the welding tool 14 does not receive the signal from the processor 20 within the predetermined interval, the control circuit 52 (or control circuit of another device) is configured to block live welding using the welding tool 14 while the signal is not detected (block 526).

Furthermore, visual presenter 62 can be configured to visually display a message indicating that the signal from processor 20 is not detected while the live weld is blocked (block 528). Consequently, the welding tool 14 can detect the ability of the processor 20 to communicate with the welding tool 14.

Figure 30 is an embodiment of a method 530 for calibrating a curved weld joint that can be used with the weld system 10. One or more cameras (eg, such as one or more cameras of the one or more detection devices 16 ) are used to detect a first position (eg, first calibration point) of the curved weld joint (block 532). For example, a calibration tool and / or welding tool 14 can be used to identify the first position of the curved weld joint to the one or more chambers (for example, such as by touching a tip of the calibration tool , and / or the welding tool 14 to the first position). Furthermore, the one or more cameras can be used to track the calibration tool and / or the welding tool 14 to determine a position and / or a

<img file="MX359249B_D0073.tif" />

orientation of the calibration tool and / or ice to ¹ INS1 detect the first position of the curved weld joint.

Furthermore, the one or more cameras are ácsclas for detecting a second position (eg, second calibration point) of the curved weld joint (block 534). For example, the calibration tool 120 and / or the welding tool 14 can be used to identify the second position of the curved weld joint to the one or more chambers. Furthermore, the one or more cameras can be used to track the calibration tool 120 and / or the welding tool 14 to determine a position and / or an orientation of the calibration tool 120 and / or the welding tool 14 to detect the second position of the curved weld joint. Furthermore, the one or more cameras are used to detect a curved portion of the curved weld joint between the first and second positions of the curved weld joint (block 536). For example, the calibration tool 120 and / or the welding tool 14 can be used to identify the curved weld joint between the first and second positions of the curved weld joint. Furthermore, the one or more cameras can be used to track the calibration tool 120 and / or the welding tool 14 to determine a position and / or an orientation of the calibration tool 120 and / or the welding tool 14 to detect the curved portion of the curved weld joint. As can be appreciated, during operation, the first position can be detected, then the curved weld joint can be detected, and then the second position can be detected. However, the detection of the first position, the second position and the curved weld joint can be presented in any suitable order. In certain embodiments, a representation of the curved portion of the curved weld joint can be stored to determine a quality of a weld operation by comparing a position and / or an orientation of the

100 14 welding tool during operation

INDUSTRIAL stored of the curved portion of the curved weld joint. As can be appreciated, in certain embodiments, the welding operation may be a multi-pass welding operation.

Furthermore, calibration for some joints, such as circular weld joints (for example, tube joints) can be carried out by touching the calibration tool to three different points around the circumference of the circular weld joint. A path of the circular weld joint can then be determined by calculating a best-fit circle that crosses all three points. The path of the circular weld joint can be stored and used to evaluate weld parameters for training welds. For a more complex geometry, the calibration tool 120 and / or the welding tool 14 can be dragged along the complete joint in order to indicate the connection to the system in such a way that all the parameters can be calculated.

In some embodiments, the method 530 for calibrating a curved weld joint that can be used with the weld system 10 may not use the weld tool 14 or the calibration tool to determine the path of the weld joint. That is, the control circuit 52 can use one or more images captured by cameras (for example, such as one or more cameras of the one or more detection devices 16) to detect the first position (block 532), the second position ( block 534) and the curved portion (block 536) of the solder joint. Alternatively, or in addition, control circuit 52 may use one or more emitters (eg, emitters 105, 109) to output a visible pattern (eg, grid, dot field) onto workpiece 82 and the joint welding. Cameras configured to detect the visible pattern can determine the shape of the part

101

IMPI ^ a 82 work and / or the path of the weld joint and particular particulars of the shape and orientation of the pattern visible in workpiece 82 and the weld joint. Control circuit 52 can determine the shape of the weld joint and / or workpiece 82 using object recognition algorithms (eg, edge detection) applied to the one or more captured images or visible pattern. The operator can provide input to aid object recognition, such as selecting a joint type (eg, butt, T, flap, corner, edge) and / or shape (eg, flat, tubular, curved) of workpiece 82.

Figure 81 is a diagram of one embodiment of a curved weld joint 538. This curved weld joint 538 can be calibrated using the method 530 described in Figure 30. The curved weld joint 538 is on a workpiece.

540. Specifically, the curved weld joint 538 includes a first position 542, a second position 544, and a curved portion 546. Using method 530, a shape of the curved weld joint 538 can be determined and / or stored to evaluate an operator for weld that performs a welding operation on the weld joint 538.

FIG. 32 is a diagram of one embodiment of a complex shaped workpiece 539 with a curved weld joint 541. Curved weld joint 541 may be calibrated through markings 543 added to workpiece 539 near the Curved weld joint 541. Marks 543 may include, but are not limited to decals, reflectors, paints, or pigments applied to workpiece 539 through a roller tool 545. The operator can roll a dial wheel 547 of the roll tool 545 along the curved weld joint

541, depositing marks 543 on workpiece 539. For example, pads 549 on marking wheel 547 can apply marks 543 to the part.

102 working 539 at regular intervals throughout the

IMPI

INDUSTRIAL

<img file="MX359249B_D0074.tif" />

541.

Chambers of the one or more detection devices 16 in the welding base 12 and / or integrated with the case 41 of the welding system 10 can detect the marks 543. Control circuits of the welding system 10 can determine the shape of the piece of Complex work 539 and / or the welding system 10 can determine the welding path along the curved weld joint 541 based at least in part on the detected marks 543. The shape of the complex shaped workpiece 539 and / or the weld path of the curved weld joint 541 can be stored to evaluate a weld operator to perform a welding operation on the curved weld joint 541 Although the marks 543 shown in Figure 39 are discontinuous, some modalities of the marks 543 may be continuous along the curved weld joint 541.

FIG. 33 is an embodiment of a method 548 for tracing a multi-pass welding operation. One or more cameras (eg, such as one or more cameras of the one or more detection devices 16) are used to detect a first pass of the welding tool 14 along a weld joint during the welding operation of several passes (block 550). Furthermore, the one or more cameras are used to detect a detect a second pass of the welding tool 14 along the weld joint during the multi-pass welding operation (block 552). Furthermore, the one or more cameras are used to detect a third pass of the welding tool 14 along the weld joint during the multi-pass welding operation (block 54). The control circuit 52 (or control circuit of another device) can be configured to store a representation of the first pass, the second pass and / or the third pass together as a single welding operation to determine a quality of the operation of

103

<img file="MX359249B_D0075.tif" />

<img file="MX359249B_D0076.tif" />

multi-pass welding. As you can see

ÓÉ THE industrial proFltTY several passes can be a live welding operation, a training welding operation, a virtual reality welding operation and / or an augmented reality welding operation.

FIG. 34 is a perspective view of one embodiment of weld base 12. Weld base 12 includes a weld surface 88 supported by legs 90. Furthermore, weld surface 88 includes one or more slots 91 for facilitating the placement of a workpiece on the weld surface 88. In addition, the weld surface 88 includes several openings 556 (eg, holes or openings) that extend through the weld surface 88. The openings 556 can be used to enable the one or more detection devices 16 to determine a position and / or an orientation of the weld surface 88. Specifically, the markers can be arranged below the openings 556, but within vision of the one or more detection devices 16 to enable the detection devices 16 to determine the position and / or orientation of the weld surface 88. The markers can be arranged below the weld surface 88 to facilitate longer lasting markers and / or to block and prevent debris from covering the markers, as explained in greater detail in relation to Figure 35.

Drawers 558 are attached to weld base 12 to enable storage of various components with weld base 12. In addition, wheels 560 are attached to weld base 12 to facilitate easy movement of weld base 12. Adjacent to drawers 558, a calibration tool holder 562 and a welding tool holder 564 make it possible to store the calibration tool 120 and the welding tool 14. In certain modalities,

104 the welding system 10 can be configured to d

<img file="MX359249B_D0077.tif" />

INDUSTRIAL calibration 120 is on the calibration tool holder 562 at various times, such as before carrying out a welding operation. A support structure 566 extending vertically from the weld surface 88 is used to provide structural support to the one or more detection devices 16 and the visual presenter 32. Furthermore, a tray 568 is coupled to the support structure 566 to facilitate the storage of different components.

Protective cover 102 is placed over visual presenter 32 to block certain environmental elements from contacting visual presenter 32 (eg, spatter, smoke, sparks, heat, etc.). A handle 570 is coupled to the protective cover 102 to facilitate rotation of the protective cover 102 from a first position (such as the illustrated one) used to block certain environmental elements from contacting the visual presenter 32 to a second raised position away from the visual presenter 32, as illustrated by arrows 572). The second position is not configured to block the environmental elements from making contact with the visual presenter 32. In certain embodiments, the protective cover 102 may be held in the first and / or second position by a latching device, a damper, an actuator, a stop, and so on.

In certain embodiments, a switch 573 is used to detect whether the protective cover 102 is in the first position or in the second position. Furthermore, switch 573 can be coupled to control circuit 52 (or control circuit of another device) and configured to detect whether protective cover 102 is in the first or second position and to block or enable various operations (for example, live welding, auxiliary power, etc.) while switch 573 detects that the protective cover 102 is in the first and / or second position. For example, if the switch

105

Τ

573 detects that the protective cover 102 is in the

<img file="MX359249B_D0078.tif" />

Properly covering the visual presenter 32), the control circuitry 52 can block the live weld and / or simulation weld (with the cuvette rotated in the second position, the one or more detection devices 16 may be unable to detect markers accurately). As another example, if the switch 573 detects that the protective cover 102 is in the second position, the soldering base control circuit 12 may block the availability of power provided to an output 574 of the soldering base 12. In In certain embodiments, the visual presenter 32 may display an indication that the protective cover 102 is in the first and / or second position. For example, while the protective cover 102 is in the second position, the visual presenter 32 may provide an indication to the welding operator that live welding and / or power at output 574 is not available. The soldering base 12 includes 575 speakers to enable audio feedback to be provided to a welding operator using the soldering base 12. Furthermore, in certain embodiments, if the trigger of the welding tool 14 is pulled while the protective cover 102 is in the second position, the welding system 10 can provide visual and / or audio feedback to the operator (for example, the 10 welding system can provide visual message and audible sound effect).

As illustrated, the support structure 566 includes a first arm 576 and a second arm 578. The first and second arms 576 and 578 can rotate around the support structure 566 to enable the first and second arms 576 and 578. are set at a selected height for vertical and / or aerial welding. In the illustrated embodiment, the first and second arms 576 and 578 can rotate independently (eg separately) from each other in such a manner

106

<img file="MX359249B_D0079.tif" />

IMPI that the first arm 576 can be placed in a primeratmtiiJtáeJO ^ 'INDUSTRIAL the second arm 578 can be placed in a second vertical position different from the first vertical position. In other embodiments, the first and second arms 576 and 578 are configured to rotate together. Furthermore, in certain embodiments, the first and second arms 576 and 578 can be independently and / or rotated together based on a selection by a welding operator. As can be appreciated, in other embodiments, the arms may not be coupled to the support structure 566, but rather be placed elsewhere, such as being placed to extend vertically over one or more front limbs, etc. Furthermore, in some embodiments, a structure may be coupled to weld base 12 to facilitate a welding operator to lean on and / or rest on it (eg, a support bar).

Each of the first and second arms 576 and 578 includes a shock absorber

580 (or other support device) that facilitates the retention of the first and second arms

576 and 578 in selected vertical positions. In addition, each of the first and second arms 576 and 578 includes a drain system 582 configured to secure the first and second arms 576 and 578 individually in selected positions. In certain embodiments, drain system 582 is unlocked by applying force to a handle, switch, foot pedal, and / or other device.

As illustrated, workpiece 82 is coupled to second arm 578 for aerial and / or vertical welding. In addition, the first arm 576 includes the weld plate 108 for aerial, horizontal and / or vertical welding. As can be appreciated, workpiece 82, weld plate 108 and / or a clamp used to retain weld plate 108 may include various markers (eg, reflective and / or light emitting) to facilitate tracing by the one or more detection devices 16.

107

IMPI

For example, in certain modalities, work piece 82, 'N'DUSTRIAL

<img file="MX359249B_D0080.tif" />

The clamp may include three markers on one surface (eg, in one plane), and a fourth marker on another surface (eg, in a different plane) to facilitate tracking by the one or more detection devices 16. As illustrates, a brake release 584 is attached to each of the first and second arms 576 and 578 to unlock each braking system 582. In certain embodiments, a pull chain may extend downward from each brake release 584 to facilitate unlocking and / or lowering the first and second arms 576 and 578, such as while the 584 brake release of the first and second arms 576 and 578 is vertically above the reach of a welding operator. Thus, the welding operator can pull a handle on the drive chain to unlock the braking system 582 and / or to lower the first and second arms 576 and 578.

As illustrated, second arm 578 includes a clamping assembly

588 for coupling workpiece 82 to second arm 578. In addition, clamping assembly 588 includes various T-handles 590 for adjusting, tightening, securing, and / or loosening clamps and other portions of clamping assembly 588. In certain embodiments, the First arm 576 may also include multiple 590 T-handles to adjust, tighten, secure, and / or loosen weld plate 108. As can be appreciated, the clamp assembly 588 may include various markers (eg, reflective and / or light emitting) to facilitate tracing by the one or more detection devices 16. For example, in certain embodiments, the Fastener 588 may include three markers on one surface (eg, in one plane), and a fourth marker on another surface (eg, in a different plane) to facilitate tracking by the one or more detection devices 16. It is worth mentioning that the welding system 10 may include the clamping assembly 588 on one or both of the first and second arms 576 and 578.

108 iMPioea

In certain modalities, the one or more dispesttwo ^ eáeA ^ téd ^ é ^^ R ^ uede ' ^r OF THE PROPERTY

INDUSTRIAL include a removable cover 592 disposed in front of one or more cameras of the detection device 16 to block environmental elements (eg, splash, smoke, heat, etc.) or other subjects from making contact with the detection device 16. The cover Removable 592 is arranged in slots 594 configured to keep removable cover 592 in front of detection device 16. In certain embodiments, removable cover 592 can be inserted, removed, and / or replaced without the use of tools. As explained in detail below, the removable cover 592 can be arranged in front of the detection device 16 at an angle to facilitate infrared light to pass through it.

As illustrated, a connection assembly 596 may be coupled between the first and / or second arms 576 and 578 and the one or more detection devices 16 to facilitate rotation of the detection devices 16 when the first and / or second Arms 576 and 578 have been rotated. Accordingly, when the first and / or second arms 576 and 578 are rotated, the detection device 16 can also rotate such that one or more cameras of the one or more detection devices 16 are positioned to trace a welding surface. selected. For example, if the first and / or second arms 576 and 578 are placed in a lowered position, the one or more detection devices 16 can be configured to track welding operations occurring on the welding surface 88. On the other hand, if the first and / or second arms 576 and 578 are placed in an elevated position, the one or more detection devices 16 can be configured to track vertical, horizontal, and / or aerial welding operations. In some embodiments, the first and / or second arms 576 and 578 and the one or more detection devices 16 may not be mechanically connected, however rotation of the first and / or second arms 576 and 578 may facilitate

109

IMPI rotation of detection devices 16.

. , MEXICAN INSTITUTE

For example,

<img file="MX359249B_D0081.tif" />

second arms 576 and 578 can be detected by the one or more detection devices 16, and detection devices 16 can be moved (eg, using motor) based on the detected position of the first and / or second arms 576 and 578.

In some modalities, the movement of the first and / or second arms

576, 578 can at least partially invalidate previous calibrations of the one or more detection devices 16 with components of the weld base 12. For example, after sensing devices 16 are calibrated with main (eg horizontal) weld surface 88 of weld base 12, subsequent movement of the first and second arms 576, 578 may invalidate the calibration of the surface main weld 88 based at least in part on movement of detection devices 16. Consequently, the one or more detection devices 16 can be recalibrated with the main welding surface 88 once the operator conducts welding sessions using the first and / or second arms 576, 578. In some embodiments, computer 18 notifies the operator through visual display 32 and / or audible notifications when the one or more detection devices 16 are to be recalibrated based on the detected movement of detection devices 16 relative to the welding surface 88. Alternatively, or in addition, the visual presenter 62 of the calibration tool 14 may notify the operator when the one or more detection devices 16 are to be recalibrated.

FIG. 35 is a cross-sectional view of one embodiment of weld surface 88 of weld base 12 of FIG. 34. As illustrated, weld surface 88 includes several openings 556 extending therethrough between a upper plane 597 of the weld surface 88 and a lower plane 598 of the surface

110

MEXICAN INSTITUTE .OS

<img file="MX359249B_D0082.tif" />

THE WELDING PROPERTY 88. A 599 bracket is placed below each »^Dattoertu supports 599 can be attached to the welding surface 88 or a suitable fastener or fastening means. In the illustrated embodiment, supports 599 are attached to weld surface 88 using fasteners 600 (eg, bolts, screws, etc.). In other embodiments, supports 599 may be welded, attached, or otherwise secured to weld surface 88. Furthermore, in certain embodiments, supports 599 can be mounted to a lateral side of weld base 12 instead of weld surface 88. Markers 602 are coupled to supports 599 and positioned vertically below openings 556, but markers 602 are horizontally offset from openings 556 to prevent dust and / or spatter from contacting markers 602 and making it possible for the one or more Detection devices 16 detect markers 602. In some embodiments, markers 602 can be placed within openings 556 and / or anywhere such that the motion tracking system is placed on one side of the top plane 597 and markers 602 are placed on the opposite side. of the upper plane 597. As can be seen, the markers 602 can be light reflective and / or light emitting. For example, in certain embodiments, markers 602 can be formed from a light reflective tape. In some embodiments, markers 602 can be spherical markers. Accordingly, the one or more detection devices 16 can detect markers 602 to determine a position and / or an orientation of the weld surface 88.

FIG. 36 is a cross-sectional view of one embodiment of a detection device 16 having the removable cover 592. As illustrated, the removable cover

592 it is arranged in the slots 594. The detection device 16 includes a camera

604 (for example, infrared camera) that has a 605 face on one side of the camera

111

604 which has a 606 lens.

IMPI

MEXICAN INSTITUTE

Removable cover 592 is ”ott ^ $ 5j $ d

<img file="MX359249B_D0083.tif" />

it is possible for infrared light to pass through it and

<img file="MX359249B_D0084.tif" />

eg, splashing, smoke, heat, etc.) or other objects making contact with lens 606 of camera 604. As can be appreciated, camera 604 may include one or more infrared emitters 607 configured to emit infrared light. If the removable cover

592 is placed directly in front of face 605, a large amount of infrared light from infrared emitters 607 can be reflected by the removable cover

592 towards lens 606 of camera 604. Accordingly, removable cover 592 is positioned at an angle 608 relative to face 605 of camera 604 to direct a substantial portion of the infrared light that is reflected back to lens 606. Specifically In certain embodiments, the removable cover 592 can be placed at an angle 608 between about 10 to 60 degrees relative to face 605 of camera 604. Furthermore, in other embodiments, removable cover 592 can be positioned at an angle 608 between about 40 to 50 degrees (eg, about 45 degrees) relative to face 605 of chamber 604. Removable cover 592 can be manufactured to from any suitable light transmitting material. For example, in certain embodiments, removable cover 592 can be made from a polymeric material, or any other suitable material.

Fig. 37 is a perspective view of one embodiment of a calibration tool 610. As can be appreciated, the calibration tool 610 can be used to calibrate a workpiece, a work surface, a solder joint, and so on. , for a welding operation. The 610 Calibration Tool includes a 612 handle to facilitate holding the 610 Calibration Tool. Furthermore, the calibration tool 610 is configured to be detected by the one or more detection devices 16 to determine a position.

112

IMPI

SPACE INSTITUTE that a tip 614 of the fffe'iSSfenoc calibration tool

<img file="MX359249B_D0085.tif" />

In certain embodiments, computer 18 coupled to the ojjáajdispositwos-de-éeteeeiún · can be configured to determine a calibration point simply by contacting tip 614 with a specific surface. In other embodiments, computer 18 is configured to determine a calibration point by providing an input weld operator indicating that tip 614 is making contact with a calibration point. Also, in the illustrated mode, computer 18 is configured to detect a calibration point by tip 614 by making contact with the calibration point while a downward force is applied to calibration tool 610 through the handle. The downward force directs a distance between two adjacent markers to decrease below a predetermined threshold thus indicating a selected calibration point. The one or more detection devices 16 are configured to detect the change in distance between the two adjacent markers and computer 18 is configured to use the change in distance to identify the calibration point. Handle 612 is attached to a light transmitting cover 616. Additionally, a gasket 618 is coupled to one end of the light transmitting cover 616, while an end cap 620 is coupled to an opposite end of the light transmitting cover 616. During operation, a downward force is applied to the tool during operation. 610 calibration using the handle

612, a distance 622 between tip 613 and packing 618 is reduced.

Figure 38 is a perspective view of the calibration tool

610 of Figure 37 having the outer cover 616 removed. Calibration tool 610 includes a first portion 624 that has a first axis 626. Furthermore, first axis 626 includes tip 614 at one end, and a bearing 628 (or mounting structure) at an opposite end. In certain embodiments, the 628 bearing has a

113

IMPI cup-like structure configured to fit around

<img file="MX359249B_D0086.tif" />

welding tool 14. Furthermore, the first shaft 626 includes a first marker 630 and a second marker 632 coupled thereto. Calibration tool 610 also includes a second portion 634 having a second axis 636 with a third marker 638 coupled thereto. A spring 640 is disposed around the second axis 636 between the third marker 638 and the bearing 628. As can be appreciated, spring 640 facilitates third marker 638 to be directed toward second marker 632. For example, by applying a downward force to calibration tool 610 using handle 612, spring 640 is compressed to reduce a first distance 642 between the second and third markers 632 and 638. In contrast, by removing the downward force from the calibration tool 610, spring 640 is decompressed to increase the first distance 642 between the second and third markers 632 and 638. A second distance 644 between the first and second markers 630 and 632 is fixed, and a third distance 646 between the first marker 630 and the tip 614 is also fixed.

In certain embodiments, the welding system 10 uses the calibration tool 610 to detect calibration points using a predetermined algorithm. For example, the third distance 646 is measured between tip 614 and the marker closest to tip 614 (eg, the first marker 630). The third distance 646 is stored in memory. The second distance 644 is measured between two fixed markers (eg, the first marker 630 and the second marker 632). The second distance 644 is also stored in memory. In addition, a compressed distance between the markers (eg, the second and third markers 632 and 638) is measured with the spring 640 disposed therebetween. A line between the two fixed markers is calculated using their x, y, z locations. The line is used to project a vector along that

114 line with a length of the third distance 646 start

<img file="MX359249B_D0087.tif" />

closer to tip 614. The direction of the vector can be selected to be away from the compressed markers. Consequently, the three-dimensional location of the tip can be calculated using the markers. In some modes, only two markers can be used by the 610 calibration tool. In such embodiments, an assumption can be made that the marker closest to tip 614 is the marker closest to the work surface (eg, table or clamp). Although the 610 calibration tool in the illustrated mode uses compression to indicate a calibration point, the 610 calibration tool can indicate a calibration point in any suitable way, such as when discovering a marker, covering a marker, lighting an LED (eg IR LED), turning off an LED (eg IR LED), enabling and / or disabling a wireless transmission to a computer, and so on.

The first, second, and third markers 630, 632, and 638 are spherical as illustrated, however, in other embodiments, the first, second, and third markers 630, 632, and 638 may have any suitable shape. Furthermore, the first, second and third markers 630, 632 and 638 have a reflective outer surface and / or include a light emitting device. Accordingly, the first, second, and third markers 630, 632, and 638 can be detected by the one or more detection devices 16. Therefore, the one or more detection devices 16 are configured to detect the first, second, and third distances 642, 644, and 646. By reducing the first distance 642 below a predetermined threshold, computer 18 is configured to identify a point calibration. As can be seen, the first, second and third distances 642, 644 and 646 are all different to enable the one or more detection devices 16 and / or the computer 18 to determine a location of the

115 tip 614 using the location of the first, second and third

IMPI

INDUSTRIAL

<img file="MX359249B_D0088.tif" />

To calibrate a workpiece 82, the workpiece 82 can first be clamped to the weld surface 88. Once the workpiece 82 is clamped to the weld surface 88, a weld operator can provide input to the system weld 10 to indicate that workpiece 82 is ready to be calibrated. In certain embodiments, the fastener used to secure the workpiece 82 to the weld surface 88 may include markers that facilitate the weld system 10 to detect that the workpiece 82 is attached to the weld surface 88. Once the welding system 10 receives an indication that the workpiece 82 is attached to the welding surface 88, the welding operator uses the calibration tool 610 to identify two calibration points on the workpiece 82. When the clamping assembly 588 securing the workpiece 82 has markers (eg, 802 visual markers), the measurements of the joint calibration tool 610 may be relative to the markers of the clamping assembly 588. Accordingly, the Computer 18 can compensate for movement of workpiece 82 and / or clamp assembly 588 once the joint has been calibrated based on the identification of clamp markers. Specifically, in the illustrated mode, the welding operator touches tip 614 to a first calibration point and applies downward force using handle 612 until the welding system 10 detects a sufficient change in distance between adjacent markers, indicating this way the first calibration point. Furthermore, the welding operator touches tip 614 to a second calibration point and applies downward force using handle 612 until the welding system 10 detects a sufficient change in distance between adjacent markers, thereby indicating the second point of calibration. In certain modalities, the

116

Soldadura »^ weld 10 will only detect a calibration point if the 610 is pressed and held at the calibration point for a predetermined period of time (eg 0.1., 0.3, 0.5, 1.0, 2.0 seconds, and so on). Welding system 10 can be configured to capture multiple calibration points (eg, 50, 100, etc.) during the predetermined time period and average them together. If the movement of the multiple calibration points greater than a predetermined threshold is detected, the calibration can be rejected and redone. Also, if a first point is successfully calibrated, a second point may have to be a minimum distance away from the first point (for example, 5, 10, 15 centimeters, etc.). If the second point is not within the minimum distance away from the first point, the calibration of the second point can be rejected and re-done. Welding system 10 uses the two calibration points to calibrate workpiece 82.

In certain embodiments, the welding system 10 can determine a virtual line between the first and second calibration points. The virtual line can be infinitely long and extend beyond the first and second calibration points. The virtual line represents a weld joint. Various welding parameters (eg working angle, displacement angle, tip to working distance (CTWD), target, displacement speed, etc.) can be in reference to this virtual line. Consequently, the virtual line can be important in calculating the different welding parameters.

It is worth mentioning that in certain modalities the first, second and third markers 630, 632 and 638 are all arranged vertically on the handle 612, while in other modalities, one or more of the first, second and third markers 630, 632 and 638 are arranged vertically under the handle 612 to make possible

117

IMPI a greater distance between adjacent markers. In cer * a ^ rmgdgfejad ^^ Wárfl'aüBra INDUSTRIAL portion 624 can be removed from the calibration tool 610 and attached to a contact tip of the welding tool 14 to calibrate the welding tool 14. As can be seen, the Tip 614 of Calibration Tool 610 can be any suitable shape. Figures 39 to 41 illustrate few modalities than shapes that the tip 614 can have.

Specifically, FIG. 39 is a side view of one embodiment of a sharp tip 648 of the calibration tool 610. Using the sharp tip 648, the calibration tool 610 can be used to calibrate various joints on workpiece 82, such as the illustrated fillet joint, a lap joint, a butt joint without any root openings, and so on. Furthermore, Fig. 40 is a side view of one embodiment of a rounded tip 650 of calibration tool 610. Using rounded tip 650, calibration tool 610 can be used to calibrate various joints on workpiece 82, such as such as the illustrated fillet joint, a butt joint with a root opening, a lap joint, and so on. In addition, Fig. 41 is a side view of one embodiment of the rounded tip 650 of the calibration tool 610 having a small sharp tip 652. Using the small sharp tip 652 at the end of the rounded tip 650, the calibration tool 610 can be used to calibrate various joints on workpiece 82, such as the illustrated butt joint without root opening, a filled joint, a lap joint, and so on. In certain embodiments, the tip of the calibration tool 610 may be removable and / or reversible, such that the tip includes two different types of tips (eg, one type of tip at each opposite end). Consequently, a welding operator can select the type of tip used by the 610 calibration tool. In certain modes, one or more markers can

118

IMPI be attached to the 610 calibration tool if the hét '^ Qg ^' ^^ ci

INDUSTRIAL

<img file="MX359249B_D0089.tif" />

it is reversible. The one or more markers can be used to indicate which side of the tip is being used such that the welding system 10 can use a suitable marker-to-tip distance for calibration calculations.

Figure 42 is an embodiment of a method 654 for detecting a calibration point. The one or more detection devices 16 (or another component of the welding system 10) detect a first marker of the calibration tool 610, a second marker of the calibration tool 610 and / or a third marker of the calibration tool 610 (block 656). Furthermore, the welding system 10 determines a first distance between the first marker and the second marker and / or a second distance between the second marker and the third marker (block 658). Furthermore, the welding system 10 detects whether the first distance or the second distance is within a predetermined distance range (eg, indicating a compressed distance) (block 660). Welding system 10 determines a position of a calibration point if the first distance or the second distance is within the predetermined distance range (eg, meaning a compressed distance) (block 662). Furthermore, the welding system 10 determines a location of a calibration tip of the calibration tool 610 with respect to at least one of the first, second and third markers to determine the spatial position of the calibration tip (block 664).

FIG. 43 is an embodiment of a method 666 for determining a weld score based on a weld path. Consequently, method 666 can be used to evaluate a welding operation. The one or more detection devices 16 (or any suitable motion tracking system) detect an initial position of the welding operation (block 668). Furthermore, the one

119

<img file="MX359249B_D0090.tif" />

IMPI or more 16 detection devices detect a position^IF^TS®^,^ e ^^ industrial welding (block 670). Furthermore, the one or more detection devices 16 detect a spatial path of the welding operation between the initial position and the terminal position (block 672). For example, the one or more detection devices 16 track a position and / or an orientation of the welding operation. Welding system 10 determines a score for the welding operation based at least partially on the spatial path of the welding operation (for example, if the welding operation receives a pass score based on the spatial path of the operation welding) (block 674). For example, in certain embodiments, the spatial path of the weld operation can be used alone to determine if a weld score fails. In some embodiments, the one or more detection devices 16 can be used to detect a calibration point that corresponds to the starting position and / or a calibration point that corresponds to the terminal position.

For example, in certain embodiments, the welding system 10 determines whether the welding operation receives a pass score when determining whether: a distance of the path of the welding operation is greater than a predetermined lower threshold, the distance of the path of the welding operation is less than the predetermined lower threshold, the distance of the path of the welding operation is greater than a predetermined upper threshold, the distance of the welding operation path is less than the predetermined upper threshold, the path of the welding operation deviates substantially from a predetermined path of the welding operation, the path of the welding operation indicates that several weld passes occurred at a single location along a weld joint, a time of weld along the path of the weld operation is greater than a predetermined lower threshold, the weld time at

120 path length of the welding operation e8 «TCHfíQiga8MK eHffjSfflgjffl below the predetermined time, the welding time along the path of the welding operation is greater than a predetermined upper threshold and / or the time of the welding along the path of the welding operation is less than the predetermined upper threshold.

Furthermore, in some embodiments, for the welding system 10 to determine a score, the welding system 10 may ignore a first portion of the path adjacent to the starting position and a second portion of the path adjacent to the terminal position. For example, the first portion of the path and the second portion of the path may include a distance of approximately 1.27 centimeters. Also, in other embodiments, the first portion of the path and the second portion of the path may include portions of the path formed over a time of approximately 0.5 seconds.

FIG. 44 is an embodiment of a method 676 for switching between welding modes using a welding tool user interface 14. Control circuit 52 of welding tool 14 (or control circuit of another device) detects a signal produced by a user interface of welding tool 14 indicating a request to change the welding mode (eg, welding training mode) (block 678). Furthermore, control circuit 52 determines a length of time that the signal is detected (block 680). Control circuit 52 is configured to change the welding mode from a simulation mode (for example, virtual reality mode, augmented reality mode, etc.) to a live welding mode if the length of time that the signal is detected is greater than a predetermined threshold (block 682). Conversely, control circuit 52 is configured to change the weld mode from live weld mode to mode

121

SIMPLE simulation if the signal is detected (hlnqWTSF ^ aiS ^ eiq ^^ gw there is INDUSTRIAL length of time the signal is to be detected before a transition from live welding mode is made). Control circuit 52 is configured to direct welding tool 14 to vibrate after switching to live welding mode (block 686). For example, control circuit 52 may be configured to direct welding tool 14 to vibrate two or more times (eg, vibrating pulses) to indicate a change to live welding mode.

Furthermore, the control circuit 52 can be configured to direct the welding tool 14 to vibrate any suitable number of times (eg, a determined number of times) to indicate a change to the live welding mode. As can be seen, the signal indicating the request to change the welding mode can be produced by pressing a button on the user interface 60 of the welding tool 14. In this way, the welding mode can be changed from the live welding mode by pressing and releasing the button (for example, the button does not have to be held down for a predetermined period of time). In contrast, the weld mode can be changed from simulation mode to live weld mode by pressing and holding the button for a predetermined period of time. In certain modes, an audible sound can be produced once the welding modes are changed. In addition, in some modes an audible sound and vibration can accompany any change between welding modes. Furthermore, a visual presenter of the welding tool 14 can display the welding mode after changing the welding mode. In some embodiments, the visual presenter may flash the weld mode on the visual presenter a predetermined number of times.

Fig. 45 is a block diagram of one embodiment of a system.

122 remote training, such as an input system

<img file="MX359249B_D0091.tif" />

INDUSTRIAL

<img file="MX359249B_D0092.tif" />

example, helmet). In some embodiments, hull 41 facilitates the acquisition of welding parameters (for example, a working angle, a displacement angle, a contact tip to work piece distance, a welding tool travel speed, an orientation of welding tool, a position of welding tool, a target of the welding tool in relation to the union of the workpiece, and so on) of a welding process and / or arc parameters (eg, a welding voltage, welding current, wire feed speed) without using the welding base 12 described above. As can be appreciated, operators wear helmets during welding, and helmet 41 integrates one or more detection devices 16 (eg emitters, receivers) into the helmet. Various modes of helmet 41 can incorporate computer 18 (for example, as a controller, dock to computer 18 through a wired connection, or dock to computer through a wireless connection. In some embodiments, helmet 41 uses a 700 lens to protect the operator from arc during a welding process. In some embodiments, visual presenter 32 is arranged within helmet 41 such that the operator can view visual 32 and lens 700 in preparation for or during a welding process. Visual presenter 32 may be a visual display presenter that is at least partially overlapped with the operator's view through helmet 41. As can be seen, the welding software 32 can use the visual presenter 32 arranged within the helmet 41 to present information to the operator in a similar manner to that described above with the visual presenter 32 external to the helmet 41. For example, the visual presenter 32 helmet 41 can display a visual representation (eg number, text, color, arrow, graphic) of one or more

123

ΙΜΡΙβ ^ arc parameters, one or more welding parameters, themselves. That is, the helmet display 32 32 can visually present a visual representation of a weld parameter relative to a predetermined threshold range and / or a target value for the weld parameter in accordance with a selected weld assignment. In some embodiments, the visual presenter 32 may display a graphical representation of a welding parameter or an arc parameter relative to a threshold in a manner similar to the visual displays 62 of the welding tool 14 described above with Figure 27. In addition, helmet 41 display 32 can display one or more parameters (eg, arc parameters, welding parameters) before, during, or after the operator wearing helmet 41 conducts a welding session (for example, weld allowance).

Helmet 41 uses one or more integrated detection devices 16 to determine welding parameters from observations of welding tool 14 and workpiece 82. One or more detection devices 16 of helmet 41 may include one or plus 702 receivers that include, but are not limited to, microphones, cameras, infrared receivers, or any combination thereof. Furthermore, in some embodiments, one or more emitters 704 may emit energy signals (eg, infrared light, visible light, electromagnetic waves, acoustic waves), and reflections of the energy signals may be received by the one or more receivers. 702. In some embodiments, fiducial points 706 (eg, markers) of the welding tool 14 and / or workpiece 82 are active markers (eg, LEDs) that emit energy signals, as described above with Figures 24 and 25. Accordingly, the one or more receivers 702 of the helmet 41 can receive energy signals emitted from active markers. In particular,

124

ΙΜΡΙ @ ^ receivers 702 can identify fiducial points (po ^^ Jgg ^ gu ^ prra ^^ to ^ Oe arranged on workpiece 82, work environment 708, and / or welding tool 14, and receivers 702 they can send feedback signals to computer 18 (eg controller) corresponding to identified fiducial points. As discussed above, arrangements of identified fiducial points 706 may enable detection device 16 to determine the position and orientation of welding tool 14 in working environment 708. Computer 18 (eg, controller) can determine the distances between the fiducial points 706 and can determine the welding parameters based at least in part on the feedback from the receivers 702. In addition, computer 18 (eg, controller) can be coupled to sensors within welding power source 28, wire feeder 30, and / or welding tool 14 to determine arc parameters of the welding process.

In some embodiments, the hull 41 can terminate the component types of the welding system 10 from the identified fiducial points. For example, the fiducial points of a TIG welding tool are different from the fiducial points of a MIG welding tool. Furthermore, the welding software 244 executed by the computer 18 can control the welding power source 28 and / or the wire feeder 30 based at least in part on the determined types of components of the welding system 10. For example, helmet 41 can control arc parameters (eg, welding voltage, welding current) based on the type of welding tool 14, the welding position of workpiece 82, and / or the workpiece material. Helmet 41 can also control arc parameters based on the experience or certification states of the operator associated with registration number 293. For example, the helmet

125

IMPI éSPSi 41 can control the welding power source 28 to^DfbtíSíSfi? íá welding available for selection by an operator .Germanians ^ da-juD, predetermined threshold of experience with welding processes in relatively thin workpieces or in the position of aerial welding. In some embodiments, the one or more helmet detection devices 16 41 include motion sensors 709 (eg, gyros and accelerometers) that are coupled to computer 18. Motion sensors 709 can enable computer 18 to determine the relative orientation and motion of helmet 41 within the environment.

In some embodiments, helmet 41 includes operator identification system 43. Operator identification system 43 may use a scanner 710 (eg, fingerprint scanner, retinal scanner, barcode scanner) or a scanning device. 712 input / output (eg, keyboard, touch screen) to receive operator identification information. As described above, identification information can be associated with registration number 293 unique to the operator. Weld data received by computer 18 (eg, controller) can be stored in memory devices 22 or storage devices 24, as described above. Computer 18 (eg controller) can associate the received and stored weld data with registration number 293 of the identified operator. Network device 36 is coupled to network 38 through a wired or wireless connection to store weld data 327 from helmet 41 in data storage system 318 (eg, cloud storage system). In some embodiments, helmet 41 can store weld data locally within storage devices 24 of computer 18 while helmet 41 is remotely operated (eg, production floor, job site). Helmet 41 can be configured to upload data from

126

MEXICAN INSTITUTE OF PROPERTY welding stored to the data storage system S ^ 't (for example, cloud storage system) after its connection to area 3', as when the operator saves helmet 41 at the end of a shift or at the end of a week of work. In some embodiments, helmet network device 36 can stream weld data to data storage system 318 (eg, cloud storage system) through network 38 during and / or after the operator carry out a welding session.

As can be appreciated, using the systems, devices, and techniques described herein, a welding system 10 can be provided to train welding operators. The welding system 10 can be inexpensive and can enable welding students to receive high-quality hands after training. Although the welding systems 10 described here can be used to receive and correlate 327 welding data for training and educational purposes, it can be appreciated that the welding systems 10 described here can be used to monitor operators and obtain 327 welding data from of non-training welding processes. That is, welding data obtained from non-training welding processes can be used to monitor weld quality and / or weld productivity of previously trained operators. For example, welding data 327 can be used to verify that the welding procedures for a particular welding process have been performed. As illustrated in FIG. 45, various welding systems 10 can be coupled to data storage system 318 (eg, cloud storage systems) through network 38. Accordingly, the data storage system 318 can receive weld data 327 associated with register numbers 293 from various weld systems 10 (for example, weld systems

127 with 12 welding bases, training systems in

<img file="MX359249B_D0093.tif" />

welds associated with each registration number 293 may include serial numbers

329 that correspond to other welding sessions carried out by the respective operator. Furthermore, as used herein, the term “allowance” should not be limited to weld tests conducted by the operator for training and educational purposes. That is, assignments can include non-training welding processes, simulated training welding processes, and live training welding processes, among others. Furthermore, the term "welding session" may include, but is not limited to, welding assignments, welds carried out on a production floor, welds carried out on a job site, or any combination thereof.

Weld data 327 from data storage system 318 (eg, cloud storage system) can be monitored and / or managed through a remote computer 44 attached to network 38. Stored weld data 327 corresponds to welding processes (eg live, simulated, virtual reality) carried out by multiple operators at one or more locations. FIG. 46 illustrates one embodiment of a user-visible dashboard display 720 that can be used by a manager or instructor to monitor and / or analyze weld data 327 stored in data storage system 318.

Weld data 327 can be organized by characteristics (eg, filter criteria) of weld data 327. The characteristics of the 327 weld data that can be used to classify the 327 weld data may include, but are not limited to, one or more 722 organizations (eg, training facility, employer, job site), one or more 724 groups (eg shift) within the organization, one or more 726 operator registration numbers

128 within selected organizations 722 or groups

<img file="MX359249B_D0094.tif" />

dates 728, time of day) when the welding processes were carried out, 725 systems and 730 welding identifications (for example, particular welding assignments, unique identifier associated with a welding session, workpiece part number or types of welds). For example, weld data 327 associated with one or more record numbers 293 over a period of time (eg, dates 728) and through different organizations 722 or different groups 724 can be displayed visually on dashboard screen 720. In Consequently, the manager or instructor can track an operator's progress over time through different organizations using welding data associated with the operator's registration number 293. In some embodiments, a 732 weld data type (eg, live training, non-live training, simulation, virtual reality) can be used to filter the viewed weld data. Also, a type of 735 welding process (eg GMAW, TIG, SMAW) can be used to filter the welding data seen in some modalities. As can be appreciated, weld data for each weld session (eg, weld assignment) can be classified (eg, filtered) into multiple subsets. As illustrated in Figure 46, live, non-training welds carried out by an operator with registration number 58,794 on June 25, 2014 with system I can be displayed visually on the 720 panel display through selection one or more of the appropriate fields for 726 record numbers, 725 systems, 728 dates, and 732 weld data types.

As an alternative, or in addition, the instructor can use a search control 733 to search for 327 weld data associated with different parameters (for example, serial numbers 329, organization 722, group 724, operator name,

129 record number 726, time, weld data type) Xj ^ Xre6pXic ^ * et'Se ^! nes IFmTTUTO MBXK1ANO

DC PROPERTY welding carried out by operators. After selection of a weld data set, a session 734 of the display board / 20 may visually display graphical cues (eg, a score) associated with the selected weld data and / or at least a portion of the welding data. Furthermore, details of weld data 327 can be viewed after selection of weld data 327 and a user control 736. The 720 dashboard display can enable the manager or instructor to save or edit the weld data layout on the 720 dashboard display. Furthermore, the 720 dashboard display can enable the manager or instructor to export at least a portion of the 327 weld data. For example, the manager can export the 327 weld data that corresponds to sessions conducted by a set of operators over the course of a day or a week. Dashboard 720 can make it possible for the administrator or instructor to export weld 327 data in various formats, including but not limited to a comma separated value (CSV) file, a spreadsheet file, and a text file. In some modalities, the administrator or instructor may remove a subset of the weld data (eg demo weld data) from the data storage system (eg cloud storage system). Alternatively, or in addition, the administrator or instructor can edit the 732 weld data type, such as to review training weld data as non-workout weld data, review the operator associated with weld data, review the associated time with welding data, and so on.

As can be seen, the 720 dashboard display can enable the manager or instructor to monitor, compare and analyze associated weld data

130

<img file="MX359249B_D0095.tif" />

with one or more registration numbers 726. In any case, experience and historical data of welding operators can be compared through organizations or groups through the numbers of * registration / 2b. In some ways, the 720 dashboard display can enable the manager or instructor to set goals or provide assignments to desired 726 record numbers. Furthermore, the administrator or instructor can monitor and adjust previously established goals. The dashboard display 720 may enable notes or comments regarding the welding performance associated with one or more record numbers to be entered and stored with the welding data.

Figure 47 illustrates an embodiment of the welding system 10 in the welding environment 11 that can track the position and / or orientation of the welding tool 14 without using markers 474 on the welding tool 14 described above with respect to the figures. 23-25. The welding system 10 of Figure 47 can track the position and / or orientation of the welding tool 14 before carrying out a welding process. In some embodiments, the welding system 10 of Figure 47 can track the position and / or orientation of the welding tool 14 during the welding process. One or more depth sensors 750 are arranged at various positions in the welding environment 11, such as a first depth sensor 752 on the workpiece 82, a second depth sensor 754 integrated with the welding helmet 41 (for example , helmet training system), or a third horizontal depth sensor 756 with workpiece 82, or any combination thereof. Each depth sensor 750 can have an emitter configured to emit a visible pattern at a desired wavelength and a camera configured to monitor the visible pattern in the welding environment 11. The visible pattern emitted by each depth sensor 750 can be

131 equal or different from the visible pattern emitted by other s

<img file="MX359249B_D0096.tif" />

Also, the desired wavelength of the visible pattern for each depth sensor

750 it may be the same or different between the depth sensors 750. Figure 47 illustrates respective visible patterns emitted from each depth sensor 750 with solid arrows, and illustrates the reflected patterns towards each depth sensor 750 with dashed arrows. The wavelength of the visible patterns can be within the infrared, visible, or ultraviolet spectrum (for example, about 1 mm at 120 nanometers). The emitter of each depth sensor emits the respective visible pattern in the welding environment 11 on the welding surface 88, the workpiece 82, the welding tool 14, or the operator, or any combination thereof. By observing the visible pattern reflected in the welding environment 11, the computer 18 can track objects (eg, welding tool 14, operator) that move within the welding environment. In addition, computer 18 can identify the shape of workpiece 82 or a weld bonding path on workpiece 82 based on observations of the pattern visible in welding environment 11.

As can be seen, an arc 758 struck by the welding tool 14 with the workpiece 82 emits electromagnetic radiation. The wavelengths and intensity of emissions at each wavelength of electromagnetic radiation emitted by the arc can be based on a variety of factors including, but not limited to, the material of the workpiece, the material of the electrode, shielding gas composition, welding voltage, welding current, type of welding process (eg SMAW, MIG, TIG). In some embodiments, the one or more detection devices 16 include a light sensor configured to detect the electromagnetic radiation wavelengths of the

132 11 welding environment before and during processes

Industrial IMPI

<img file="MX359249B_D0097.tif" />

ra of the welding system 10 can determine the emitted wavelengths and the intensity of the emitted wavelengths from the emitted wavelengths based on feedback received from the one or more detection devices 16. Alternatively, or in addition, computer 18 may determine emitted wavelengths and intensity of emitted wavelengths from data stored in memory of computer 18 or data storage system 318, welding parameters, and the arc parameters. For example, computer 18 may determine that the steel MIG welding arc has different predominant wavelengths than the aluminum TIG welding arc.

In some embodiments, the wavelengths of the one or more visible patterns emitted by depth sensors 750 can be selected to reduce arc noise 758 during welding processes. Furthermore, in some embodiments, depth sensors 750 may vary the wavelength of the emitted visible pattern. Accordingly, computer 18 can adaptively control the wavelengths of emitted visible patterns to improve the precision of position and orientation determinations from depth sensor feedback. That is, computer 18 can control depth sensors 750 to output the visible pattern in a first interval for steel MIG welding, and to output the visible pattern in a different second interval for aluminum TIG welding. Alternatively, or in addition, computer 18 may filter the signals received by depth sensors 750 to reduce or eliminate the effects of emissions from arc 758.

Furthermore, arc 758 may not be continuous during weld formation, for some welding processes (eg, short-circuit MIG). The

133

WRONG ^ electromagnetic radiation emitted when the arc 758 8§t &lt;KI0i ^^^) rx ^^^^^ (during a short-circuit phase of the welding process) may be substantially less than the electromagnetic radiation emitted when the arc 758 is active. Computer 18 can control depth sensors 750 to output the respective visible patterns when arc 758 instead of when arc 758 is live, then making it possible for depth sensors 750 to track the position and / or orientation of the tool weld 14 during the welding process. That is, computer 18 can synchronize the visible patterns emitted to substantially coincide with the short-circuit phases of the welding process. The short-circuit frequency may be greater than 30 Hz, thereby enabling the computer 18 to determine the position and / or orientation of the welding tool 14 in the welding environment 11a at approximately 30 Hz or more.

In addition, or as an alternative to depth sensors 750, the welding system 10 can use a local positioning system 762 to determine the position of the welding tool 14 within the welding environment 11. Beacons 764 of the local positioning system 762 are arranged at known locations around the welding environment and emit signals 766 (eg, ultrasonic, RF) received through one or more microphones 429 in the welding tool. Computer 18 coupled to one or more microphones 429 can determine the location of the welding tool 14 within the welding environment 11 based at least in part on signals received from three or more beacons 764. The computer can determine the position of the welding tool 14 through triangulation, trialteration, or multi-alteration. More than three beacons 764 of the local positioning system 762 distributed around the welding environment 11 increase the robustness of the local positioning system 762 and increase the probability that the tool

134 welding 14 is within a line of sight of I'M ° Pí^s ^ | g ^ 4 in

MEXICAN INSTITUTE any point along a work piece 82 that has ^ ^ ^ SOJ &amp; n ^ S • (for example, tube). In some embodiments, depth 764 beacons 750 or components of the welding system 10, such as the welding power source 28.

Returning to Figures 24 and 25, the weld tool 14 embodiments may have multiple sets of visual markers 802 to facilitate detection of the position and orientation of the weld tool 14 relative to weld base 12 and to the workpiece 82. In some embodiments, the 802 visual markers are 64 LEDs that can be independently controlled.

For example, each set (eg, first set 804, second set 806, third set 810) of LEDs 64 can be separately controlled such that only one set is turned on and emits light at a time. Reducing the amount of visual markers 802 detectable by the one or more detection devices 16 can reduce the complexity of determining the position and orientation of the welding tool 14. That is, the one or more detection devices 16 can easily determine which side (eg top, left, right) of the welding tool 14 is oriented to the one or more detection devices 16 based on the arrangement of the LEDs. 64 detected when only one set of LEDs 64 is lit at a time. Control circuit 52 of welding tool 14 can control LEDs 64 such that at least one set of LEDs 64 is detectable by one or more detection devices 16 during the simulated or live welding session (for example, live weld mapping).

Processor 20 coupled to one or more detection devices 16 and / or control circuit 52 can determine which set of LEDs 64 to turn on to track

135

<img file="MX359249B_D0098.tif" />

The movement and position of the welding tool illustrated in Fig. 48. 860 As can be seen, the line by a controller, which includes, but is not limited to, 20, e-etf Control Kit 52, or a combination of them. Generally, the controller can turn on each set of LEDs 64 sequentially for a detection interval, then compare the response detected by the one or more detection devices 16 from each set to determine which set of LEDs 64 enables better tracking of data. For example, the controller may turn on (block 862) the left set (eg, second set 806) of LEDs 64. The controller determines (node ​​864) whether the left set of LEDs 64 is detected within the detection range (eg, approximately 50 to 500 ms). If the left set of LEDs 64 is not detected at node 864, the controller may turn on (block 866) the upper set (eg, first set 802) of LEDs 64. The controller then determines (node ​​868) whether the upper set of LEDs 64 is detected. If the upper set of LEDs 64 is not detected at node 868, the controller may turn on (block 870) the right set (eg, third set 810) of LEDs 64. The controller then determines (node ​​872) whether the set LEDs 64 right is detected. If the right set of LEDs 64 is not detected at node 872, then the controller can return to the start of method 860, and turn on (block 862) the left set of LEDs 64. In some embodiments, the controller may repeat method 860 to light each set of LEDs 64 in sequence until at least one set of LEDs 64 is detected during the detection interval.

As discussed here, when the controller determines if a set of LEDs 64 is detected (eg, nodes 864, 868, 872), the controller can determine if the threshold amount of LEDs 64 is detected for the respective set.

136

As described above, the threshold quantity can be

INSTITUTO MEXICANO Df THE TOTAL PROPERTY of visual markers (for example, LEDs 64) of a respective düñpW. In some modalities, the controller is configured'paia arresniiidi Ull fflódéTCTen rigid body (RB) of the welding tool 14 after detection of the threshold amount of LEDs 64. The controller determines (nodes 874) which rigid body model corresponding to Tracked sets of 64 LEDs is closest to an ideal model. As can be appreciated, the ideal pattern may correspond to when an array of LEDs 64 is directed directly at the one or more detection devices 16 within a predetermined range of angles (eg, approximately 20, 30, 45, or 60 degrees) . Furthermore, each side of LED set 64 can have its own predetermined angle range, such as about 45 degrees for the upper set of LEDs 64 and about 30 degrees for the left and right sets of LEDs 64. In some embodiments, the The first set 802 of LEDs 64 can approach the ideal model when the Y axis 784 in relation to the welding tool 14 is directed to the one or more detection devices 16. If the determined rigid body model of the soldering tool 14 that corresponds to one set of LEDs 64 (eg, second set 806) does not approximate the ideal pattern, the controller can turn off one of the sets and turn on the next set ( for example, first set 802) of LEDs 64 to determine whether an approximately ideal rigid body model can be detected with the following set. Alternatively, or in addition, the controller may use the detected non-ideal angle of one set (eg, first set 804) of LEDs 64 and the predetermined relative angles of the other sets (eg, second set 806, third set 810) of LEDs 64 to determine which set (eg, third set 810) of LEDs 64 corresponds most closely to the ideal model, making it possible

137

<img file="MX359249B_D0099.tif" />

<img file="MX359249B_D0100.tif" />

then that the controller turns on that set (eg rl O MEXICANO DE LA PROPIEDAD INDUSTRIAL ____

LEDs 64 directly without lighting other sets (eg second set 806).

The controller can be configured to latch onto a set of lit 6'4 LLbs when the given rigid body model approaches the ideal model.

In some embodiments, an array of LEDs 64 can approximate the ideal pattern when LEDs 64 are oriented within approximately 20 to 60 degrees or approximately 30 to 50 degrees of the one or more detection devices 16.

Accordingly, based on the orientation of the LED sets 64, some modes of the controller may be able to determine a rigid body model that corresponds to more than one set of LEDs 64 at a time. When several rigid body models can be determined, the controller can determine which LED array 64 is most oriented toward the one or more detection devices 16. In addition, the controller may use hysteresis control when the orientation of the soldering tool fluctuates near an angle threshold when various rigid body models may be respective respective sets of LEDs 64. As discussed above, the first set 802 of LEDs 64 can be oriented approximately along the Y axis 784, and the second set 806 of LEDs 64 can be oriented such that the second direction 808 is offset approximately 45 degrees from the axis And 784. In some embodiments, rigid body models can be determined for each respective set of LEDs 64 oriented within approximately 30 ° of the one or more detection devices 16, such that rigid body models for each respective set can be determined for a overlapping range of approximately 15 °. Using the hysteresis control, the control can remain hooked to the first set 802 of LEDs 64 when the first set 802 is oriented within approximately 25 ° of offset from the

138 Y axis 784 and within approximately 20 ° of displacement ^^^ l ^ e

<img file="MX359249B_D0101.tif" />

OF INDUSTRIAL PROPERTY ____

808. That is, the hysteresis control can reduce the sets of LEDs 64 on and off when multiple sets of LEDs 64 can be detected by one or more detection devices 16 and prevents rapid oscillation between sets of LEDs 64 when the soldering tool 14 is oriented near the threshold between sets of LEDs 64.

After latching onto a set of LEDs 64 that approximates the ideal model, the controller (blocks 876) can update the items visually displayed on the weld system display 32 32, helmet display 32 32 and / or the visual presenter 62 of the welding tool 14 based at least in part on the position and orientation determined from the tracked array of LEDs 64. The controller can maintain the state (eg, on, off) of each set of LEDs 64 as the given rigid body model approaches the ideal model. In some embodiments, the controller may repeat method 860 at intervals during operation, thereby lighting each set of LEDs 64 sequentially to verify that the determined rigid body pattern of the hooked set of LEDs 64 is closest to the ideal pattern. For example, the controller may repeat method 860 every 1, 5, or 15 minutes. Alternatively, or in addition, the controller may repeat method 860 after receiving an assignment, selecting an assignment, after lifting the welding tool 14 from the welding base 12, or any combination thereof.

As described above, various elements of the welding system 10 may have markers that are for use in tracking the movement of the respective element within the welding environment in real time and / or to calibrate the position and orientation of the element with respect to the welding base 12 or to the piece

139 working 82. For example, solder base 12 of the luele ^^^^^

MEXICAN INSTITUTE

I gave LA PRORFOAD and second markers 95, 96, the weld surface 112 can have the markers

116, 118, the calibration tool 120 in figure 4 'can have iós rtiátó &amp; doTés

130, the clamping assembly 132 of FIG. 5 may have the first and second markers 134, 136, and the welding tool 14 of FIG. 23 may have the visual markers 802. FIG. 49 illustrates a cross-sectional view of a component of 880 base that can be provided with 882 visual markers. Base component 880 may include, but is not limited to, weld base 12, workpiece 82, weld surface 112, calibration tool 120, clamp assembly

132, the welding tool 14, the clamping assembly 588, or any combination thereof.

The base component 880 can be coated with a thermally insulating layer 884 (eg, plastic, fabric, ceramic, resin, glass). Thermally insulating layer 884 can be wrapped around, molded to, mechanically attached to, or bonded to base component 880. As can be appreciated, base component 880 can receive or conduct thermal heat from the welding process.

Visual markers 882 can be placed at different locations on insulating layer 884 of base component 880. Visual markers 882 can be easily detectable by one or more detection devices 16. For example, visual markers 882 can be reflective of one or more electromagnetic waves. For example, visual markers 882 can reflect visible and / or infrared (IR) light. The position of each visual marker 882 can be configured to enable the one or more detection devices 16 to determine the position and orientation of the base component 880 within the welding environment. Visual markers 882 can be placed on one or more faces of base component 880. Different amounts and / or

140

<img file="MX359249B_D0102.tif" />

<img file="MX359249B_D0103.tif" />

J&gt; J 882 visual marker arrangements on each lad rwpoae Éjg® 880 ^r INSTITUTO MÍX1CANO í t-í tX LA nonilMD can facilitate the identification of the respective sides by simply defecting the arrangement of the visual markers 882.

A cover layer 886 (eg cover plate) is coupled to insulating layer 884 and visual markers 882. Cover layer 886 can cover visual markers 882, thereby protecting visual markers 882 from some environmental factors, such as splash, dust, accidental removal, and so on. In some embodiments, cover layer 886 does not cover or only partially covers visual markers 882. In some embodiments, the cover layer

886 it is a plastic, such as polycarbonate. Cover layer 886 may be a material that is not substantially reflective of one or more electromagnetic waves that are reflected by markers 882. Alternatively, or in addition, coating layer 886 may be conditioned to reduce or eliminate reflections of electromagnetic waves . For example, cover layer 886 can be painted, coated, or textured (eg, sandblasting), or any combination thereof. In some embodiments, cover layer 886 is substantially non-reflective except in an area that immediately covers visual markers 882.

FIG. 50 is a perspective view of one embodiment of the weld base 12, arms 576, 578, and clamp assembly 588. As described above, the first and second arms 576, 578 can rotate around the structure of bracket 566 to enable the first and second arms 576, 578 to be placed at a selected height for vertical and / or aerial welding. As illustrated, the second arm 578 includes a clamping assembly 588 for coupling the workpiece 82 to the second arm 578. The second arm 578 and clamping assembly 588 can be placed at various heights with respect to the weld base 12 As an alternative, or

141

<img file="MX359249B_D0104.tif" />

and the

IMPI also, the 588 clamping assembly can be dockedi®tead_ol¡&lt;^ Z ^ ^Gave ^ INDUSTRIAL 588 clamping assembly can be oriented in various directions relative to detection device 16. As can be appreciated, 588 clamping assembly can include various 802 visual markers (eg, reflective and / or light emitting) to facilitate tracking by detection device 16. For example, in certain embodiments, clamp assembly 588 may include three markers on one surface (eg, in one plane) of a clamp body 889, and a fourth marker on another surface (eg, in a different plane) to facilitate tracking by the one or more detection devices 16. A clamping face 890 of clamping body 889 may be substantially parallel to a sensing device 16, or oriented at an angle of displacement from a sensing device 16. An assembly 892 couples clamping assembly 588 to second arm 578. .

Figure 51 is a top view of one embodiment of mounting 892 of clamp assembly 588 of Figure 50, taken along line 51-51. A clamping shaft 900 couples mounting 892 to clamping body 889. In some embodiments, a clamping feature 902 of clamping shaft 900 can limit movement of clamping shaft 900 along a clamping shaft 904 by at least one direction. Furthermore, a clamp fastener 906 can be interconnected with retention feature 902 and mount 892 to retain clamp shaft 900 in a desired position along clamp shaft 904. Mount 892 can rotate about axis 908. , thereby adjusting the orientation of the clamping body 889 and clamping face 890 relative to a detection device 16. In some embodiments, a fastener 910 (eg, pin) can couple an assembly 892 to the second arm 578 in a desired orientation. The clamp 910 can be fixedly attached to the 892 mount, thereby preventing removal of the clamp 910 from the welding system 10. In

142

<img file="MX359249B_D0105.tif" />

be some modalities, the retention characteristic 902 and /

INDUSTRIAL driven (eg, spring loaded) with respect to clamping assembly 588, thereby making possible automatic coupling the clamping assembly 588 in one or more predetermined positions. For example, inserting fastener 910 in a first cavity 912 orients fastening face 890 in a first direction 914 substantially parallel to a detection device 16, inserting fastener 910 in a second cavity 916 orients fastening face 890 in a second direction 918, and inserting fastener 910 in a third cavity 920 orients fastening face 890 in a third direction 922. The second and third directions 918 and 922 can be oriented within approximately 10, 20, 30, 40 or 50 degrees of direction 914 (for example, towards a detection device 16). The second and third directions 918 and 922 of FIG. 51 are approximately 30 ° offset from the first direction 914. When the clamping assembly 588 is mounted on the second arm 578 and the clamping face is oriented in the second direction 918, the clamping assembly 588 can be configured for welding in positions where a portion of the workpiece 82 can obscure part of the vision junction of one or more detection devices 16. For example, welds performed at the 3F position (eg, vertical T-joint and lap weld welds) can be easily observed by the one or more sensing devices 16 when workpiece 82 is coupled to the clamp 588 on the second arm 578 such that the clamp face 890 is oriented in the second direction 918.

The position and orientation of the respective arms and clamping assemblies are calibrated to enable one or more detection devices 16 to track the movement of the welding tool 14 relative to a joint of workpiece 82 coupled to the assembly of clamp 588. As illustrated in figure

143

<img file="MX359249B_D0106.tif" />

ra

52, a calibration block 930 can be coupled by facilitating calibration of clamp assembly 588. In some embodiments, the calibration tool 610 of Figures 37 and 38 is coupled to the calibration block 930 such that the calibration tool Calibration 610 extends from calibration block 930 at a predefined angle (eg, perpendicular). Calibration block 930 and calibration tool 610 can enable the one or more detection devices 16 to calibrate the normal vector of clamping assembly 588, calibrate the normal vector of workpieces 82 secured to clamping assembly 588, and / or calibrate the actual vertical vector (eg zenith) relative to the floor. The one or more detection devices 16, through computer 18, can determine a rigid body model and / or a clamp marker centroid for clamp assembly 588 when mounted to each arm 576, 578, during the Which different sides of clamping assembly 588 are in view of the one or more sensing devices 16 wherein each side of clamping assembly 588 has a unique marker configuration. The one or more detection devices 16 can be coupled to the arms 576, 578 in such a way that when each arm is raised and lowered, a value and a centroid of the holding markers on the respective side changes. As described above, the movement of each arm 576, 578 can adjust the orientation of the one or more detection devices 16. Consequently, the one or more detection devices 16 can determine the y value of the centroid of the clamp markers for clamp assembly 588 at various heights of the respective arms 576, 578. Computer 18 can determine the zenith vector for each of the centroids at the respective heights, thus making it possible for computer 18 to determine (eg interpolate) the zenith vector for any height using the y value of the centroid of clamp markers when clamp assembly 588 is attached

144 to each arm 576, 578. A level can be used with ie ^ foqueicjdfe

OF INDUSTRIAL PROPERTY

<img file="MX359249B_D0107.tif" />

clamp 930 during calibration at each height to ensure that the orientation of the 610 calibration tool accurately represents the zenith vector. The y value of the centroid of the clamp markers can also be used to determine the clamp height and to provide the operator with feedback on the correct height placement for the welding session. The height of clamping assembly 588 during a welding session can be stored with the welding data 327 for each welding session. In some embodiments, the welding system 10 can determine the orientation of the clamping assembly 588 relative to the sensing device 16, thereby making it possible for the welding system 10 to notify the operator if the workpiece 82 is in an orientation unsuitable for the welding session. For example, the welding system 10 can notify the operator when the clamping assembly 588 and workpiece 82 are oriented such that the visual markers 802 of the welding tool 14 could be at least partially obscured from each other's vision. or more detection devices 16 during the welding session, thereby enabling the operator to adjust clamp assembly 588 so that all visual markers 802 can be observed.

Fig. 53 is a flow chart 940 illustrating the installation and execution of a weld assignment session using one of the arms for a vertical or aerial (eg, out of position) session. The operator selects (block 942) an out-of-position session (eg 2G, 3G, 3F, 4G, 4F) and turns (block 944) the workpiece together. The operator then configures (block 946) the desired arm to the height corresponding to the session and adjusts the clamp assembly for calibration with the detection device. After arm setup and assembly

145

<img file="MX359249B_D0108.tif" />

ion.

clamping, the operator couples (block 948) the work piece ^^ JísiX OE LA MOHEDA D INDUSTRIAL

Then the operator can adjust (block 950) the clamping orientation, just as if the sensing, workpiece at least partially obscured the nail.

if markers of the workpiece or clamping assembly are obscured from the sensing device, or if the clamping assembly is not substantially perpendicular to the ground, or any combination thereof. After adjusting the clamping orientation, the operator, instructor, or administrator can calibrate (block 952) the clamping assembly. In some embodiments, calibration can be performed once for each time the arm is moved or for each time the clamp assembly is attached to the arm, such that the clamp assembly cannot be calibrated before of each session. The clamp assembly calibration can validate that the clamp assembly is detected in the configuration and / or orientation specified for the session. The operator calibrates (block 954) the joint ends, thereby establishing the two points on a line representing the joint. In some embodiments, such as for welding sessions in the 3F position, the operator calibrates (block 954) the joint assemblies using the calibration tool 610 described above with Figures 37 and 38, where an axis of the calibration tool stays within about 5^or from the plane parallel to the detection device. As can be seen, the welding sessions in other positions can be calibrated with the calibration tool that has other orientations in relation to the detection device. Alternatively, or in addition, the computer can compensate for the orientations of the calibration tool during calibrations where the markers of the calibration tool are viewed at a skewed angle. For example, the computer can determine the angle of the calibration tool relative to the clamp assembly, then use the determined angle

146

IMPI to adjust calibration values ​​of union ends ^^ $ £ g $ | ge

INDUSTRIAL

<img file="MX359249B_D0109.tif" />

Union ion concludes, the operator then performs (block 956) the welding session and reviews (block 958) the results. In some embodiments, the weld base visual presenter 12 and / or the welding tool visual presenter 14 may provide instructions to the operator to guide the setup of the welding session.

The one or more detection devices 16 can track the position and orientation of the clamp assembly 588, the workpiece 82, and the welding tool 14 prior to performing the assignment welding session, during the welding session, and after carrying out the welding session. As described above, the one or more detection devices 16 may include a camera that detects visual markers 802, such as visual markers from clamp assembly 588, workpiece 82, and welding tool 14. In some embodiments, computer 18 may use data that corresponds to fixed surface visual markers 802 (eg, clamp assembly 588, workpiece 82) for reference to other subjects tracked in the welding environment at all times. that the visual markers 802 of the fixed surfaces are detectable. That is, the visual markers 802 on the fixed surfaces facilitate real-time tracking of other objects (eg, welding tool 14, calibration tool 610) within the welding environment. Visual markers 802 detected by the camera of detection device 16 may include passive markers (eg, decals, reflectors, patterns) and / or active markers (eg, lights, LEDs). Passive markers can best be seen with a first exposure setting of the cameras of the one or more detection devices 16, and active markers can best be seen with a second

147 camera exposure settings, which can

<img file="MX359249B_D0110.tif" />

D £ LA RROMEDAO INDUSTRIAL

<img file="MX359249B_D0111.tif" />

exposure settings. In some embodiments, the visual markers 802 of the clamping assembly 588 and the workpiece 82 may be passive markers, and the visual markers 802 of the welding tool 14 may be active markers (eg LEDs 64). Furthermore, passive markers can be illuminated by lights (eg LEDs 64) from detection device 16, where light (eg infrared light) from the lights is reflected off of the passive markers and is observed by cameras. of the one or more detection devices 16. Accordingly, the exposure setting of the camera can be adjusted based at least in part on the type of visual marker that will be observed. As can be appreciated, the second exposure setting for sampling the active light-emitting markers may be less than the first exposure setting for sampling the passive light-reflecting markers.

The computer 18 may alternatively trace the visual markers 802 of the welding tool 14 and the fixed surfaces of the welding environment before carrying out and during the execution of a welding session (for example, simulated welding assignment, assignment of live welding). Consequently, the computer 18 can track in real time the position and orientation of the welding tool 14, the clamping assembly 588, and the workpiece 82 with respect to each other and to the welding base 12. Before live welding, computer 18 can primarily track the visual markers 802 of welding tool 14 when it detects the position and orientation of objects in the welding environment around weld base 12, and computer 18 can track secondarily the visual markers 802 of the fixed surfaces (e.g. main weld surface 88, clamping assembly 588, workpiece

148 clamped 82).

Active tool markers

<img file="MX359249B_D0112.tif" />

OF INDUSTRIAL PROPERTY

<img file="MX359249B_D0113.tif" />

lit continuously substantially before, during and after a simulated or live welding session (eg weld assignment). The computer can control the exposure settings of the cameras of the one or more detection devices 16 to control the respective sampling rates of the fixed surfaces and the welding tool 14. For example, the visual markers 802 of the welding tool 14 can be sampled 1.5, 2, 3, 4, 5, or more times than the visual markers 802 of the fixed surfaces are sampled. That is, computer 18 cycles the camera's exposure setting between the second exposure setting (eg, low exposure value to track active markers from welding tool 14) and the first exposure setting (for example, high exposure value to track passive markers on fixed surfaces).

Before initiating a simulated welding session (eg, weld assignment), computer 18 may control the lights of one or more detection devices 16 (eg, LEDs 64) to be turned on, thus making it possible for computer 18 track the passive markers of the fixed surface and the active markers of the welding tool 14 before starting the simulated welding session, during the simulated welding session and after the simulated welding session. As described above, computer 18 can cycle the camera's exposure settings to sample the passive markers with the first exposure setting and to sample the active markers with the second exposure setting. During live welding (for example, while the trigger of the welding tool 14 is pulled), the computer 18 can control the lights of the one or more detection devices 16 to pulse level

149

Increased brightness IMPI, thus increasing^1NCTgH ^ ®OS

INDUSTRIAL

<img file="MX359249B_D0114.tif" />

¡Ha from passive markers. Pulsing the lights can enable the cameras of the one or more detection devices 16 to easily track passive markers with reduced exposure settings during live welding with bright arc and spatter. The computer 18 can control the exposure settings of the camera to be synchronized with the pulsation of the lights of the detection device 16, so that the lights pulse more brightly when the exposure setting is in the first exposure setting (for example, high), and the lights dim when the exposure setting is in the second exposure setting (for example, low). Additionally, or alternatively, computer 18 may control the lights of one or more detection devices 16 to turn off during calibration of clamp assembly 588, thereby distinguishing active markers from welding tool 14 from passive markers. from clamp assembly 588. In some embodiments, a pulsed brightness level of the lights of the one or more detection devices 16 may be higher than when the lights were turned on substantially continuously. The one or more detection devices 16 can more easily detect the passive markers at the increased brightness level of the lights than at the lower brightness level. However, pressing the lights of one or more detection devices 16 during a simulated weld may accidentally activate a self-darkening circuit of a weld helmet. Consequently, the lights of the one or more detection devices 16 can be pulsed during live welding when the welding helmet has darkened due to arc, however the lights of the one or more detection devices 16 are continuously on during welding. simultaneous when the welding helmet is not darkened.

150 a

<img file="MX359249B_D0115.tif" />

OF ERONETY

INDUSTRIAL

ERRORNESS multi-pass session (eg, multiple runs), thus recording 327 weld data for each pass (eg, run) of the multi-pass session. As described above, the control circuit 52 of the welding system 10 can record the welding data 327 for each run of the multi-run session as a single weld operation to determine a session quality of multiple runs or for otherwise return the session from multiple executions. In some embodiments, the control circuit 52 of the welding system 10 can record welding data 327 for a multi-run session as a group of runs corresponding to a serial number or other identifier for the multi-run session. That is, the weld data 327 for a multi-run session can be reviewed and evaluated as a group, or each multi-run session run can be performed and evaluated separately. Multi-run sessions can include, but are not limited to, a live process, a simulated process, a virtual reality process, or any combination thereof.

FIG. 54 is a flowchart 970 illustrating the selection and execution of a multi-pass welding session (eg, multiple runs) (eg, weld assignment). The operator selects (block 972) a multi-run session and installs (block 974) workpiece 82 along with weld base 12. Placement of workpiece 82 may include attaching workpiece 82 to the base welding 12. The operator calibrates (block 976) the joint, such as by using the joint calibration tool 610 to calibrate the position of the first end of the joint and the second end of the joint. As can be seen, the junction calibration tool 610 can interface directly with the workpiece 82 for calibration (block 976) before the first session run

151 of various executions.

The operator selects (node

<img file="MX359249B_D0116.tif" />

increasing

INDUSTRIAL (i.e. first) run of the session of multiple runs in a simulated weld mode or a live weld mode. In some embodiments, the selected weld session (eg weld assignment) may prohibit or limit the number of simulated welds that can be performed prior to live welds. In some modes, the selected session may prohibit the live weld mode until the conclusion (for example, successful completion) of a simulated weld. When the simulated weld mode is selected, the operator performs (block 980) the simulated run. The control circuit 52 can visually present (block 982) the results of the simulated execution through the visual display 32 of the welding base 12 and / or the visual display 62 of the welding tool 14. For example, the Control 52 can visually display weld data 327 from the simulated run and target specifications for the simulated run. As an alternative, or in addition, the control circuit may visually display the weld score for the simulated run. After completing the simulated run, the operator selects again (nodes 978) whether to perform the next run in simulated weld mode or live weld mode.

When the simulated weld mode is selected, the operator performs (block 984) the live weld run on the calibrated joint. The control circuit 52 can visually present (block 986) the results of the live execution through visual display 32 of the welding base 12 and / or visual display 62 of the welding tool 14. For example, the control circuit 52 may visually present the weld data 327 of the live run and the target specifications for the live run. As an alternative, or in addition, the

152 the

<img file="MX359249B_D0117.tif" />

IMPI

I heard THE PROPERTY control circuit 52 can visually present the score W^RÍíéld live performance. Visualméffl ^ p ^ ffrtr gjeouG¡ón..ecu¿iyo presented results can be visually presented with results of any previous simulated runs for the same junction.

Each run (eg simulated or live) of the multi-run weld session (eg weld assignment) can be evaluated separately based at least in part on target specifications (eg minimum, target, maximum ) for tool position parameters (eg, working angle, offset angle, CTWD, travel speed, target) and / or electrical parameters (eg, welding voltage, welding current, wire feed speed). For example, a root pass run may have different specification parameters than subsequent runs. After a multi-run session run is completed, control circuit 52 can determine whether the completed session run satisfies the target parameter values ​​for the respective run. For example, weld data 327 for a multi-run session run can be compared to the target parameter values ​​to generate a score for each parameter and / or a total score for the respective run. Control circuit 52 can determine if the run passes the target specifications for the respective run.

Control circuit 52 determines (node ​​988) whether all executions of the selected weld session (eg weld assignment) have been completed. If all runs of the selected multi-run session have not been completed, then the operator selects (block 990) the next run. In some modes, the operator can proceed to the next multi-run session run regardless of whether the previous run passes the

153

<img file="MX359249B_D0118.tif" />

target specifications. As an alternative, or in addition, to

INDUSTRIAL next session run of multiple runs regardless of whether weld data 327 for the previous run is complete. For example, if the one or more detection devices 16 cannot track the position and orientation of the welding tool 14 for at least a portion of a multi-run session run, the operator can continue to carry out each run of the multi-run session. The operator calibrates (block 976) the joint for each run of a multi-run session, such as by using the joint calibration tool 610 to calibrate the position of a first end of the joint and the second end of the joint. As can be seen, the joint calibration tool 610 can be directly interconnected with the workpiece 82 for the initial calibration of the joint before the first run. Subsequent calibrations can directly interface the 610 joint calibration tool with the previously formed weld bead from one or more previous runs. Consequently, the calibrated ends of the joint for each execution can have a different position in relation to the one or more detection devices 16 of the welding system 10. When the subsequent calibration for the next run is complete, the operator selects again (nodes 978) whether to run the next run in simulated weld mode or live weld mode.

If all runs of the selected multi-run session have been completed, then the control circuit 52 can visually present (block 992) the results of each of the live runs through the display 32 of the weld base 12 and / or the visual display of the welding tool 14. For example, the control circuit 52 can visually display the welding data 327 of each of the live performances and the

154

IMPI target specifications for each of the executions # ^^^^ * ^

INDUSTRIAL

<img file="MX359249B_D0119.tif" />

in addition, control circuit 52 can determine whether the execution group passes the target specifications for the multi-execution session based on one or more evaluations of the executions. For example, control circuit 52 may evaluate the group of runs based on a geometric mean of the scores for each run, an arithmetic mean of the scores for each run, whether each run was completed with a pass or pass score, or any combination thereof. In some embodiments, a threshold number (for example, 1, 2, or 3) of runs with untracked weld tool position and orientation may not affect the session evaluation of multiple runs. That is, the one or more runs with untracked position and tool orientation cannot be counted in the geometric and / or arithmetic mean. After visual presentation of the session results (block 992), the operator can select (block 994) to retest with the selected session. The operator removes the previously tested joint, and configures (block 974) a new joint for further testing. Control circuit 52 may assign a different serial number to the new joint for additional testing than the previously tested joint serial number, then making it possible for the operator and an instructor to review and evaluate weld data 327 for each Union.

As described herein, various parameters can be tracked (eg, detected, displayed, and stored) during the operation of the welding system 10 (eg, in real time while the welding system 10 is being used) including, but not limited to, tool position parameters (eg working angle, offset angle, CTWD, travel speed, target) and arc parameters (eg welding voltage, welding current, wire feed speed). The

155

IMPI

<img file="MX359249B_D0120.tif" />

INSTITUTO MEXICANO DI LA NOMÍDAD arc parameters, for example, can be detected in the héffaffltehta (for example, using the 425 voltage sensor, the 427 sensor-de-eorrientc, or other sensors, as illustrated in figure 18), converted using analog to digital conversion (ADC) circuits and communicated to computer 18 via communication interface 68 (e.g., RS-232 communication channel), as described herein with respect to FIG. 1. As an alternative, or in addition, when detected in the welding tool 14 (for example, in the handle of the welding tool

14), arc parameters can be detected in welding cable 80, welding power source 28, wire feeder 30, or some combination thereof, each of which is illustrated in Figure 2.

The welding system 10 can visually detect and display (eg, numerically, graphically, and so on) the arc parameters through a screen visible on the display 32 of the welding system 10. An example of screen 996 having A weld mode indicator 998 indicating that the weld system 10 is in a live arc weld mode can be displayed visually on display 32 as illustrated in FIG. 55.

As illustrated in FIG. 55, arc parameters can be visually displayed on screen 996. For example, on illustrated screen 996, a voltage graph 340 can visually display a time series of arc voltage 337 produced by the welding tool 14, and an amperage graph 340 can visually present a time series of current 338 produced by welding tool 14. In certain embodiments, filters can be applied to at least some of the arc parameters and tool position parameters to smooth output noise on the time series plots 340 of the values ​​detected by the welding tool 14.

156

<img file="MX359249B_D0121.tif" />

ΙΜΡΓ

It will be appreciated that the parameters of aróS ^ SüSdJ ^ E ^ r

INDUSTRIAL timing by 244 welding software in real time with tool chassis position parameters that are captured through the motion tracking system (eg, one or more detection devices 16). In other words, the arc parameters and tool position parameters can be plotted on their respective graphs 340 such that the data points for each of the time series are vertically aligned with data points from each of all other time series that are captured at approximately the same time (for example, within 100 milliseconds, within 10 milliseconds, or even closer in time, in certain modes). This makes it possible for the user to correlate the arc parameters with the tool position parameters. Although not illustrated in Figure 55, in certain modes the wire feed speed can also be detected in real time in the same way as voltage and current

As illustrated in Figure 55, in certain modes, each arc parameter (as well as each tool position parameter) can be individually rated relative to a predefined upper limit, lower limit, and / or target value, and scores 341 can be illustrated on screen 996. In addition, in certain embodiments, a total score of 1000 can be determined by welding software 244 and displayed on screen 996. In addition, in certain modalities, the total score 1000, indications of target total scores 1002, and high total scores 1004 (for example, of an entire class) can be determined by the welding software 244 and displayed on screen 996. In addition, in In certain modalities, an indication 1006 of whether the test was successful or unsuccessful can also be determined by welding software 244 and displayed on screen 996. In certain modalities, the total score 1000 can be based on the scores

157

Individual IMPI 341 for the position parameters of herrgjwM ^ ípftRa ______ «λ _____ Say LA FHOhiOAD INDUSTRIAL

<img file="MX359249B_D0122.tif" />

at individual scores 341 for arc parameters.

Furthermore, as illustrated in FIG. 55, in certain embodiments, a general status bar 1008 may be displayed on screen 996. General status bar 1008 may include indications of whether all of the tool position parameters are within their respective upper and lower limits or not. For example, if one of the tool position parameters is not within their respective upper and lower limits, the general status bar 1008 may indicate, in the same vertical position on display 996, that the pattern values ​​within corresponding tool, a red state. Conversely, if all of the tool position parameters are within their respective upper and lower limits, the general status bar 1008 may indicate, in the same vertical position on the screen

996 than the corresponding tool position parameter values, a green state. It will be appreciated that other status colors can be used in other modalities.

As illustrated, in certain embodiments, the value 339 for each of the parameters (eg, tool position parameters and arc parameters) can be visually presented as an average value during the course of a trial period. For example, as illustrated in Figure 55, the average voltage and amperage over the illustrated test period are 18.7 volts and 146 amps, respectively. Figure 56 is another illustration of display 996 shown in Figure 55. In this case, the average voltage and amperage are illustrated as being 0.1 volts and 2 amps, respectively, which are in the order of noise, indicating that an arc Actual weld is not being detected. In such a situation, the amperage and voltage can be used by the 244 welding software to determine whether the welding took place or not.

158 during a test period in “weld mode” of HWWMSwS e ^^ wSea of ​​industrial voltage or amperage is below a certain predetermined threshold (for example, the average «-ΜΚΙΚΤ voltage is less than 10 volts) or between a certain minimum and maximum threshold By default (for example, the average voltage is between -8 volts and +10 volts), the 244 welding software can determine that a weld did not actually take place during the time period. In such a scenario, the welding software 244 can automatically mark a test as failed (or "unsuccessful") and / or the test can be marked by the welding software 244 as having no weld detected. For example, as illustrated, in certain embodiments, if the average voltage and / or average amperage for a given test period does not meet certain predetermined thresholds or fall within certain predetermined ranges, indication 1006 of whether the test was successful or unsuccessful can show that the test was "unsuccessful" (which can also be presented visually for other reasons, such as the total score not meeting a specific requirement, for example). In addition, as illustrated also, in certain modalities, when the average voltage and / or average amperage for a given test period do not meet certain predetermined thresholds or fall within certain predetermined ranges, rather than illustrating the total score 1000 on screen 996, an "arc not detected" message 1010 may be displayed instead.

Figure 57 illustrates an example of screen 1012 that can be presented visually as part of the welding software mapping development routines 244. In particular, Figure 57 illustrates a screen 1012 that enables entry of completion criteria for a series of weld tests and length requirements associated with the test. As illustrated, screen 1012 is visually presented when the Conclusion Criteria / Length Requirements 1014 tab of

159

<img file="MX359249B_D0123.tif" />

in the

IMPI assignment development routines is selected '(y £ ^ y $$ gnt $' INDUSTRIAL screen 1012). As illustrated, other tabs associated with configuration settings of weld software 244 mapping development routines may include, but are not limited to, a Task Name 1016 tab that causes a screen to be visually presented where the assignment name and other general information related to the assignment may be entered; and the Joint Design tab 1018 which causes a screen to be visually displayed in which joint properties to be welded (eg joint type, length, etc.) can be entered; a 1020 Base Metals tab that causes a display to be visually displayed in which properties related to the base metals to be welded can be entered; a Filler / Protection Metals tab

1022 which causes a screen to be visually displayed when properties related to filler metals (eg, welding electrode) and shielding gases can be entered; a 1024 Electrical Load / Position tab that causes a screen to be visually displayed in which properties (eg upper limits, lower limits, target values, etc.) of the tool position parameters and arc parameters, respectively, can be entered; a Preheat / Post-weld Heat tab 1026 that causes a screen to be visually presented in which properties related to pre-heat and post-weld heat, respectively, can be entered; a Welding Procedure / 1 Pass tab 1028 that causes a screen to be visually displayed in which properties related to the welding procedure (eg, type of process, etc.) and the number of passes in the test (eg, one pass or more than one pass); and a 1030 Real-Time Feedback tab that makes a screen visually presented that can be entered

160

ΙΜΡΙ @ 2 | feedback related properties in certain modes, all assignment related properties can be entered in the described screens, can be automatically detected by the welding software 244 (eg based on specific equipment of the welding system 10, with based on other properties that are established, and so on), or some combination thereof.

As illustrated in Figure 57, the display 1012 related to the completion criteria / length requirements tab 1014 includes a first section 1032 dedicated specifically to completion criteria properties and a second section 1034 specifically dedicated to associated length requirements with the test. In certain embodiments, in completion criteria section 1032 of screen 1012, a series of entries 1036 enables an objective score (eg, 90 as illustrated), a number of welding tasks to be entered into a set of welding tasks (eg 5 as illustrated), a number of successful weld tests required per weld assembly (eg 3 as illustrated) and whether a weld test will not be passed if an arc is not detected (eg, as shown in figure 56). In addition, as illustrated, in certain embodiments, is an illustration 1038 of what these selections of completion criteria will look like to the user (eg, as illustrated in Figure 55 in Actions section 1040 of screen 996). In addition, in certain embodiments, in the length requirements section 1034 of the display 1012, a series of entries 1042 makes it possible for a length of a starting section (A) of a weld to be ignored in the compilations of scores, a section End (B) of a weld that will be ignored in the compilation of scores and a maximum length (C) of the test, which may be less than the ingot length (which, for example, can be entered through the

161

IMPI ~

MEXICAN INSTITUTE screen related to the tab union design 1018) will be4i ^ j ^^ the

<img file="MX359249B_D0124.tif" />

In certain embodiments, respective illustrations 1044 of relative dimensions of the entered properties with respect to length requirements can also be illustrated to assist the user in configuring length requirements.

Figure 58 illustrates an example of a 1046 display that can be displayed visually when the weld procedure / one pass tab is selected.

1028. As described above, this display 1046 makes it possible to enter properties related to the welding procedure and the number of passes in the test (for example, one pass or more than one pass). As illustrated, in certain embodiments, a first series of 1048 inputs makes it possible to enter a process type (eg, FCAW-G as illustrated), a class and diameter of the filler metals (eg, the welding electrode) (for example, E71T-8JD H8 and 0.182 centimeters, respectively as illustrated), a welding pattern (for example in wire versus fabric; illustrated in wire), a vertical progression (for example, up versus down; above as illustrated) and any comments related to the welding procedure. In addition, as illustrated, in certain modes, a second series of 1050 inputs enables minimum, maximum, and target values ​​to be entered for the arc parameters (for example, volts, wire feed speed, and amps), marked as settings. welding power source, and tool position position parameters (eg working angle, displacement angle, CTWD, displacement speed and target), marked as tool technique parameters. As also illustrated, in certain embodiments, a third series of inputs 1052 makes more detailed input related to minimum, target, and maximum values ​​possible (for example, related to how much deviation from target values ​​are allowed for the upper and lower limits, and so

162

INSTITUTO MEXIO.NO successively) for a highlighted arc parameter or parafñfcÍ ^ YES ££ d¡

IMPI

ΙΝΚΤΓΠΓΥη Mmr'ivA

<img file="MX359249B_D0125.tif" />

'of tool (for example, volts as illustrated). In certain modes, when more than one pass is selected for a given assignment, the minimum, target and maximum values ​​for the arc parameters and / or the tool position parameters can be set individually for each pass within the assignment. In certain modes, inputting properties for multiple passes for a given assignment can be made possible through an Add Pass button 1054, as illustrated.

As described above with respect to Figures 55 and 56, the arc parameters can be displayed visually when the welding software 244 is in a live arc welding mode. Conversely, FIG. 59 illustrates an example of a display 1056 showing the welding software 244 when it is in a simulated welding mode, as indicated by the welding mode indicator 998. As illustrated, when welding software 244 is in a simulated welding mode, arc parameters are not displayed visually since actual welding is disabled in this mode, and a message indicating that may be displayed visually on your place.

In certain embodiments, the arc parameters are not visually displayed by default below the tool position parameters, as illustrated in Figures 55 and 56. Rather, Figure 60 illustrates an example screen 1058 that is illustrates by default (that is, before a weld test has been started). As illustrated, instead of the arc parameters, a welding procedure summary panel 1060 is illustrated to summarize to the user what the general properties (eg, target properties) are for a given test weld. In certain modes, from the 1060 welding procedure summary panel, a user can select a WPS 1062 view button, which will cause

163

ΪΜΡΙΟ ^

INSTITUTE MtXtCANO that the screen 1064 illustrated in figure 61 is presented B ^, SS ^^ eHg «iBgwan is illustrated, figure 61 is a summary of all the information related to all the parameters of a weld test session or an assignment of weld test (for example, which can be entered through the selection of the different mapping development tabs 1014-1030 illustrated in Figures 57 and 58).

Turning now to Figure 60, once the user has completed pre-test procedures and prepares to start a weld test, after activation of the trigger 70 of the weld tool 14 to initiate a weld test, the welding procedures summary panel 1060 is replaced by the information related to the arc parameters to visually present the real-time graphs of the arc parameters during the execution of the welding test (see, for example, figure 62, allowing the user to view all graphs related to tool position parameters and arc parameters in real time during the weld test. In fact, in certain embodiments, after activation of the trigger 70 of the welding tool 14 to initiate a welding test, any screen that is currently being visually presented can be replaced with, for example, screen 996 illustrated in FIG. 62 in such a way that all tool position parameters and arc parameters can be visually presented in graphical form and in real time.

FIG. 63 illustrates an alternate display 1066 that can be visually displayed after the execution of a weld test. As illustrated, in certain modes, in addition to the arc parameters (eg, voltage, amperage, wire feed speed), the heat input 1068 can be displayed visually and, as with all other position parameters tool and arc parameters, it is time synchronized throughout its time series

164

IMPIOS

Respective MEXICAN INSTITUTE. In general, the detected displacement speed amperage and voltage data can be used to calculate the heat input in real time for each point in time throughout the time series (for example, time-based) or in each location along the weld joint (eg, based on distance). In particular, in certain modes, heat input (in kilojoules) can be calculated as a function of voltage, amperage, and travel speed (in inches per minute) as:

HeatInput =

Amps x Volts x 60 1000 x Travel Speed

In addition, although not illustrated in Figure 63, in certain embodiments, the weld size (fillet size; in millimeters) can be calculated in real time using the wire feed speed (WFS; in inches per minute), which which can be either detected or specified by a user, travel speed (in meters per minute) and a default value for efficiency (%) and wire diameter (in millimeters) such as:

Size File lOOOx Displacement Speed ​​\ l 2 J - x Diameter Wire² jx (25.4x W^zF.S ') x Efficiency i

In certain embodiments, the default value for efficiency can take into account any detected spatter, which can be determined using the techniques described in "Devices and Methods for Analyzing Spatter Generation Events," US Patent Application No. 2013/0262000 , filed on March 30, 2012 in the name of Richard Martín Hutchison et al., which is incorporated herein in its entirety. For example, the default efficiency value may be

165

IMPI adjusted to, for example, lower the default value Hg ^ fc ^ ftfi &amp; ni

INDUSTRIAL

<img file="MX359249B_D0126.tif" />

determine that more spatter generation events occur, increase the default efficiency value when it is determined that fewer spatter generation events occur, and so on.

As described above, the welding tool 14 can either be an actual welding tool configured to facilitate the creation of an actual welding arc between the actual welding tool and an actual workpiece 82 or a configured simulated welding tool to simulate the creation of a simulated welding arc between the simulated welding tool and a simulated workpiece 82 (for example, a workpiece 82 in which an actual weld is not believed, but which serves as a user guide during a simulated welding process). For example, in certain embodiments, the welding tool 14 may be an actual MIG welding torch configured to facilitate the creation of an actual welding arc between actual welding wire supplied by the actual MIG welding torch and a workpiece 82 real, or the welding tool 14 may be a simulated MIG welding torch configured to simulate the creation of a simulated ura weld arc between simulated welding wire supplied by the simulated MIG welding torch and a simulated workpiece 82. Furthermore, in certain embodiments, the welding tool 14 may be an actual rod welding electrode holder configured to facilitate the creation of an actual welding arc between an actual rod welding electrode supported by the welding electrode holder with real rod and 82 real workpiece, or the welding work tool 14 may be a simulated rod welding electrode holder configured to simulate the creation of a simulated welding arc between a simulation rod welding electrode supported by the welding electrode holder

166 with simulation rod and a workpiece 82

<img file="MX359249B_D0127.tif" />

How welding 14 can make simulated welding processes possible, as described in more detail in pVeséfflU: 7K9üniáb, a modal tieilas, the welding tool 14 can be a real TIG welding torch configured to facilitate the creation of a real welding arc between a real tungsten electrode supported by the real TIG welding torch and a workpiece 82 real, or the welding tool 14 may be a simulated TIG welding torch configured to simulate the creation of a simulated welding arc between a simulated tungsten electrode supported by the simulated TIG welding torch and a simulated workpiece 82.

In certain embodiments, the welding tool 14 can be configured both to facilitate the creation of a real welding arc between a real rod welding electrode and a real workpiece 82, and to simulate the creation of a simulated welding arc between a simulation rod welding electrode and a simulated workpiece 82. For example, in certain embodiments, the simulation rod welding electrode holder 1070, in addition to being configured to mechanically retract the simulation rod welding electrode 1072 toward the rod electrode retention assembly 1078 to simulate consumption of the simulation rod welding electrode 1072 during a simulated rod welding process, the rod electrode holder assembly 1078 of the simulation rod welding electrode holder 1070 can be configured to supply an electrical current through a 1076 real rod welding electrode contained by the assembly supported by the electrode holder assembly of rod 1078 (eg, through conductive properties of rod electrode support assembly 1078), where the electric current is sufficient to generate an arc of

167 iMPio ^ n

Mexican INSTITUTE Jj welding to a workpiece 82 through a tip of the S ^ rwá © d ^^ MOTra with real 1076 rod during a rod welding process · roalj Móg it will be appreciated that the 244 welding software can be configured to operate interoperable with all the different types of welding tools 14 described herein.

Figures 64A, 64B, 65A, and 65B illustrate embodiments of the welding tools 14 that are rod welding electrode holders. More specifically, Figures 64A and 64B illustrate one embodiment of a simulation rod welding electrode holder 1070 configured to simulate the creation of a simulated welding arc between a simulation rod welding electrode 1072 supported by the simulation rod welding electrode 1070 and a simulated workpiece 82 (see figure 66A), and Figures 65A and 65B illustrate one embodiment of a 1074 real rod welding electrode holder configured to facilitate the creation of a real 1075 welding arc between a 1076 real rod welding electrode supported by the weld electrode holder with real rod 1074 and a real workpiece 82 (see figure 66B). In certain embodiments, both rod welding electrode holders 1070, 1074 are coupled to communication lines. In certain embodiments, the communication lines can be arranged within the welding cable 80 through which power can be provided to the 1070, 1074 rod welding electrode holders. In other embodiments, the communication lines can be directly coupled to the welding cable 80 (for example, arranged in a sleeve that can be attached to the welding cable 80). It will be appreciated that the modalities of the 1070 rod welding electrode holders can include any and all of the relevant components of the welding tool 14 described herein, for example, as

168 illustrated in figure 2.

IMPI MEXICAN INSTITUTE OF INDUSTRIAL PROPERTY

<img file="MX359249B_D0128.tif" />

In certain embodiments, both rod welding electrode supports 1070, 1074 include visual markers 802 arranged in an outer structure 1077 that is configured to at least partially surround respective rod electrode support assemblies 1078,1080 of the electrode supports. welding rod 1070, 1074. In certain embodiments, the 802 visual markers arranged on the outer frame 1077 are substantially similar to (and substantially similarly arranged on outer surfaces of the 1070,1074 rod welding electrode holders) the visual 802 markers arranged on the neck 800 of the welding tool 14 described with reference to Figures 24 and 25, which facilitate detection by the one or more detection devices 16. For example, as indicated above with respect to FIG. 48, in certain embodiments, visual markers 802 may be LEDs 64 configured to emit light that is detected by the one or more detection devices 16 to determine position, orientation, and / or movement of the 1070, 1074 rod welding electrode holders. For example, similar to the embodiments illustrated in Figures 24 and 25, in certain embodiments, the rod welding electrode holders 1070, 1074 may include multiple sets 804, 806, 810 of 802 visual markers, each set 804 , 806, 810 of 802 visual markers including various LEDs 64 which emit light in different directions from the 1070 rod welding electrode holders, 1074 which can be detected by the one or more detection devices 16 to determine the position, orientation and / or movement of the rod welding electrode holders 1070, 1074. In particular, in certain embodiments, four or more sets 804, 806 810 of 802 visual markers, each set including various LEDs 64, can be used.

In other modalities, the different sets 804, 806, 810 of

169

IMPI 802 visual markers can be arranged in the assembly¹^^^^

INDUSTRIAL

<img file="MX359249B_D0129.tif" />

rod 1078 of the simulation rod welding electrode holder 1070, and can be arranged in the rod electrode holder assembly 1078 such that visual markers 802 can be detected by the one or more detection devices 16. As described in more detail herein, the rod electrode holder assembly 1078 of the simulation rod welding electrode holder 1070 can be used to retract a simulation rod welding electrode 1072 (or a welding electrode with real rod 1076, in certain situations where a real rod welding electrode 1076 is used in place of a simulation rod welding electrode 1072, but during a simulated rod welding process where an actual welding arc is not generated through the actual rod welding electrode 1076) to simulate the consumption of the rod welding electrode 1072, 1076 and thus can function as a rod welding electrode retraction assembly having 802 visual markers arranged thereon, the position, orientation and / or movement of which can be tracked by the one or more detection devices 16, thus making it possible for the position, orientation and / or movement of a rod welding electrode 1072, 1076 to be supported by the 1078, 1080 rod electrode holder assembly is inferred by 244 welding software.

In this way, visual markers 802 arranged on the outer surface 1077 of the rod welding electrode holders 1070, 1074 enable the welding software 244 to determine the position, orientation and / or movement of the welding electrode holders with rod 1070, 1074 using the one or more detection devices 16. Knowing the position, orientation and / or movement of the rod welding electrode holders 1070, 1074 makes the software possible

170

IMPIOUS ^ solder 244 inferring the orientation of a tip from those of rod 1072, 1076 respectively. The position and / or movement of the tip of the rod welding electrode 1072, 1076 can be inferred by, for example, estimating the actual consumption of the actual rod welding electrode 1076 during an actual rod welding process carried out by the real rod welding electrode holder 1074 (or, in the case of the simulation rod welding electrode 1072, directly tracing the retraction of the welding electrode with simulation rod 1072, as described in greater detail here). As an alternative, or in addition to, as illustrated in Figure 66A, in the case of the simulation rod welding electrode holder 1070, in certain embodiments, one or more visual markers 802 may be arranged directly on the welding electrode with simulation rod 1072 along an axis of the welding electrode with simulation rod 1072 such that the position, Orientation and / or movement of the simulation rod welding electrode 1072 can be detected directly using the one or more detection devices 16. In addition to, or in lieu of, having the visual markers 802 directly on the simulation rod welding electrode 1072, in certain embodiments, the visual markers 802 may be connected (for example, indirectly) to the welding rod welding electrode. simulation 1072 by, for example, being attached to some rigid body extending from the simulation rod welding electrode 1072. As will be appreciated, the modalities described herein as having visual markers 802 disposed elsewhere on the rod welding electrode holders 1070, 1074 (eg, on the outer frame 1077 and / or the electrode support assemblies 1078, 1080) may instead have similarly the visual markers 802 connected (for example, indirectly) to these other parts of the rod welding electrode holders

171

1070, 1074.

IMPI

MEXICAN INSTITUTE OF INDUSTRIAL PROPERTY

<img file="MX359249B_D0130.tif" />

As illustrated in Figures 64A, 64B, 65A and 65B, in certain embodiments, the outer structure 1077 of the rod welding electrode holders 1070, 1074 may be substantially similar to each other. In fact, in certain embodiments, many of the components of the rod welding electrode holders 1070, 1074 will be substantially similar to each other. For example, in certain embodiments, both rod welding electrode holders 1070, 1074 include substantially similar handles 1082 through which electrical current can be supplied to the respective rod electrode holder assemblies 1078, 1080 (and finally , to the respective rod welding electrodes 1072, 1076), and each of these handles 1082 can be coupled to the rod electrode support assemblies 1078, 1080 and the outer structure 1077 at a distal end 1084 of the handle 1082.

In certain embodiments, both the 1070, 1074 rod welding electrode holders include a 1086 trigger that can be depressed by a user to bring the 1086 trigger closer to the 1082 handle. For each of the 1070 rod welding electrode holders , 1074, the effect of pressing the trigger 1086 may be different. For example, for the simulation rod welding electrode holder 1070, pressing the trigger 1086 may cause the rod electrode holder assembly 1078 of the simulation rod welding electrode holder 1070 to cause the welding electrode with simulation rod 1072 is extended from the rod electrode support assembly 1078 to a simulated unconsumed position, thereby allowing a new simulated welding procedure to be carried out by the simulation rod welding electrode holder 1070. In certain embodiments, a release mechanism may be used.

172

IMPI to reset the welding electrode with syracc rod ^ ^ rtS ^ S

<img file="MX359249B_D0131.tif" />

not consumed. In contrast, for the 1074 real rod welding electrode holder, pressing the trigger 1086 may cause a more conventional effect for the 1074 real rod welding electrode holder, in particular, than in opposing jaws 1088 of the 1074 real rod welding electrode holder rod electrode be open, such that a real rod welding electrode 1076 can be inserted between the opposing jaws 1088, thereby making it possible for a new actual welding procedure to be carried out by the actual rod welding electrode holder 1074.

As illustrated in Figure 66B, the 1074 real rod welding electrode holder illustrated in Figures 65A and 65B is configured to facilitate the supply of actual welding power through a 1076 real rod welding electrode supported by the rod welding electrode holder actual 1074 such that an actual 1075 welding arc at a distal tip of the actual 1076 rod welding electrode is created when the tip of the actual 1076 rod welding electrode is bring into the vicinity of a real workpiece 82, thereby completing an electrical circuit between the welding power source 28, the real rod welding electrode holder 1074 (such as the welding tool 14), the welding electrode real rod welding 1076, and real workpiece 82 (eg, provided by welding cable 80 and work cable 84). As will be appreciated, when actual welding is carried out using the 1074 real rod welding electrode holder, the 1076 real rod welding electrode is consumed in such a way that the tip of the 1076 real rod welding electrode gradually moves towards the jaws 1088 of the real rod welding electrode holder 1074 which supports the real rod welding electrode 1076 in place with respect to the

173

IMPI Mexican institute 1074 real rod welding electrode. “^ Wusreu?

In contrast, as illustrated in Figure 66A, the simulation rod welding electrode holder 1070 illustrated in Figures 64A and 64B is not configured to facilitate the supply of actual welding power through the rod welding electrode 1072 to a distal tip 1090 of the 1072 simulation rod welding electrode. Rather, in certain modalities, the simulation rod welding electrode holder 1070 is configured to simulate the consumption of the simulation rod welding electrode 1072 by retracting the simulation rod welding electrode 1072 back into the rod electrode support assembly 1078 of the simulation rod welding electrode holder 1070 when simulated welding process is carried out by simulation rod welding electrode holder 1070. For example, in certain embodiments, the simulation rod welding electrode holder 1070 includes a motor that facilitates retraction of the simulation rod welding electrode 1072 into the rod electrode holder assembly 1078 of the welding electrode holder with simulation rod 1070.

As described above, in certain modalities, The rod electrode holder assembly 1078 of the simulation rod welding electrode holder 1070 is configured to retract the simulation rod welding electrode 1072 toward the rod electrode holder assembly 1078 to simulate the consumption of the Simulation rod welding 1072 during a simulated welding process carried out by the simulation rod welding electrode holder 1070. Referring to Figures 64A and 64B, assuming tip 1090A is tip 1090 being used as the simulated tip of the simulation rod welding electrode 1072 in which the simulated weld arc is to be created.

174

IMPI when tip 1090A is brought into proximity with a piece d ^ tfáS ^^ mOtSSKS ^ 'the rod electrode support assembly 1078 is configured for. xatraAr- ^ i simulation rod welding electrode 1072 in one direction toward the rod electrode support assembly 1078 during the simulated rod welding process, as illustrated by arrow 1092.

FIG. 67 illustrates one embodiment of the rod electrode support assembly 1078 of the simulation rod welding electrode 1072. In the illustrated embodiment, the rod electrode support assembly 1078 includes three distinct rails 1094 within which simulation rod welding electrode 1072 can be supported. In certain embodiments, each rail 1094 comprises a respective drive wheel 1096, which can be configured to rotate, thereby driving the movement of the simulation rod welding electrode 1072 when the simulation rod welding electrode 1072 is being supported within of the respective 1090 lane. In alternative embodiments, instead of drive wheels 1096, each rail 1094 may include a screw driver configured to mate with threading on the simulation rod welding electrode 1072 (for example, as shown on the welding electrode with simulation rod 1072 illustrated in Figures 64A and 64B) such that the screw driver drives the displacement of the welding electrode with simulation rod 1072.

In certain embodiments, each rail 1094 may include at least one guide 1098 that guides the simulation rod welding electrode 1072 through the respective rail 1094. It will be appreciated that each discrete rail 1094 is defined by the respective guide features (eg drive wheels 1096 and guides 1098) defining a respective axis of rail 1094 through which the simulation rod welding electrode 1072 can be moved. . In the illustrated mode, an assembly of

175

INSTITUTO MEXICANO motor 1100 causes the rotation of the central axis 1102, as desired ^ g ^ p · lagft8gÍ &amp; ffiO4 · The rotation of the central axis 1102 directly causes the rotation of at least one of the drive wheels 1096 (i.e. drive wheel 1096A). In addition, in certain embodiments, each rail 1094 may be associated with a respective gear 1106 of a gear assembly 1108. More specifically, as illustrated, in certain embodiments, the center shaft 1102 may be coupled to a first gear 1106A that is associated with the first drive wheel 1096A. The first gear 1106A can be directly coupled to the second and third gears 1106B and 1106C, which in turn can be directly coupled to the second and third drive wheels 1096B and 1096C. In the illustrated embodiment, the second and third gears 1106B and 1106C are generally oriented at angles of approximately 45 ° to the first gear 1106A, however, other orientations of the gears 1106 are contemplated. Furthermore, although the illustrated embodiment shows the first rail 1094A being generally oriented transversely to a certain axis 1110 of the simulation rod welding electrode holder 1070, and the second and third rails 1094 are generally offset from the central axis 1110 by approximately 45 °, other orientations of the rails 1094 (as well as the associated drive wheels 1096 and guides 1098) are contemplated.

Although Figure 67 illustrates an embodiment where a plurality of discrete rails 1094 can be used that remain in a relatively fixed position with respect to the 1078 rod electrode support assembly of the 1070 electrode, in other embodiments, a single rail can be used. 1094, and the rod electrode support assembly 1078 may be rotatable with respect to the simulation rod welding electrode 1072, thus making possible any continuous angular orientation of the simulation rod welding electrode 1072 with respect to the

176

IMPI simulation rod welding electrode holder TÍÍSÍla f ^^^ mR ^^^^^ modes, only the first rail 1094A, the first drive wheels 1096A, the first set of guides 1098A, etc., may exist in the Simulation rod welding electrode holder 1078 rod electrode holder assembly 1078, and the entire rod electrode holder assembly 1078 can be rotatable (for example, pivotable) with respect to the simulation rod welding electrode holder 1070, as illustrated by arrow 1112, thus making possible the different angular orientations (for example, any continuous angular orientation, unlike the discrete angular orientations made made possible by the first rails 1094 illustrated in Figure 67) of the simulation rod welding electrode 1072 with respect to the electrode holder 1070 (for example, with respect to the handle 1082 of the electrode holder 1070). In other embodiments, a combination of both the plurality of rails 1094, as illustrated in FIG. 67, and a rotatable (eg, pivotable) rod electrode support assembly 1078 can be used, making even more control possible and customization of the angular orientation of the welding electrode holder with simulation rod 1070, making either a relatively small number of discrete angular orientations possible or making an infinite number of continuous angular orientations possible.

Unlike making the continuous angular orientations of the simulation rod welding electrode holder 1070 possible through the rotating rod electrode holder assembly 1078 (eg pivotable), in certain embodiments, The rod electrode holder assembly 1078 can be configured to be fixed in a discrete number of angular orientations when rotated with respect to the simulation rod welding electrode holder 1070 (for example, with respect to the handle 1082 of the welding electrode holder with

177

<img file="MX359249B_D0132.tif" />

simulation rod 1070) by, for example, coupling onto surfaces of the support assembly l and outer structure 1077. In certain embodiments, a past Fc3Fg330 ÓOII lUSUllu can support the rod electrode support assembly 1078 in place with with respect to the outer structure 1077 and, when the pin is removed, the rod electrode support assembly 1078 may be movable with respect to the outer structure 1077. Furthermore, in certain embodiments, the rod electrode holder assembly 1078 can be rotated such that the simulation rod welding electrode 1072 is generally aligned parallel to the center axis 1110 of the simulation rod welding electrode holder 1070. In such an alignment, the motor assembly 1100 can be configured to retract the simulation rod welding electrode 1072 into an interior volume of the handle 1082 of the simulation rod welding electrode holder 1070 (for storage purposes, for example) .

In certain embodiments, once the user selects one of the discrete angular orientations of the simulation rod welding electrode 1072 relative to the simulation rod welding electrode holder 1070 (for example, by selecting a discrete rail 1094 from the assembly rod electrode holder 1078), user can enter which discrete angular orientation was selected. In other embodiments, the selected angular orientation of the simulation rod welding electrode 1072 with respect to the simulation rod welding electrode holder 1070 can be detected by a sensor assembly 1113 arranged in the simulation rod welding electrode holder. simulation 1070. For example, the sensor assembly 1113 may include a sensor (eg, an optical sensor) configured to detect when the simulation rod welding electrode 1072 is inserted into a particular discrete rail 1094 of the

178 1078 rod electrode holder and / or a sensor (for

IMPI

INDUSTRIAL

<img file="MX359249B_D0133.tif" />

configured to detect an angular orientation (eg, discrete or continuous angular orientation) of the 1078 rod electrode support assembly in embodiments including a rotatable (eg, pivotable) 1078 rod electrode support assembly.

In certain embodiments if only one rail 1094 is used in the rod electrode holder assembly 1078 of the simulation rod welding electrode holder 1070, the simulation rod welding electrode 1072 may be permanently captured in rail 1094 and , therefore, not removable from the 1078 rod electrode support assembly. In other embodiments, the simulation rod welding electrode 1072 may be removable from rail 1094 (for storage purposes, for example). In embodiments where multiple rails 1094 are used in the rod electrode holder assembly 1078 of the simulation rod welding electrode holder 1070, the simulation rod welding electrode 1072 will also be removable, for example, to change the lane 1094 inside the simulation rod welding electrode 1072 is held. Furthermore, again, even in modes having only one rail 1094, the rod electrode holder assembly 1078 can still be configured to be rotated in various angular orientations with respect to the simulation rod weld electrode holder 1070 ( for example, with respect to the handle 1082 of the simulation rod welding electrode holder 1070).

Figures 64A and 64B illustrate another embodiment of the rod electrode holder assembly 1078 of the simulation rod welding electrode holder 1070. In the illustrated embodiment, the simulation rod welding electrode 1072 includes threads which are manipulated by gears of a 1108 gear assembly

179

<img file="MX359249B_D0134.tif" />

IMPI to cause the welding rod electrode to

INDUSTRIAL returned to the 1078 rod electrode support assembly in the direction of arrow 1092 (as well as extending back away from the 1078 rod electrode support assembly, for example, opposite the direction of arrow 1092). The gear assembly 1108 can be driven by a motor assembly 1100 in a manner substantially similar to the motor assembly 1100 described with respect to FIG. 67. In certain embodiments, a coupling mechanism, such as a pulley or gear, can couple rotary shafts associated with the motor and gear assemblies 1100, 1108.

As described above, The rod electrode holder assembly 1078 of the simulation rod welding electrode holder 1070 is configured to retract the simulation rod welding electrode 1072 toward the rod electrode holder assembly 1078 to simulate the consumption of the Simulation rod welding 1072 during a simulation welding process carried out using the simulation rod welding electrode holder 1070. The welding software 244 determines the speed at which the simulation rod welding electrode 1072 must be retracted, and sends control signals to the rod electrode support assembly 1078 to adjust the retraction speed accordingly. For example, in certain embodiments, welding software 244 determines the retraction speed of the simulation rod welding electrode 1072, and sends control signals to the motor assembly 1100 of the rod electrode support assembly 1078 to effect the speed. for retraction of the welding electrode with simulation rod 1072.

The welding software 244 can determine the retraction speed of the simulation rod welding electrode 1072 in several different ways,

180

IMPI each selectable through the preswi $ ^ "$ §j ^ l screens

INDUSTRIAL

<img file="MX359249B_D0135.tif" />

the visual presenters described here. For example, in certain modalities, the retraction speed can be set to a constant retraction speed by an instructor. The constant retraction speed can be entered directly by the instructor, or can be established indirectly based on assignment parameters established by the instructor (or, in certain modalities, established by the user himself), such that a type (by example, E7018, E6010, etc.) of the simulation rod welding electrode 1072, a diameter (for example, 3/32 ", 1/8", 5/32 ", etc.) of the welding rod welding electrode. simulation 1072, a length (eg, up to 14 ", in certain embodiments) of the simulation rod welding electrode 1072, a simulated welding current, a desired simulated arc length, etc. Furthermore, in certain embodiments, instead of causing a constant retraction speed of the simulation rod welding electrode 1072, the welding software 244 can instead dynamically change the retraction speed of the simulation rod welding electrode. 1072 based on welding parameters (for example, working angle, displacement angle, arc length, displacement speed, target, arc length and so on) detected in real time during the execution of the simulated welding process. In other words, the 244 welding software can continuously adjust (for example, control in real time) the retraction speed (for example, update and implement a new retraction speed every 1 second, every 0.1 second, every 0.01 second or even more frequently, in certain modalities) during the execution of the simulated welding process. In certain embodiments, continuous adjustment of the retraction speed can be based at least in part on the welding parameters (for example, working angle 328, displacement angle 330,

181

<img file="MX359249B_D0136.tif" />

IMPI displacement 334 and objective 336) related to

INDUSTRIAL simulation 1072, which may be terminated based at least in part on tracking position, bearing, and / or position, bearing, and / or motion data related to 802 visual markers arranged in (or otherwise fixedly connected a) the simulation rod welding electrode holder 1070. As illustrated, the term "fixedly connected" is intended to mean connected in a fixed manner, eg, not mobile relative to. In other embodiments, the welding software 244 can query the retraction rate, for example, in a lookup table stored in memory devices 22.

In certain embodiments, the welding software 244 can continuously adjust (for example, control in real time) the retraction rate of the simulation rod welding electrode 1072 based at least in part on a simulated arc length, which can be determined by welding software 244 based at least in part on tracking position data, orientation and / or movement related to visual markers 802 arranged in (or otherwise fixedly connected to) the simulation rod welding electrode holder 1070. The simulated arc length determined by the welding software 244 represents the distance from tip 1090 of the simulation rod welding electrode 1072 from the simulated workpiece 82. Thus, in addition to relying on position, orientation and / or movement data related to the simulation rod welding electrode holder 1070, the simulated arc length determined by the welding software 244 can also be based on at least starts from the continuously adjusted retraction speed of the simulation rod welding electrode 1072 (for example, such that the welding software 244 displays the position, orientation and / or movement of the welding electrode holder with

182

<img file="MX359249B_D0137.tif" />

do

IMPI simulation rod 1070, as well as the position, orientation ^ and ^^ ft ^ fj ^ git of industrial welding with simulation rod 1072 with respect to the support of welding electrode with simulation rod 1070), as well as the other mentioned parameters previously.

In certain embodiments, the simulation rod welding electrode holder 1070 can be configured to simulate an arc start for the simulated welding process carried out by the simulation rod welding electrode holder 1070. In particular, in certain embodiments, the simulated welding process can be initiated when a tip 1090 of the simulation rod welding electrode 1072 comes into contact (eg, electrically or physically) with the simulated workpiece 82. The determination That the tip 1090 of the simulation rod welding electrode 1072 has contacted the simulated workpiece 82 can be accomplished in several ways. For example, in certain embodiments, the rod electrode holder assembly 1078 of the simulation rod welding electrode holder 1070 may be configured to supply a low-level current, which is not for the purpose of establishing a welding arc , through tip 1090 of simulation rod welding electrode 1072 when tip 1090 contacts the simulated workpiece 82 (by closing an electrical circuit similar to conventional welding processes). Low level current detection (eg, through current detection circuits 1242 arranged in a junction box 1194, as illustrated in Figure 84, in certain embodiments) initiates the start of a simulation test , during which welding parameters are captured and the simulation rod welding electrode 1072 is retracted. In certain modalities, once a test has started, subsequent detection of the low level current causes the test to end and retraction of the test electrode

183 Welding with simulation rod 1072 stops. In

<img file="MX359249B_D0138.tif" />

244 can determine that the tip 1090 of the simulation rod welding electrode 1072 has contacted (or is at least in close proximity to) the simulated workpiece 82 based at least in part on a difference in voltages simulated workpiece 82 and simulation rod welding electrode 1072 (for example, at least in part through voltage sensing circuits 1242 arranged in junction box 1194, As illustrated in Figure 84, in certain embodiments).

Alternatively, or in addition to, in certain embodiments, welding software 244 can infer the location of tip 1090 of simulation rod welding electrode 1072 using the known length of simulation rod welding electrode 1072 and the position, known orientation and / or movement of the simulation rod welding electrode holder 1070 detected by the one or more detection devices 16 (for example, by tracing the visual markers 802 on the simulation rod welding electrode holder 1070, for example). The welding software 244 can compare after the location of the tip 1090 of the simulation rod welding electrode 1072 with the location of the simulated workpiece 82, which can either be known by the welding software 244 or detected using the one or more detection devices 16. In other embodiments, the welding software 244 can determine that the tip 1090 of the simulation rod welding electrode 1072 has contacted the simulated workpiece 82 based on actuation of a mechanical characteristic of the welding rod welding electrode. simulation 1072 (for example, a button provided on tip 1090 of the simulation rod welding electrode 1072, in certain modalities) when the mechanical characteristic of the simulation rod welding electrode

184

1072 contact the simulated workpiece

IMPI

INDUSTRIAL

<img file="MX359249B_D0139.tif" />

Welding software 244 can determine that the tip 1090 of the simulation rod welding electrode 1072 has made contact with the simulated workpiece 82 based on feedback from other types of sensors (eg force sensors, accelerometers, etc. .) arranged on the simulation rod welding electrode 1072 that are configured to detect a certain position, orientation and / or movement of the simulation rod welding electrode 1072 with respect to the simulated workpiece 82.

Regardless, once the welding software 244 determines that the tip 1090 of the simulation rod welding electrode 1072 has contacted the simulated workpiece 82, the welding software 244 sends suitable control signals to the welding support assembly. rod electrode 1078 to initiate retraction of the simulation rod welding electrode 1072. In certain embodiments, the simulation rod welding electrode holder 1070 can be configured to generate vibrations (eg, via haptic feedback mechanisms) and / or audible feedback (eg, via speakers) to simulate startup of the arch when retraction begins. It should be mentioned that, in certain embodiments, an additional function that the mechanisms of the welding electrode holders 1070, 1074 to generate the audible feedback may have is to generate a sound effect when the rod welding electrode holder 1070,1074 does not is tracked by the one or more detection devices 16 during a given threshold time period (eg, 1 second, in certain modes), in other words, when the rod welding electrode holder 1070, 1074 has been moved from the detection area of ​​the one or more detection devices 16 or when the one or more visual markers 802 in the rod welding electrode holder

185 simulation 1070, 1074 are obstructed from the

IMPI vision defWMJ »INDUSTRIAL

<img file="MX359249B_D0140.tif" />

detection 16. Furthermore, in certain embodiments, if the actual rod welding electrode holder 1074 is not tracked for the given threshold time period, the welding power to the actual rod welding electrode holder 1074 may be disabled by contactor 1212 ( for example, contactor 1212 illustrated in Figure 84), but an alert screen can remain on screen for a given period of time (for example, 5 seconds, in certain modes, otherwise known as a "5-second lock") before it disappears.

Once retraction of the simulation rod welding electrode 1072 has started, retraction can continue until either the simulation rod welding electrode 1072 has been fully retracted (i.e. can no longer be retracted any more) or when tip 1090 of simulation rod welding electrode 1072 exceeds a threshold distance (eg, 1 "in certain embodiments) from simulated workpiece 82. Detection of the distance of the tip 1090 of the simulation rod welding electrode 1072 from the simulated workpiece 82 can be carried out using any of the position detection techniques described herein with respect to the establishment of simulated weld arc . In addition, in certain embodiments, other types of sensors (eg, accelerometers, in certain embodiments) arranged on simulation rod welding electrode 1072 (or anywhere on the simulation rod welding electrode holder 1070) can be use to determine when the tip 1090 of the simulation rod welding electrode 1072 has moved away from the simulated workpiece 82 by the threshold distance, such that retraction of the simulation rod welding electrode 1072 can be stopped. In addition, in certain modalities, in addition to being based on the distance of the tip 1090 of the simulation rod welding electrode

186

1072 from simulated workpiece 82, retracted it

<img file="MX359249B_D0141.tif" />

with

Df INDUSTRIAL PROPERTY simulation rod 1072 can be stopped based on the detected angle of the simulation rod welding electrode 1072, which can be detected by an angle sensor arranged on the simulation rod welding electrode 1072 (or in either side on the simulation rod welding electrode holder 1070) for example.

FIG. 68A illustrates one embodiment of the actual rod welding electrode holder 1074 with the outer structure 1077 removed for illustration purposes.

As illustrated, in certain embodiments, the 1074 real rod welding electrode holder includes a discrete number of distinct grooves 1114 formed on interior surfaces of at least one of the jaws 1088 of the 1074 real rod welding electrode holder which they are configured to hold the 1076 real rod welding electrode. FIG. 68B illustrates an example of inner surface 1116 of a jaw 1088 of the actual rod welding electrode holder 1074 having two transverse grooves 1114A and 1114B and two longitudinal grooves 1114C and 1114D, however other numbers are also contemplated, discrete slot sizes and configurations 1114.

One benefit of using the discrete number of grooves 1114 in the 1080 rod electrode holder assembly of the 1074 real rod welding electrode holder is that the 244 welding software can more easily know exactly where the actual rod welding electrode 1076 is with respect to the support of 1074. For example, since the length of the actual rod welding electrode 1076 is known from the welding software 244, when the welding software 244 also knows the slot 1114 of the rod electrode support assembly 1080 that is supporting the welding electrode. 1076 real rod welding in place, the software

187

<img file="MX359249B_D0142.tif" />

X .NO solder 244 can calculate the tip location di

<img file="MX359249B_D0143.tif" />

ura

I HEARD THE INDUSTRIAL HtOHBTY ___ with 1076 real rod before consumption of the 1076 real rod welding electrode.

To that end, the user may be guided through an on-screen display 1117, as illustrated in Figure 68C, to insert the actual rod welding electrode.

1076 in one of the discrete grooves 1114 (marked grooves 1,2, 3 and 4 in the illustrated mode). In certain embodiments, corresponding labels (eg, 1, 2, 3, and 4) may be on an outer surface of one or both of the jaws 1088 of the 1074 real rod welding electrode holder to assist in guiding the user. Once the user inserts the actual 1076 rod welding electrode into one of the slots 1114, the user can select which slot 1114 into which the 1076 actual rod welding electrode was inserted. The 244 welding software uses this information to precisely locate the distal tip of the 1076 real rod welding electrode, and to help track the placement of the 1076 real rod welding electrode as it is consumed during a rod welding process real. For example, in certain embodiments, the welding software 244 may use the information related to the selected slot 1114 into which the actual rod welding electrode 1076 is inserted to determine from which side of the actual rod welding electrode holder 1074 that 1076 real rod welding electrode is stretching. For example, for any given slot 1114, when knowing the length of the 1076 real rod welding electrode (before consumption of the 1076 real rod welding electrode), there are only two possible locations of the actual rod welding electrode tip 1076 (which can both be determined by the 244 welding software at any given time). The welding software 244 may use other information related to the position, orientation and / or movement of the 1074 real rod welding electrode holder (for example, when

188

<img file="MX359249B_D0144.tif" />

trace visual markers 802) to determine^T&gt; f ^ M ^ ANes industrial

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Determined points makes sense (for example, estimating a relative location from an actual workpiece 82 for both of the two determined points, and determining which is closest). To make the system more precise, in certain modalities, the user may be instructed not to flex the 1076 real rod welding electrode.

In addition, in certain embodiments, if the user selects a slot 1114 that is unsuitable for a particular type of weld (eg, certain types of slot positions for an overhead weld), the user may be notified via an indication in screen. Alternatively, or in addition, in certain embodiments, certain slot selection options are not provided to the user through the on-screen indication for particular weld types. In addition, in certain embodiments, the welding software 244 stores a user-selected slot option for a particular type of welding in memory devices (eg, memory devices 22 or storage devices 24 of computer 18), and automatically returns to this user selected slot option during subsequent tests on the same type of welds.

In another embodiment, the rod electrode holder assembly 1080 of the actual rod welding electrode holder 1074 may only have a slot 1114 into which the actual rod welding electrode 1076 can be inserted. In this case, the rod electrode holder assembly 1080 can be rotated with respect to the handle 1082 in a plurality of angular orientations (substantially similar to the rod electrode holder assembly 1078 of the simulation rod welding electrode holder 1070 ). In certain embodiments, 802 visual markers can also be attached to this rotating rod electrode assembly to facilitate tracing of the 1076 real rod welding electrode (as indicated

189

IMPI similarly here regarding the bracket assembly

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welding electrode holder with simulation rod 1070).

It will be appreciated that in certain embodiments of the rod electrode holder assembly 1078 of the simulation rod welding electrode holder

1070 having more than one 1094 rail into which the 1072 simulation rod welding electrode can be inserted, similar on-screen prompts can be used to guide the user to insert the 1072 simulation rod welding electrode into a suitable 1094 rail, and enter which 1094 lane into which the 1072 simulation rod welding electrode was inserted. It is worth mentioning that the user can freely switch between using the simulation rod welding electrode holder 1070 and the actual rod welding electrode holder 1074. In this way, certain characteristics of the rod welding electrode holders 1070,

1074 They can help prevent the user from inserting unsuitable 1072, 1076 rod welding electrodes into either the rails 1094 of the simulation rod welding electrode holder 1070 or the grooves 1114 of the actual rod welding electrode holder 1074. For example, in certain embodiments, simulation rod welding electrodes 1072 may be larger than actual rod welding electrodes 1076 (eg, have larger diameters) such that simulation rod welding electrodes 1072 does not fit within the grooves 1114 of the 1074 real rod welding electrode holder (i.e. because they are too large), and the electrodes 1076 cannot be held firmly within the rails 1094 of the simulation rod welding electrode holder 1070 (ie because they are too small). It should be noted that, in other embodiments, a 1076 real rod welding electrode can be used with the simulation rod welding electrode holder 1070. For example, in such

190

IMPI modalities, electrodd bracket rails 1094^Nn ^^ SSiteifei

INDUSTRIAL

<img file="MX359249B_D0147.tif" />

Simulation 1070 can be suitably dimensioned such that real rod welding electrodes 1076 can be inserted into it.

Figures 69A and 69B illustrate embodiments of button panels 1118,

1120 which can be arranged in the simulation rod welding electrode holder 1070 and in the real rod welding electrode holder 1074, respectively. As primarily indicated herein as including buttons, in other embodiments, the buttons of the rod welding electrode holder 1070, 1074 described herein may include other different input devices or input elements that include, but are not limited to, touchscreens, sliders, scrolling wheels, switches, knobs, liquid crystal displays, or any other suitable input device or input elements configured to enable operator interaction with welding software 244 through the rod welding electrode holder 1070, 1074. In certain embodiments, button panels 1118, 1120 They may include translucent membranes with LEDs underneath to make certain icons glow as illustrated in Figures 69A and 69B. Locating the button panels 1118, 1120 on the 1070,1074 rod welding electrode holders makes it easier for the user to select certain options. Both button panels 1118, 1120 include two navigation buttons 1122, 1124 (although, in certain embodiments, button panels 1118, 1120 may include only one navigation button) that can be manipulated by the user to assist in navigating the screens, menus, etc. that are displayed visually on the display devices described here. Also, both button panels 1118, 1120 include a power button 1126, however tampering with the power button 1126 causes slightly different functionality than the brackets.

191 of 1070, 1074 rod welding electrodes.

<img file="MX359249B_D0148.tif" />

INDUSTRIAL

<img file="MX359249B_D0149.tif" />

When the user presses the power button 1126 of the simulation rod welding electrode holder 1070, the simulation rod welding electrode holder 1070 is activated by the welding software 244, and a welding process indicator simulation rod 1128 (for example, a blue LED in certain modes) is lit. It will be appreciated that, in certain modes, the buttons described here make context sensitive navigation possible through screens, menus, etc. that are displayed visually on the display devices described here. In other words, the button navigation functions described herein may change based on the context of the information that is currently being displayed visually on the display devices. In such situations, context sensitive prompts can be visually displayed on the display devices to help the user navigate the screens, menus, etc.

In contrast, in certain embodiments, when the user first presses the power button 1126 of the 1074 real rod welding electrode holder, the 1074 real rod welding electrode holder is activated by the welding software 244, and an indicator 1130 real rod welding process (for example, an orange LED in certain modes) is lit, but welding power is not yet provided to the 1074 real rod welding electrode holder. Once the 1074 real rod welding electrode holder is activated, the power button 1126 can be subsequently pressed for a certain amount of time (for example, two seconds in certain modes) to activate welding energy through the 1074 real rod welding electrode, at the time a 1132 real rod welding power indicator (for example, an LED

192

<img file="MX359249B_D0150.tif" />

orange in certain modes) starts flashing *

INDUSTRIAL welding is enabled through real rod welding electrode holder

1074. In certain embodiments, the subsequent pressing of the power button 1126 causes the welding power to be disabled. In certain embodiments, the actual welding power is only activated through the 1074 real rod welding electrode holder when the welding software 244 determines that the 1076 actual rod welding electrode is close (for example, within 2.54 cm , for example) of the actual workpiece 82, using the position detection techniques described here. In certain embodiments, both rod welding electrode holders 1070, 1074 may only be activated when suitable displays are being visually presented to the user. In addition, in certain embodiments, the rod welding electrode holders 1070, 1074 can be configured to generate vibrations (eg, through the haptic feedback mechanisms) to confirm to the user that the button has been depressed.

The button panels 1118, 1120 illustrated in Figures 69A and 69B may have various shapes and may be arranged at various locations on the rod welding electrode holders 1070, 1074. For example, as illustrated in Figure 70, The button panel 1120 of the 1074 real rod welding electrode holder can be located near a proximal end 1134 of the handle 1082 of the 1074 real rod welding electrode holder. In addition, as illustrated in FIG. 71, the button panel 1120 of the actual rod welding electrode holder 1074 may be located on an outer surface of the outer structure 1077 of the actual rod welding electrode holder 1074. It will be appreciated that In certain embodiments, the button panel 1118 can similarly be located on the simulation rod welding electrode holder 1070.

193

In certain modalities, the supports of

<img file="MX359249B_D0151.tif" />

INDUSTRIAL

IMPI

MEXICAN

<img file="MX359249B_D0152.tif" />

1070, 1074 may include certain features to facilitate real-time feedback to the user during operation of the rod welding electrode holders

1070, 1074. For example, in certain embodiments, the rod welding electrode holders 1070, 1074 may include a status indicator 1136 that can indicate to a user whether a parameter of specific interest (for example, welding parameters such as working angle, angle displacement, target, and so on, arc parameters such as voltage and current), or combination of parameters, is acceptable or not (for example, within a range of acceptable values, for example, predetermined upper and lower limits. Other parameters of interest that may be indicated by status indicator 1136 may include whether the visual markers 802 of the rod welding electrode holder 1070, 1074 are blocked from being detected by the one or more detection devices 16, when the report of rod welding electrode 1070, 1074 is in a particular mode of operation (for example, a welding mode versus a configuration mode, for example), and so on. It will be appreciated that the specific parameter of interest can be selected by a user through the different screens presented to the user as described herein. As illustrated in Figures 72A and 72B, in certain embodiments, the status indicator 1136 can be arranged near a distal end of the rod welding electrode holder 1070,1074.

In certain embodiments, the status indicator 1136 may be an LED capable of either green or red illumination, and if the specific parameter of interest is acceptable (for example, if the specific parameter is within a predetermined upper and lower limit) , the status indicator 1136 may be illuminated green, if the parameter of specific interest is not acceptable, the status indicator 1136 may not

194

IMPI be illuminated at all, and when visuat markers ^^^ cgjg

INDUSTRIAL

<img file="MX359249B_D0153.tif" />

When tracked, the status indicator can be illuminated in red. Furthermore, in certain embodiments, the color, intensity, and / or illumination parameters of the status indicator 1136 can be varied based on a relationship of the parameter of interest to the limits. In certain embodiments, to minimize the potential to distract the user, the status indicator 1136 may not be illuminated at all unless the rod welding electrode holder 1070, 1074 is near work piece 82, using the techniques position detection described here.

Furthermore, in certain embodiments, the status indicator 1136 may also be capable of generating vibrations (eg, through haptic feedback mechanisms) and / or audible feedback (eg, through loudspeakers) to indicate to the user whether the parameter of specific interest is acceptable or not. Regarding the 1074 real rod welding electrode holder (and sometimes with the simulation 1070 rod welding electrode holder), in certain modalities, in order to minimize the potential to distract the user, these feedback characteristics can be deactivated in real time during the real rod welding process carried out by the real rod welding electrode holder 1074, while in most modalities, these real-time feedback characteristics can be left on during the simulated rod welding process carried out by the simulation rod welding electrode holder 1070.

Furthermore, in certain embodiments, the rod welding electrode holders 1070, 1074 may include a plurality of status indicators 1136 that may indicate a plurality of states. In addition, each of the plurality of status indicators 1136 may indicate several different states (eg,

195 depending on the color, intensity and / or parameters of

<img file="MX359249B_D0154.tif" />

OF UA INDUSTRIAL PROPERTY

<img file="MX359249B_D0155.tif" />

status 1136 (in the case of LEDs), depending on the intensity and / or vibration patterns (in the case of haptic feedback mechanisms), depending on volume, tone and / or audible feedback patterns (in the case of speakers ), and so on). In certain embodiments, any combination of the plurality of status indicators 1136 can be turned on or off at any given time.

In certain embodiments, the real-time feedback characteristics described with respect to Figures 72A and 72B can be particularly beneficial when the user is initiating the particular rod welding process (for example, by setting the rod welding electrode holder 1070 , 1074 in position to carry out the particular rod welding process). Figure 73 illustrates an example of a display 1138 that can be displayed visually when the actual rod welding electrode holder 1074 is activated, before an actual welding process has been started, and while the actual rod welding electrode holder 1074 is not in position (for example, welding software 244 has determined that actual rod welding electrode 1076 is not close to actual workpiece 82). When this is the case, the welding procedure summary table 1060 is illustrated to summarize to the user what the general properties (eg, target properties) are for a given test weld. It will be appreciated that the screen 1138 illustrated in Figure 73 will be substantially similar when the simulation rod weld electrode holder 1070 is activated, before the simulated welding process has been started, and while the welding electrode holder with simulation rod 1070 is not in position (for example, welding software 244 has determined that the

196

<img file="MX359249B_D0156.tif" />

simulation 1072 is not close (for example, within 2. simulated working 82).

It is worth mentioning that for the rod welding processes carried out by the rod welding electrode holders 1070, 1074, the contact tip to workpiece distance 332 can be replaced by the arc length index 1140 in the case of actual rod welding processes carried out by the actual rod welding electrode holder 1074 (and can be arc length in the case of simulated rod welding processes carried out by the simulation rod welding electrode holder 1070). In the case of actual rod welding processes carried out by the actual rod welding electrode holder 1074, the arc length index is an index that attempts to approximate the arc length (i.e. the length of the tip of the 1076 real rod welding electrode to the workpiece 82 along the axis of the 1076 real rod welding electrode). The need for the approximation is that the actual arc length between the tip of the 1076 real rod welding electrode and the workpiece 82 cannot be directly determined as precisely as the simulated rod welding processes carried out by the simulation rod welding electrode 1070 (for example, by tracing visual markers 802 on the simulation rod welding electrode 1072, in certain embodiments). This is particularly attributable to the fact that the position of the tip 1090 of the simulation rod welding electrode 1072 relative to the simulated workpiece 82 is more easily determined than the position of the tip of the actual rod welding electrode 1076 relative to an actual workpiece 82 (due at least in part to the actual consumption of the actual rod welding electrode 1076 during the actual rod welding process). In certain modalities, the arc length index can

197 be calculated as a function of the voltage across the elect

1076 during the actual rod welding process.

<img file="MX359249B_D0157.tif" />

to real

MEXICAN INSTITUTE

Μ ΙΛ reOftEDAD ___

More eápe'alicamerTferen certain modalities, the arc length index can caluuiaiser'cóínó 2.5 times the voltage across the 1076 real rod welding electrode during the real rod welding process, and the arc length index can be illustrated on a scale of 0 to 100 in certain modalities.

In the case of simulated arc welding, instead of length index, an arc length can be calculated. For example, in certain embodiments, visual markers 802 arranged on the simulation rod welding electrode 1072 can be traced, and the arc length can be calculated based on a position of the tip 1090 of the simulation rod welding electrode 1072. relative to a position of the simulation workpiece 82 (which can be similarly tracked, as described here. In this scenario, the arc length is the difference in distance between the tip 1090 of the simulation rod welding electrode 1072 and the simulation workpiece 82 as measured along the axis of the simulation rod welding electrode 1072. In certain embodiments where visual markers 802 are instead disposed on the outer structure 1077 of the simulation rod welding electrode holder 1070, the relative position of tip 1090 of the simulation rod welding electrode 1072 can be determined by detect current flows from tip 1090 of simulation rod welding electrode 1072 to simulation workpiece 82. At that time, the position of the tip 1090 of the simulation rod welding electrode 1072 is known through the known position of the simulation workpiece 82. Using this known location, as well as the known retraction speed of the electrode welding rod simulation 1072, the location

198

<img file="MX359249B_D0158.tif" />

<img file="MX359249B_D0159.tif" />

Continuously updated 1090 electr tip

INDUSTRIAL PROPERTY simulation 1072 can be determined, and the arc length can be calculated based on this continuously updated location. In turn, the calculated arc length can be used by the welding software 244 to dynamically update the retraction speed of the simulation rod welding electrode 1072.

In certain embodiments, during a weld, if a remaining length of the 1076 real rod weld electrode is determined to be shorter than a threshold electrode length (for example, 8 centimeters, in certain embodiments), the weld energy to the support 1074 real rod welding electrode can be deactivated, thus protecting the 1074 real rod welding electrode holder from heat / spatter, and prolonging the life of the 1074 real rod welding electrode holder. In addition, in certain embodiments, the 1074 real rod welding electrode holder may include one or more sensors configured to detect temperatures of the actual rod welding electrode holder. 1074, and the user can be notified (and weld power off) when detected temperatures exceed certain threshold temperatures.

Fig. 74 illustrates an example of a display 1142 that can be displayed visually when the actual rod welding electrode holder 1074 is activated, before the actual welding process has been started, while the actual rod welding electrode holder 1074 is in position (for example, welding software 244 has determined that the 1076 real rod welding electrode is close (for example, within 2.54 centimeters, for example) of the actual workpiece 82), but before a contactor (e.g. contactor 1212 illustrated in Figure 84) has been activated to provide actual welding power through the actual rod welding electrode holder 1074 (and, in this way, the

199 real rod welding 1076).

As illustrated, the

<img file="MX359249B_D0160.tif" />

It can be visually presented (which functions as visual guides) to provide an indication to the user of how the placement of the 1074 real rod welding electrode holder should be adjusted. The illustrated solid round circle is intended to represent the current targeting 1146 of the 1076 real rod weld electrode, the larger open circle is intended to represent the desired working objectives and offset angle 1148, and the horizontal line is intended to represent the desired target 1150. The purpose of the 1144 Routing Chart is to assist the user in correcting the placement of the 1074 Real Rod Welding Electrode Holder such that the current routing 1146 is moved within the desired 1148 working and displacement angle targets and level Aiming 1150. When this is done, placement of the 1076 real rod welding electrode is considered acceptable. In certain embodiments, the addressing graph 1144 may include a vertical line that is designed to represent a desired travel speed.

Figure 75 illustrates an example of a screen 1152 that can be displayed visually when the actual rod welding electrode holder 1074 is activated, before the actual welding process has been started, while the actual rod welding electrode holder 1074 is in position (for example, welding software 244 determined that the actual rod welding electrode 1076 is close to the actual workpiece 82), and after a contactor (eg, contactor 1212 illustrated in FIG. 84) has been energized to provide actual welding power through the actual 1074 rod welding electrode holder (and, thus, the welding electrode with real rod 1076). As illustrated, a message can be visually presented to viewers that the process

200

<img file="MX359249B_D0161.tif" />

actual welding is about to start, and that the ^ ^ 6Glí¡Wé &amp; neágwsc ^ are seeing on the 1152 screen, but rather they should be paying attention to the impending actual welding process. FIG. 76 illustrates an example of a display 1154 that can be displayed visually when the actual rod welding electrode holder 1074 is activated, right after the actual welding process has been started. As will be appreciated, this is the next stage in the process after screen 1152 of FIG. 75 and that, once the actual welding process has been started, the address chart 1144 is removed to further reduce the possibility of distraction to user.

To further assist in drawing the user's attention away from the rod welding electrode holders 1070, 1074, in certain embodiments, the targeting graph 1144 illustrated in Figures 74 and 75 may be placed more conveniently for the user. More specifically, Figures 77A to 77C illustrate various modalities of display devices whereby a display of the address chart 1144 can be produced at various locations closer to the welding process being carried out by the mounting brackets. rod welding electrode 1070, 1074. For example, Figure 77A illustrates an embodiment in which a visual presenter 1156 is integrated into the rod welding electrode holders 1070, 1074. In the illustrated mode, the visual presenter 1156 is integrated into the outer structure 1077 of the 1070, 1074 rod welding electrode holders. More specifically, the illustrated embodiment includes the visual presenter 1156 arranged in an extension of the outer structure 1077 of the rod welding electrode holders 1070, 1074. However, in other embodiments, the visual presenter 1156 can be integrated into the 1082 handle or some other component of the 1070, 1074 rod welding electrode holders.

201

As illustrated in Figure 77A, Visual Presenter 1

<img file="MX359249B_D0162.tif" />

visually display addressing graph 1144 so that the user can receive real-time feedback related to the placement of the rod welding electrode holders 1070, 1074 without having to direct the user's attention away from the welding electrode supports. rod welding 1070, 1074. It will be appreciated that the welding software 244 can be configured to send control signals through the rod welding electrode holders 1070, 1074 and to the visual presenter 1156 in substantially real time to adjust the display of the addressing graph 1144.

FIG. 77B illustrates another embodiment in which a handheld device 1158 having its own visual presenter 1160 is configured to visually display the address graph 1144. It will be appreciated that the illustrated handheld device 1158 can be located at various locations near workpiece 82 and / or rod welding electrode holders 1070, 1074 in such a way that the user can receive real-time feedback regarding the placement of the rod welding electrode holders 1070,1074 with respect to the workpiece 82 without having to draw the user's attention to the workpiece. 82 and / or 1070, 1074 rod welding electrode holders. It will be appreciated that, in certain embodiments, welding software 244 can be configured to send control signals to visual presenter 1160 wirelessly (eg, via network device 36 illustrated in Figure 1) in substantially real time to adjust the visual display of the addressing graph 1144. In certain embodiments, the handheld device 1158 may be a device specifically dedicated to visually display the addressing graph 1144 and / or graphical representations referring to the welding system 10. However, in the embodiment illustrated in Figure 77B, the device

202 manual 1158 may instead be a device not to

INDUSTRIAL visually display addressing graphic 1144 and / or other graphic representations related to welding system 10, but rather a multi-purpose device (such as a smartphone) that has a software application installed on it that is configured to visually display the addressing graph 1144 and / or other graphical representations related to the welding system 10. As illustrated in FIG. 77B, in certain embodiments, a base 1162 can be used to assist in orienting the handheld device 1158 to a convenient orientation for the user to view visual display 1160 of the handset 1158. In certain embodiments, the base 1162 it can be integrated into workpiece 82 or any other component of the welding system 10. In certain embodiments, the visual presenter 1156 of the rod welding electrode holders 1070, 1074 of FIG. 77 A and / or the visual presenter 1160 of the handheld device 1158 of FIG. 77B can be configured to visually display the screenshots illustrated in figure 27.

Figure 77C illustrates yet another embodiment in which the rod welding electrode holders 1070, 1074 include a projection system 1164 configured to project targeting graph 1144 directly onto workpiece 82. In the illustrated mode, the 1164 projection system is integrated into the outer structure 1077 of the 1070, 1074 rod welding electrode holders. However, in other embodiments, the projection system 1164 may be integrated into the handle 1082 or some other component of the rod welding electrode holders 1070, 1074. It can be appreciated that, in such embodiment, the projection system 1164 can having to be configured to direct the projected images around the 1072,1076 rod welding electrodes. For example, the projection system

203

IMPI6Í51

1164 may require at least two subsystems of prtJV ^ Wt &amp; 'S ^ &amp; ui ^^^^^ two opposite INDUSTRIAL rod welding electrodes 1072, 1076. Due at least in part to the fact that, in certain embodiments, the rod welding electrodes 1072, 1076 can be located at various locations and orientations relative to the rod welding electrode holders 1070, 1074, numerous projection subsystems of the 1164 projection system may have to be located around the 1070, 1074 rod welding electrode holders, and the welding software 244 can be configured to control which of the different projection subsystems of the projection system 1164 is used to project the address graph 1144 onto the workpiece 82 by, for example, selectively activating and controlling the subsystems of projection of the projection system 1164. It will also be appreciated that, in certain embodiments, the addressing graph 1144 can be displayed visually on an internal visual display 32 of the welding helmet 41 described herein.

In addition, in certain embodiments, the rod welding electrode holders 1070, 1074 may include other graphical indicators (eg, visual guides) to provide real-time feedback to the user. For example, as illustrated in FIG. 78, in certain embodiments, the rod welding electrode holders 1070, 1074 may include one or more graph range gaps 1166 (eg, arranged on an extension of the outer structure 1077 ) to show where a specific parameter of interest is currently with respect to an acceptable range (for example, between an acceptable lower and upper limit). Although illustrated in FIG. 78 as being related to travel angle and working angle, the one or more graph range gauges 1166 may be related to any of the parameters described herein. In the illustrated mode, the one or

204

IMPIg ^ more interval indicators graph 1166 are illustrated!

substantially parallel. However, in other embodiments, the one or more graph range gaps 1166 can generally be aligned across from each other, thereby representing a cross-type representation. In the illustrated mode, the one or more graph range gauges 1166 are integrated into the outer frame 1077 of the rod welding electrode holders 1070,1074. However, in other embodiments, the one or more graphical range gauges 1166 may be integrated into the handle 1082 or some other component of the rod welding electrode holders 1070,1074. In certain embodiments, the graphical range indicators 1166 can be used in conjunction with the status indicators 1136 described with respect to Figures 72A and 72B. For example, if the value for a parameter of interest tracked by one of the graph range gaps 1166 begins to fall outside the illustrated range, corresponding status flags 1136 may be properly activated.

As described with respect to Figures 68A-68C, in certain embodiments, the actual rod welding electrode holder 1074 may include several discrete grooves 1114 into which the actual rod welding electrode 1076 can be inserted and maintained. As described herein, the user may be instructed that the 1076 real rod welding electrode should not be bent (in order to improve the tracking accuracy of the 1076 real rod welding electrode during the welding process with However, in certain embodiments, the user may have reasons to bend the 1076 real rod welding electrode. In such situations, as illustrated in Figure 79, a calibration device 1168 can be slid over the tip of the 1076 real rod welding electrode after the 1076 real rod welding electrode has been

205

IMPI

MEXICAN INSTITUTE folded. In general, in certain modalities, the device

<img file="MX359249B_D0163.tif" />

be, for example, a sleeve that includes a generally cylindrical body having an internal hole that is specifically dimensioned to receive (e.g., fit circumferentially around) tips (e.g., distal ends) of 1076 real rod welding electrodes. In certain modalities, the calibration device

1168 it may include a detection mechanism (eg, a force sensor, in certain embodiments) provided on the calibration device 1168 and configured to detect when the calibration device 1168 has been secured on the 1076 real rod welding electrode.

In certain embodiments, the calibration device 1168 may include two or more 802 visual markers, which may be either active or passive markers, the position of which is capable of being detected by the one or more detection devices 16 to calibrate exactly where it is. the tip of the 1076 real rod welding electrode (for example, relative to the actual rod welding electrode holder 1074) and to determine an axis of the actual rod welding electrode 1076 for use by the welding software 244. The 802 visual markers on the 1168 calibration device work in substantially the same way as the 802 visual markers on the simulation rod welding electrode 1072, in certain embodiments, to locate the position of the tip 1090 of the rod welding electrode simulation 1072. It will be appreciated that, in certain embodiments, the calibration device 1168 can be used in lieu of having the user select into which discrete slot 1114 of the real rod welding electrode holder 1074 the real rod welding electrode 1076 has been inserted. In certain embodiments, the calibration of the 1168 calibration device can be initiated through a user input, or when internal circuits to the 1168 calibration device detect that the

206

IMPI 1168 calibration device has been placed compleOffSISfáSOlfe ^r INDUSTRIAL

<img file="MX359249B_D0164.tif" />

1076 real rod welding electrode. In other embodiments, calibration of calibration device 1168 may be initiated based on compression or expansion of a distance between visual markers 802 of calibration device 1168.

As described herein, many different types of simulation welding tools and real-world welding tools can be used with the welding system 10 described herein. Consequently, many different screens can be presented to the user when using the welding system 10 described here. Figures 80A and 80B illustrate examples of displays 1170, 1172 related to allocation lists for MIG welding torches ("SmartGuns") and rod welding electrode holders ("SmartStingers"), respectively. Both screens 1170, 1172 show assignment lists 1174 for the respective type of welding tool 14. In addition, both screens display filters for joint types 1176 (for example, butt joint, lapel joint, T-joint, etc.) and position 1178 (for example, horizontal, vertical, etc.). The main difference between the data shown in allocation lists 1174 and the filters on screens 1170, 1172 is that, for MIG welding torches, the allocation lists 1174 and filters include data related to process type 1180 (for example, GMAW, GMAW-S, FCAW-G, etc.) and, for the rod welding electrode holders, the 1174 assignment lists and filters include data related to electrode class 1182 (eg E6010, E6013 , E7018, etc.). In certain embodiments, for any given user, up to six 1182 electrode class filter options can be presented visually.

In certain modes, when a user views their assignments, the preset screen 1170, 1172 will be that of the last welding tool 14 that the

207

IMPI user had selected. For example, if the last^INRSiíSf ^ SSílS8 ^J INDUSTRIAL a 14 selected by the user was a 1070 rod welding electrode holder,

1074, screen 1172 will be the user preset assignment screen. In certain embodiments, if a user selects an assignment for a welding tool 14 that is not connected to the welding system 10, a message may be visually displayed on the screen informing the user to connect that type of welding tool 14 before proceeding. . In certain embodiments, the selected 1148 welding tool type can be visually displayed in the upper left corner of the assignment selection screens 1170, 1172, and all subsequent setup and test screens. The selected type of welding tool 1184 can also be visually displayed on history screens corresponding to the particular type of welding tool 14, as well as assignment management screens.

In addition to the assignment selection screens 1170, 1172 illustrated in Figures 80A and 81B, welding tool calibration screens 1186 can be visually presented for each type of welding tool 14. Figure 81 illustrates an example of a welding screen. 1186 calibration for a MIG welding gun (“Smart Gun”). As illustrated, calibration screens 1186 can provide a step-by-step procedure for calibrating the selected type of welding tool 14. As illustrated in Figure 81, the first step in calibrating a MIG welding gun is to select whether the gun is new to welding system 10. The second step in calibrating the MIG welding gun is to confirm and update dimensions of a gun shaft calibration tool (eg, 610 calibration tool illustrated in Figures 37 and 38), if necessary. The third step in calibrating the MIG welding gun is to fix the tip of

208

IMPI gun shaft calibration (for example, tip 614 of the herflftwrórta ^ g

INDUSTRIAL

<img file="MX359249B_D0165.tif" />

Illustrated in Figures 37 and 38) as shown. The fourth step in calibrating the gun ------------—------------- V-- ·· MIG welding is to mount the gun and select calibrate for various positions.

As illustrated, there are also additional options for advanced users, which can be selected. As illustrated in FIG. 82, additional help screens 1188 may be displayed to help users know how to use, among other things, address graphics 1114 (ie, visual guides).

As discussed here with respect to FIG. 73, in certain embodiments, the arc length or arc length index can be determined by the welding software 244 and visually displayed on the screen as a tracked parameter.

However, in other embodiments, as illustrated in FIG. 83, instead of arc length or arc length index, feed rate 1192 can be determined and visually displayed on the screen as a tracked parameter. In general, the feed rate 1192 (for example, an approximation of the draw rate of the rod welding electrode 1072, 1076) is the rate of change of distance between the rod welding electrode holders 1070, 1074 and the workpiece 82 along an axis of the rod welding electrode 1072, 1076. Thus, it will be appreciated that since the position, orientation and / or movement of the rod welding electrode holders 1070, 1074 is tracked by the one or more detection devices, and the position of the workpiece 82 is whether tracked by the one or more detection devices 16 or known, then the rate of change of the distance between the 1070 rod welding electrode holders, 1074 and the workpiece 82 along an axis of the rod welding electrode 1072, 1076 is a very simple calculation.

As described herein, various types of

209

IMPI Mexican Institute of Real and Simulation Welding 14 can be used with the ^ j ^ f ^ system

<img file="MX359249B_D0166.tif" />

rite in the present. Consequently, it will be appreciated that, in certain modalities, sources of '' '^{1 1 1} ..... .........

Power configured to provide power to these different simulation and real welding tools 14 can also be used in conjunction with the welding system 10 described herein. As will also be appreciated, the handling of energy and data between these different power sources, real and simulation welding tools 14 and the welding system 10 can become a bit cumbersome, due to at least the complex or extensive number of possible connections, cables and so on. Accordingly, in certain embodiments, as illustrated in FIG. 84, a dedicated 1194 junction box (router) can be used to connect the different power sources, real and simulation soldering tools 14, soldering system 10, and other related components and devices.

As illustrated in FIG. 84, in certain embodiments, the junction box 1194 may include a connector 1196 configured to connect to a data cable 1198 configured to connect to the welding system 10 such that data (from the welding tools 14 and other components and devices connected to junction box 1194) can be communicated from junction box 1194 to welding system 10 for processing. It will be appreciated that, in certain embodiments, control signals can also be communicated from the welding system 10 to the welding tools 14 and other components and devices connected to the junction box 1194 via the data cable 1198. In this way, junction box 1194 is used to route data between welding system 10 and welding tools 14.

In certain embodiments, the different power sources that provide power to the welding tools 14 can interact with the welding tools 14.

210

<img file="MX359249B_D0167.tif" />

of the

IMPIf welding 14 and the connection box 1194 of vañae-n ^ Rejagg di fNDterWAl particular needs of the welding tools 14. For example, as illustrated in Fig. 84, in certain embodiments, a power source 1200 can provide welding power directly to a MIG welding tool 14, and the MIG welding tool 14 can communicate directly with the MIG power source. 1200, for example, to provide trigger control signals, and so on. Thus, in certain embodiments, the junction box 1194 may include only a single connector 1202 configured to connect to a data cable 1204 configured to connect to the MIG welding tool 14 such that data can be communicated from the tool. 14 MIG weld through junction box 1194 to weld 10 for processing. It will be appreciated that, in certain embodiments, control signals can also be communicated from the welding system 10 (via junction box 1194) to the MIG welding tool 14 via the data cable.

1204.

In contrast, in certain embodiments, junction box 1194 may include a connector 1206 configured to connect to a welding power cable 1208 configured to connect to a rod welding power source 1210 configured to provide adequate power for a process welding rod carried out by a 1074 real rod welding electrode holder. In certain embodiments, the junction box 1194 may include a contact 1212 configured to be activated (eg, closed) or deactivated (eg, open) to provide welding power to a 1074 real rod welding electrode holder that is Connected to the 1194 junction box or prevent welding power from being supplied to the 1074 real rod welding electrode holder.

211

IMPI

MBUCANO INSTITUTE

MRXfCANO INSTITUTE

For this purpose, in certain modalities, the connection box ^ i ^ g ^ | $ pt

<img file="MX359249B_D0168.tif" />

Include a connector 1214 configured to connect to a welding power cable 1216 configured to connect to a real-rod welding electrode holder 1074 such that the welding power provided by the rod welding power source 1210 can be provided with 1074 real rod welding electrode holder through junction box 1194 when contactor 1212 in junction box 1194 is activated. In certain embodiments, after contactor 1212 has been turned on, the amount of power used to drive contactor 1212 may vary based on the state of contactor 1212. For example, significantly more power is used to power contactor 1212 than to keep contactor 1212 in the on state.

In certain embodiments, when the length of the actual rod welding electrode 1076 is determined to be below a certain length (eg, less than 8 centimeters, in certain embodiments), contactor 1212 can be opened to stop welding. In addition, in certain modes, contactor 1212 will be configured to open normally (eg, in a safe mode). In certain embodiments, the solder system 10 and / or control circuit 274 of junction box 1194 can track the number of times contactor 1212 opens the light junction and, when the life limit (for example, 100,000 cycles in certain modalities) of the contactor 1212 approaches, the user (or, perhaps more commonly, the instructor) may be alerted (for example, through a visual display associated with the welding system 10 and / or the junction box 1194 ).

In addition, in certain embodiments, junction box 1194 may include a connector 1218 configured to connect to a data cable 1220 configured to connect to the 1074 real rod welding electrode holder such that

212 Data from the welding electrode holder t ^^^^^ will be communicated back through junction box 1194 to the welding system 10. It will be appreciated that, in certain modes, control signals can also be communicated from the system 10 to the 1074 real rod welding electrode holder via data cable 1220. Similarly, in certain embodiments, junction box 1194 may include a connector 1222 configured to contact a data cable 1234 configured to connect to a carrier 1070 such that data from carrier 1070 can be communicated back through the junction box 1194 to the welding system 10. It will be appreciated that, in certain embodiments, control signals may also be communicated from welding system 10 to support 1070 via data cable 1224.

It should be noted that, in certain modalities, a simulation TIG welding torch can be connected to the welding system 10 through a separate TIG junction box 1226 and is connected to junction box 1194 and then has specific circuits configured to control the flow of welding energy and data to and from the simulation or real TIG welding torch. To that end, in such embodiments, the junction box 1194 may include a connector 1228 to connect to the TIG junction box 1226.

In addition, in certain embodiments, junction box 1194 may include a connector 1230 configured to connect to a DC power source 1232, such that DC power can be provided to junction box 1194 to provide power for 1234 control (as well as other circuits) of the 1194 junction box. It will be appreciated that, in certain embodiments, power source 1232 may instead be an AC power source, and junction box 1194 may include AC to DC conversion circuits configured to convert AC power

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IMPI

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ions

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DC power to the 1234 control circuit (and other circuitfey '^ T ^^ ji

1194. In certain modalities, the control circuit 1234 of the connection line 1194 may include, among other things, one or more processors 1236, one or more of other memory devices 1238, and one or more memory devices 1240. In other modalities , control circuit 1234 may not include processors 1236, memory devices 1238, and / or storage devices 1240. Processors 1236 can be used to execute software algorithms such as those described herein. Furthermore, processors 1236 may be similar to processors 20 described above. Also, memory devices 1238 can be similar to memory devices 22, and storage devices 1240 can be similar to storage devices 24. It will be appreciated that, in certain embodiments, the control circuit 1234 of the junction box 1194 can operate in comparison to the welding software 244 of the welding system 10, for example, sharing some information processing.

It will be appreciated that the junction box 1234 control circuits

1194 they may obviate the need for processing circuits arranged in some of the simulation and actual welding tools 14 (eg, the 1070, 1074 rod welding electrode holders illustrated in Figure 84). For example, in certain embodiments, the control circuit 1234 can be configured to control all, or at least most, of the local operating characteristics of the 1070, 1074 rod welding electrode holders described herein without the need for Processing circuits arranged in the 1070, 1074 rod welding electrode holders. For example, control functions to control rod electrode support assemblies 1078,1080 (see, eg, Figures 64A, 64B, 65A, 65B, and 67), control functions to control arc characteristic

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Simulated IMPL, control functions to interact with, 1120 (see, eg, Figures 69A and Figure 69B), control functions to control status indicators 1136 (see, eg, Figures 72A and 72B), graphs Addressing 1144 (see, for example, Figures 77A, 77B, and 77C) and graphic range indicators 1166 (see, for example, Figure 78, and so on, can be performed by control box 1234 circuitry 1194 connections, Thus obviating the need for processing circuits in the 1070, 1074 rod welding electrode holders to carry out these control functions. Furthermore, in certain embodiments, junction box 1194 may include one or more status indicators 1241 (eg, light emitting diodes, in certain embodiments) arranged in an outer housing 1243 of junction box 1194. Status indicators 1241 can indicate one or more states related to junction box 1194 operations including, but not limited to, a state of contactor 1212 (eg, closed or open, activating or deactivating welding power, and so on). ), if communications are established with the welding system 10, if the junction box 1194 is on or off, and so on. It should be noted that all other components of the junction box 1194 illustrated in FIG. 84 as being arranged within, or arranged above, the housing 1243 of the junction box 1194 are, in fact, arranged within, or arranged above, from common housing 1243 of junction box 1194.

Furthermore, having a dedicated 1194 junction box for connecting the different power sources, real and simulation soldering tools 14, the soldering system 10, and other related components and devices, also provides some functionality regarding power management and data that might otherwise be difficult, if not impossible, without the 1194 junction box described here.

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For example, in certain modalities, the connection box

<img file="MX359249B_D0171.tif" />

current detection or voltage detection (C / V detection circuits) 1242, which can detect the current or voltage being supplied to the 1074 real rod welding electrode holder through the 1216 welding power cable. An added benefit of having 1242 C / V sensing circuits in junction box 1194 is that junction box 1194 can determine when more current is flowing to the 1074 real rod welding electrode holder, and can notify the welding software 244 that the test has started or ended based on this determination (for example, that a detected current exceeds, or does not exceed, a threshold). In certain embodiments, the 1242 C / V sensing circuits can be configured to sense the voltage, and the sensed voltage can be used to sense the polarity of the welding power (eg, alternating current (AC), negative electrode of direct current (DCEN), positive direct current electrode (DCEP), and so on), and the user can be notified if the detected polarity is correct (i.e. that the 1074 real rod welding electrode holder is properly connected). In other words, the control circuit 1234 (and / or the welding software 244) can generate an indication through the status indicators 1241 of the junction box 1194, through the status indicators 1136 of the weld 14 and / or by any other status indicator (or other output device) described herein, when the detected polarity is not the same as a polarity setting for the weld system 10 (i.e. a desired polarity set by a user through the welding system 10 ok is programmed differently in the welding system 10).

In addition, in certain modes, the control box 1234 of junction box 1194 (in conjunction with the C / V detection circuit 1242) can perform a

216 stick rod algorithm (e.g. stored

<img file="MX359249B_D0172.tif" />

1232 and / or storage devices 1240 of control circuit 1234 and executable by processors 1236 of control circuit 1234) which is configured to determine when a real rod welding electrode 1076 sticks to workpiece 82. An example The logic for such a glued stick algorithm is presented in US Patent No. 6,750,427, which is incorporated herein by reference in its entirety. In addition, in certain embodiments, junction box 1194 control circuit 1234 may include a stick-stick algorithm (for example, stored in memory devices 1238 and / or storage devices 1240 of control circuit 1234 and executables). by processors 136 of control circuit 1234) that is configured to estimate when a simulated rod welding electrode 1072 would have stuck to the simulated workpiece 82 (eg, if it were a real 1076 rod welding electrode and the workpiece 82 were a real part). After sticky rod detection, various responses can be generated including, but not limited to, providing on-screen messages, recording the occurrence of the sticky rod event (for example, on 1238 memory devices and / or storage devices 1240 from control circuit 1234), do not automatically pass the test, determine a state of contactor 1212 (for example, closed or open, activating or deactivating welding power, and so on), and so on. Furthermore, in certain embodiments, upon detection of a stick rod event, control circuit 1234 may cause contactor 1212 to open to disable welding. In certain modes, once detached, the user can press a button (or otherwise activate another input element) to restart the stick rod algorithm. One possible way to determine if a stuck rod element is still occurring may be to send a low voltage signal through

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IMPI of the 1076 real rod welding electrode, and if the signal ceases;

OF INDUSTRIAL MDFIEDAD

<img file="MX359249B_D0173.tif" />

Suppose the 1076 real rod welding electrode is still attached to workpiece 82. In certain embodiments, once a state of contactor 1212 (for example, closed or open, activating or deactivating welding power, and so on) has been determined by control circuit 1234 (and / or welding software 244) , the control circuit 1234 (and / or the welding software 244) can determine a condition of contactor 1212 (for example, if contactor 1212 is working properly, if contactor 1212 has failed, and so on), for example, comparing a driven state of contactor 1212 (eg, as set by welding system 10) versus actual state of contactor 1212.

The 1212 contactor and 1242 junction box 1294 C / V sensing circuit make different additional functionality possible. For example, in certain embodiments, control circuit 1234 (and / or welding software 244) can calibrate the current and / or voltage of the welding power provided to a connected welding tool 14 based at least in part on the current and / or voltage detected by the C / V 1242 detection circuit. For example, in certain modes, control circuit 1234 (and / or welding software 244) may command that the current (or voltage) of the welding power provided to the connected welding tool 14 be lowered (raised) if the current (or voltage) detected by the 1242 C / V sensing circuit is greater (less) than a desired current (or voltage) (eg, a current (or voltage) set by the welding system 10). Also, in certain modalities, the 1242 C / V detection circuit can detect an open circuit voltage (OCV), and the control circuit 1234 (and / or the welding software 244) can generate an indication through the status indicators 1241 from junction box 1194, through status indicators 1136 from the

218

IMPI welding 14, and / or through any other indicator

INDUSTRY t.

<img file="MX359249B_D0174.tif" />

output) described herein, after detection of OCV. For example, in certain embodiments, a user may be instructed to properly connect a soldering tool 14, and so on. In addition, in certain embodiments, if a particular type of welding tool 14 is used (eg, rod, MIG, TIG, and so on) that is not compatible with a selected type of welding process (eg, rod, MIG , TIG, and so on) for the welding system 10 (i.e., a desired type of welding process established by a user through the welding system 10 or otherwise programmed into the welding system 10), the control circuit 1234 (and / or the welding software 244) can generate an indication through the status indicators 1241 of the junction box 1194, by means of the status indicators 1136 of the welding tools 14, and / or through any other status indicator (or other output device) described herein.

In certain embodiments, a state machine can be implemented (eg, in welding software 244) to help control the operation of the 1074 real rod welding electrode holder. Figure 85 illustrates a summary of an example of state machine. In general, the elements to the left of the black bar represent current operating conditions, and the elements to the right of the black bar represent responses to particular combinations of operating conditions. For example, the operating conditions taken into account are if a screen cover is open or closed (for example, 1244), if the test is in a pre-test mode (for example, if the welding process has not yet is being carried out) or an intermediate test mode (for example, if the welding process is currently being carried out (for example, 1246), if the position, orientation and / or movement of the welding electrode holder with real rod 1074 is being

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<img file="MX359249B_D0175.tif" />

with

IMPI currently tracked (eg 1248), if support d ^ glQig ^ gj ^ Nge

INDUSTRIAL actual rod 1074 is near (near / far) from workpiece 82 (eg 1250, and if an arc has been detected (eg 1252). Depending on these operating conditions, the contactor 1212 of the junction box 1194 can be opened or closed (for example, 1254), certain graphics can be visually presented to the user (for example, 1256), the addressing graphics 1144 can be presented Visually and / or the status indicators 1136 can be activated, as described here (eg 1258), certain sound effects can be generated (eg 1260), an alert can be visually presented through the primary visual presenter (eg 1262), and the test can either be started (eg 1264) or terminated (eg 1266).

It should be noted that although this is described herein as a junction box 1194 that includes a variety of components enclosed within a common housing 1243, and that junction box 1194 is separate from the welding system 10, in certain embodiments, the components illustrated in FIG. 84 as part of junction box 1194 can be integrated into the welding system 10 illustrated in FIG. 1 and can be configured to communicate with the control circuit (eg, welding software 244 , among other control circuits) of the welding system 10 and, in this way, These components can collectively form a weld training system interface to interface with the weld system 10.

As used herein, the term "predetermined range" can mean any of the following: a group of numbers limited by a predetermined upper limit and a predetermined lower limit, a group of numbers greater than a predetermined limit, and a group of numbers less than a predetermined limit. Plus

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INSTITUTO MEXICANO still, the interval can include numbers equal to one or more lim¡t§ &amp;^L0J ^^ Smlq ^^^^

Although only certain features of the present invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. Therefore, it should be understood that the appended claims 5 are intended to cover all such modifications and changes that are within the true spirit of the invention.

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