CN104221069A - Virtual welding system - Google Patents

Abstract

This written description uses examples to disclose the invention, including the best mode, and also to enable one of ordinary skill in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Description

Virtual welding system

the cross reference of related application: the application is the u.s. patent application serial number submitted on July 10th, 2009 is No.12/501, the part continuation application of 257.

background

Technical field

The disclosure relates to virtual reality emulation, and more specifically, relates to the system and method for providing arc welding training under the reality environment or augmented reality environment of emulation.

technical discussion

How study carries out guidance that arc-welding needs many hours traditionally, training and exercise.Existence can carry out the many dissimilar arc-welding that learns and arc welding process.Student usually uses real welding system and on real metal works, performs welding operation to learn welding.The training of such real world can take rare welding resource and exhaust limited welding material.But, recently use the training idea of welding simulation to become more popular.Some welding simulation are via PC and/or via internet canbe used on line., current known welding simulation is often limited to its training emphasis (focus).

Such as, emphasis is put in only for the training of " muscle memory " by some welding simulation, and this only trains welding student how to grip and positioning welding instrument.Other welding simulation are also only with limited and usually for emphasis to be put in the visual effect and audio frequency effect that welding technology is shown by unpractiaca mode, and it is the expectation feedback that the height of real world welding characterizes that described mode does not provide to student.The feedback of this reality guides student to carry out necessary adjustment with the welding completed just.By checking electric arc and/or molten bath (puddle) instead of learning welding by means of only muscle memory.

By such approach and the embodiment of the present invention as set forth in all the other contents of the application with reference to accompanying drawing being compared, those skilled in the art are by other restriction and shortcomings of approach that is clear routine, traditional and that proposed.

Summary of the invention

In one aspect of the invention, virtual welding system comprise based on programmable processor subsystem and be operably connected to the spatial pursuit device of the subsystem based on programmable processor.Simulation soldering appliance is used, and described simulation soldering appliance spatially can be followed the trail of by spatial pursuit device.Simulation soldering appliance comprises one or more adapter, and wherein each adapter emulates the real world outward appearance of a specific weld type (weld type).Pedestal is each by what be coupled in one or more adapter removedly.

In another aspect of the present invention, simulate soldering appliance to be used in virtual welding system.One or more adapter is used, and wherein each adapter emulates the physical features of a specific weld type.Pedestal is each by what be coupled in one or more adapter removedly, and pedestal identification simulation soldering appliance is relative to the real-time spatial position of reference position.

Further, a kind of method is adopted to use simulation soldering appliance in virtual welding system.First adapter is removably connectable to pedestal, and the first adapter is associated with the first welds types.First adapter is removed from pedestal, and wherein the second adapter is removably connectable to pedestal, and the second adapter is associated with the second welds types.The use of the easy-to-use portable virtual welding system of multiple type of adapter and common base, described portable virtual welding system can be used in (mobile) position of any movement substantially.

This brief description is provided to the selection introducing design in simplified form, and described design is further described herein.This brief description is not intended to the key feature or the essential feature that limit theme required for protection, is also not intended to the scope being used to limit theme required for protection.In addition, theme required for protection is not limited to solve the implementation of any or all shortcoming be documented in any part of the present disclosure.Further embodiment of the present invention, aspect and advantage are educible from specification, drawings and the claims.

brief Description Of Drawings

With reference to accompanying drawing, wherein as in book described below in greater detail, specific embodiment and the further advantage of the present invention are illustrated, in the accompanying drawings:

Fig. 1 is the block scheme of the virtual welding system comprising the interchangeable simulation soldering appliance with pedestal, and it is each that described pedestal can be connected in multiple adapter;

Fig. 2 is an implementation of system set forth in fig. 1;

Fig. 3 is the exemplary lateral plane figure of the GMAW adapter being coupled to pedestal removedly;

Fig. 4 is the exemplary perspective view of the manual welding tool adapter being coupled to pedestal removedly;

Fig. 5 is the exemplary perspective view of combustible gas (oxyfuel) adapter being coupled to pedestal removedly;

Fig. 6 is the skeleton view of the pedestal that can be connected with Fig. 3, Fig. 4 and adapter set forth in fig. 5;

Fig. 7 is the broken-open perspective view of the pedestal described in Fig. 6;

Fig. 8 A is the skeleton view of the simulation soldering appliance assembled comprising pedestal and manual welding tool adapter;

Fig. 8 B is the skeleton view of the simulation soldering appliance of the decomposition comprising pedestal and manual welding tool adapter;

Fig. 9 is the skeleton view being used to welded specimen and magnet to remain on the support in known locus;

Figure 10 is the skeleton view illustrating the support with interchangeable, compact position, welded specimen and magnet being remained on the Fig. 9 in known locus;

Figure 11 is the component view illustrating the suite comprising the parts transporting and operate mobile virtual welding system;

Figure 12 is the front elevational view illustrating the user interface communicated with virtual welding system;

Figure 13 is the front elevational view illustrating the interchangeable user interface communicated with virtual welding system;

Figure 14 is the skeleton view of the helmet that can be used in virtual welding system by user;

Figure 15 is mounted in the backward skeleton view of the FMDD in the welding helmet, and the described welding helmet is used in virtual welding system;

Figure 16 is the process flow diagram of the exemplary of the subsystem block scheme of the subsystem based on programmable processor (PPS) shown in Fig. 1;

Figure 17 is the process flow diagram of the exemplary of the block scheme of the Graphics Processing Unit of the PPS of Figure 16;

Figure 18 is the process flow diagram of the exemplary of the functional-block diagram of the system of Fig. 1;

Figure 19 is the process flow diagram of the embodiment of the training method of the Virtual Reality Training System using Fig. 1;

Figure 20 is the front elevation that welding pixel (welding pixel) (weldering unit (wexel)) dislocation figure (displacement map) is shown according to embodiment of the present invention;

Figure 21 is the sample space (coupon space) of the smooth welded specimen emulated in the system of fig. 1 and the skeleton view in corresponding x-y weld seam space (weld space);

Figure 22 is the turning of turning (T connector) welded specimen emulated in the system of fig. 1 and the skeleton view in corresponding T-S weld seam space;

Figure 23 is the pipe sample of the pipe welded specimen emulated in the system of fig. 1 and the skeleton view in corresponding T-S weld seam space; And

Figure 24 A-24C is the front elevation that the concept in molten bath is put in the two-track of the system illustrating Fig. 1.

describe in detail

Referring now to accompanying drawing, embodiments more of the present invention or implementation are described hereinafter by reference to the accompanying drawings, wherein similar reference number in the whole text in be used to refer to similar element.The present embodiment refers to virtual welding system, and described virtual welding system adopts simulation soldering appliance, and described simulation soldering appliance has pedestal to receive multiple adapter, and wherein each adapter emulates different welds types.Adapter can have common size, to allow removable be coupled seamless with pedestal when being supposed to.Although be illustrated hereinafter under the background of various example virtual welding system and describe, the invention is not restricted to the illustrated embodiment illustrated.

More specifically, the embodiment of this theme relates to virtual reality welding system, described virtual reality welding system comprises based on the subsystem of programmable processor, the spatial pursuit device being operably connected to the subsystem based on programmable processor, at least one the simulation soldering appliance that spatially can be followed the trail of by spatial pursuit device, and is operably connected at least one display device of the subsystem based on programmable processor.In order to provide additional dirigibility, simulation soldering appliance comprises pedestal and multiple adapter, and wherein each adapter is used to emulate different welds types.Such as, the first adapter can emulate GMAW welding, and the second adapter can emulate SMAW welding, and the 3rd adapter can emulate combustible gas welding etc.Alternatively or in addition, instrument can be used to simulation slicing device, such as combustible gas or other cutting torches.Adapter all can have standardized size to provide portable use, and compact support is used to welded specimen to keep in space, to use together with simulation soldering appliance.By this way, system can emulate multiple welds types in virtual reality space, and wherein welding pool has the real-time molten metal flow corresponding to often kind of welds types and heat dissipation characteristics.

When displayed, the real-time molten metal flow in the molten bath of described emulation and heat dissipation characteristics provide real-time visual feedback to the user of described simulation soldering appliance, allow described user to regulate in real time in response to described real-time visual feedback or keep welding skill and technique.Shown molten bath is the sign that will be formed on the molten bath in real world based on the welding skill and technique of user and selected welding technology and parameter.By viewing molten bath (such as shape, color, slag, size), user can revise its skill and technique to carry out good welding and to determine the welds types that is done.The shape in described molten bath is in response to the motion of simulating soldering appliance.As used herein, term " in real time " means with will the identical mode of perception and experience under the welding sight of real world with user, perception and experience in time under the environment of emulation.In addition, described molten bath, in response to the effect of physical environment comprising gravity, allows user to practise realistically welding with various position (comprising level, vertical and overhead welding (overhead welding)) and various pipe soldering angle.

Referring now to accompanying drawing, the content shown in it is the object in order to illustrate exemplary, and Fig. 1 is the system block diagram of system 100, and system 100 provides arc welding training under real-time virtual actual environment.Virtual welding system 100 comprises the subsystem (PPS) 110 based on programmable processor.Virtual welding system 100 comprises the spatial pursuit device (ST) 120 being operably connected to PPS 110 further.Virtual welding system 100 also comprises the physical weld user interface (WUI) 130 being operably connected to PPS 110, and is operably connected to the display device (FMDD) 140 being placed on face of PPS 110 and ST 120.Virtual welding system 100 also comprises the observer's display device (ODD) 150 being operably connected to PPS 110.Virtual welding system 100 also comprises at least one simulation soldering appliance (MWT) 160 being operably connected to ST 120 and PPS 110.Virtual welding system 100 also comprises support 170, and can be attached at least one welded specimen (WC) 180 of support 170.MWT 160 can comprise the pedestal (not shown) being coupled to one or more adapter (not shown), to emulate multiple different welds types.

Fig. 2 illustrates system 200, and described system 200 illustrates a kind of implementation of system set forth in fig. 1.FMDD 140 is utilized for the virtual environment that user shows emulation and visually experiences welding.In order to provide accurately presenting (rendering) of this simulated environment, FMDD 140 communicates with PPS 110 and receives and send the data of the locus about the FMDD 140 in system 200.Known wired and/or wireless technology (comprising bluetooth, wireless ethernet etc.) can be utilized to carry out convenient communication.For obtaining spatial position data, one or more sensor 142 is arranged in FMDD 140 and/or contiguous FMDD 140.In turn, sensor 142 assesses locus relative to the specific benchmark (such as magnet 172) in system 200.Magnet 172 can be positioned at known reference point and be set to the distance 178 predetermined relative to of welded specimen 180.This predetermined distance 178 can keep by utilizing shape factor, template or the pre-configured structure be associated with support 170.Therefore, sensor 142 can provide FMDD 140 relative to the position data of the welded specimen 180 in support 170 relative to the movement of magnet 172 inherently.Sensor 142 can wirelessly communicate to identify the position relative to magnet, utilize known communication protocol upgrade in real time FMDD 140 with the keeping strokes of user.

System 200 also comprises MWT 160, and described MWT 160 comprises the adapter 162 being coupled to pedestal 166.Will be appreciated that adapter 162 is only of representing in multiple adapter, each adapter emulates specific welds types.Adapter 162 is coupled to pedestal 166 removedly, to allow an adapter as another alternative removing and replace.Removable coupling can utilize lug, recess, slide block, button etc., and presses, reverse or otherwise mechanically change adapter 162 and/or pedestal 166 to allow user.In order to accurately emulate specific welds types, each adapter 162 is sized the equality unit characterizing real world, and described equality unit performs actual welding operation by being used to.Once specific adapter is coupled to pedestal, user can the type of in use input adapter, loads to allow PPS and performs suitable instruction set associated with it.By this way, corresponding to each type of adapter accurately presenting is displayed on FMDD 140.

One or more sensor 168 can be arranged in pedestal 166 or contiguous pedestal 166.The same with FMDD 140, sensor 168 can determine the locus about the magnet 172 on support 170 wirelessly.By this way, adapter 162 in a joint manner and pedestal 166 have known position and space inherently relative to magnet 172, because adapter 162 and the size both pedestal 166 are predetermined.Be properly calibrated in order to ensure system 200 and receive each adapter 162, user can (such as via WUI 130) be connected with PPS 110 interface, to indicate a specific adapter in use current.Once form such instruction, PPS 110 can from storer 112 retrieval table, and described storer 112 comprises rule set, correctly to present the environment of emulation when user is experienced by FMDD 140.

In embodiments, PPS 110 is the computing machines that can operate to perform disclosed architecture.In order to provide additional background to various aspect of the present invention, discussion below intention provides succinct, the general description of applicable computing environment, in the computing environment that this is applicable to of the present invention various in can be implemented.PPS 110 can adopt the executable instruction of computing machine, and this instruction can run on one or more platform computing machine, and this instruction realizes in conjunction with other program modules and/or as the combination of hardware and software.Usually, program module comprises routine, program, parts and data structure etc., and described program module performs specific task or realizes specific abstract data type.Such as, such program and the executable instruction of computing machine can use various apparatus control example to process via robot.

And, those skilled in the art will recognize that inventive method can be implemented by other computer system configurations, comprise uniprocessor or multiprocessor computer system, microcomputer, mainframe computer and personal computer, hand-held computing device, based on microprocessor or programmable consumption electronic products etc., each device that can be operatively coupled to one or more and be associated in them.The aspect illustrated of the present invention also can be implemented in distributed computing environment, and in this distributed computing environment, specific task is performed by the remote processing device be linked by communication network.In a distributed computing environment, program module can be positioned at local and remote both memorizer memory devices.

PPS 110 can utilize exemplary environments to realize the various aspects of the invention comprising computing machine, wherein in order to this computing machine communication objective comprises processor 114, storer 112 and system bus.System unit (including but not limited to storer 112) is coupled to processor 114 by system bus.Processor 114 can be any various commercially available processor.Dual micro processor and other multiprocessor architectures also can be used as processor 114.

System bus can be any one in some types of bus structure, comprises the memory bus or memory controller, peripheral bus and local bus that use the commercially available bus architecture of any kind.Storer 112 can comprise ROM (read-only memory) (ROM) and random access memory (RAM).Basic input/output (BIOS) is stored in ROM, and this basic input/output (BIOS) comprises basic routine, and this basic routine contributes to transmission of information between the element in PPS 110, such as unloading phase.

PPS 110 can also comprise hard disk drive, disc driver and CD drive, this disc driver such as reads or write moveable magnetic disc from moveable magnetic disc, and this CD drive is such as used for reading CO-ROM disk or reading from other light media or write other light media.PPS 110 can comprise at least certain form of computer-readable medium.Computer-readable medium can be can by any obtainable medium of computer access.By mode instead of the restriction of embodiment, computer-readable medium can comprise computer storage media and communication media.Computer storage media comprises in any method or technology realize for information (such as, computer-readable instruction, data structure, program module or other data) store volatile with non-volatile, moveable and non-moveable medium.Computer storage media comprises, but be not limited to, RAM, ROM, EEPROM, flash memory or other memory technologies, CD-ROM, digital versatile disc (DVD) or other magnetic storages, or can be used to store information needed and the other media can accessed by PPS 110.

Communication media typically comprises computer-readable instruction, data structure, program module or other data in modulated data-signal (such as carrier wave or other transmission mechanisms), and comprises any information delivery media.Term " modulated data-signal " is meant to have one or more the signal in its characteristic arranging in order to coded message in the signal by this way or change.By mode instead of the restriction of embodiment, communication media comprises wire medium such as wired network or direct wired connection, and (acoustic) of wireless medium such as sound, RF, infrared medium and other wireless mediums.Combination above any also should be included in the scope of computer-readable medium.

A large amount of program module can be stored in driver and RAM, comprises operating system, one or more application program, other program modules and routine data.Can be any a large amount of commercially available operating system in the operating system of PPS 110.

In addition, user will be able to be ordered by keyboard and indicator device (such as mouse) and information input computing machine.Other input medias can comprise microphone, IR Long-distance Control, trace ball, pen-based input device, control lever, cribbage-board, digitizing tablet, satellite disk and scanner etc.These or other input media is connected to processor by the serial port interface being coupled to system bus usually, but can be connected by other interfaces, such as parallel port, game port, USB (universal serial bus) (" USB "), IR interface and/or various wireless technology.The other types of monitor (not shown) or display device also can be connected to system bus via interface (such as video adapter).Visual output also can be completed by long-range display procotol (such as RDP, VNC and X-window system etc.).Except visual output, computing machine typically comprises other peripheral output devices, such as loudspeaker and printer etc.

Display (such as ODD 150 and WUI 130) can make for presenting electronically from the data that processor receives together with PPS 110.Such as, display can be the monitor of LCD, plasma and CRT etc., and this monitor presents data electronically.Alternatively or in addition, display can present the data of reception with hard Format Painter (such as printer, facsimile recorder and plotting apparatus etc.).Display can present data with any color and can receive data via any wireless or hardwire protocol and/or standard from PPS 110.In embodiments, WUI 130 is touch-screens, and described touch-screen allows user to be connected with PPS 110 interface, such as, check the welding data from emulation before one or more.User can also handle by various data example the information identified about particular analysis (such as welding quality), and wherein such data pin is evaluated to one or more benchmark, compares for storage or other.

Computing machine can operate in the network environment of the logic and/or physical connection that use one or more remote computer (such as remote computer (one or more)).Remote computer (one or more) can be workstation, server computer, router, personal computer, microprocessor, equity (peer) device or common network node based on converter tools, and it is many or all typically to comprise in the parts described relative to computing machine.The logic described connects and comprises LAN (Local Area Network) (LAN) and wide area network (WAN).Such networked environment is common in the computer network of office, enterprise-wide, intranet and internet.

When being used in lan network environment, computing machine is connected to local network by network interface or adapter.When being used in WAN network environment, computing machine typically comprises modulator-demodular unit, or is connected to the communication server on LAN, or has for other devices in the upper foundation communication of WAN (such as internet).In a network environment, the program module described about computing machine or part wherein can be stored in remote memory storage device.Will be appreciated that networking described herein connects to be exemplary and can be used at other devices that intercomputer sets up communication linkage.

Fig. 3-Fig. 5 illustrates the nonrestrictive exemplary of adapter 162, and wherein Fig. 3 illustrates the adapter 162 as GMAW welding gun 300; Fig. 4 illustrates the adapter 162 as manual welding instrument 400; And Fig. 5 illustrates the adapter 162 as flammable gas torch 500.Although be described to that there are multiple different parts at this paper adapter, will be appreciated that the single of adapter and multipart embodiment are considered within the scope of the invention.First forward Fig. 3 to, GMAW welding gun 300 comprises mouth 310, and described mouth 310 is connected to interface (interface) 318 via pipe 312.Welding gun 300 can have with as in real-world application the substantially the same weight of the GMAW welding gun that uses and size.The size of each parts in welding gun 300 can be known value, and described size can be used to calibrate welding gun when considering welded specimen 180 and magnet 172.Interface 318 can comprise one or more mechanical features to allow adapter 300 to the removable coupling of pedestal.

Fig. 4 illustrates the manual welding instrument 400 for plate welding and pipe welding, and comprises the stick electrode 410 of clamper 422 and emulation.In embodiments, emulation stick electrode 410 can comprise haptic type (tactilely) resistance end, with emulate occur in such as real world pipe welding in root run (root pass) welding process during or welding plate time resistance feedback.If user too deviates from the stick electrode 162 of root of weld movable simulation, then user can feel or perceive lower resistance, thus obtain the feedback for regulating or keep current welding technology.Interface 418 allows manual welding instrument 400 to the removable coupling of pedestal.

Fig. 5 illustrates the combustible gas adapter 500 comprising mouth 510 and interface 518, and described interface 518 allows combustible gas adapter 500 to the removable coupling of pedestal.In this embodiment, interface 518 comprises neck ring 522, and described neck ring 522 can be fixed around the diameter of pedestal.Button 520 can comprise teat or other features are mechanically connected with the complementary characteristic (such as recess) on pedestal.By this way, adapter 500 whether can be pressed according to button or otherwise handle and " lock " to pedestal.In other embodiments, combustible gas adapter can be used to characterize cutting torch, and described cutting torch is used to cutting metal object.In this embodiment, cutting torch to be displayed in virtual welding system as it operates in the application of real world.Such as, PPS 110 can load and run time version, described code representative cutting torch application, instead of welding torch.

According to a further embodiment of the present invention, other simulation soldering appliances are also possible, and comprise the MWT such as emulating hand-held semi-automatic gun, described MWT has the welding wire welding rod be sent to by described rifle.In addition, according to other particular of the present invention, even if instrument is not used in and in fact creates real electric arc in virtual welding system 100, real soldering appliance can be used as the actual sensation that MWT 160 emulates the described instrument in user's hand better.Moreover, the milling tools of emulation (grinding tool) can be provided to be used for using under the polishing pattern of the emulation of virtual welding system 100.Similarly, the cutting tool of emulation can be provided, be used for using under the cut mode of the emulation of virtual welding system 100.In addition, gas tungsten arc welding (GTAW) welding torch or the filling material material of emulation can be provided, be used for using in virtual welding system 100.

Fig. 6 illustrates pedestal 600, and described pedestal 600 is used to interface and connects one or more adapter, such as GMAW welding gun 300, manual welding instrument 400 and combustible gas adapter 500.Pedestal 600 comprises body 620, and described body 620 can hold one or more electronic unit, such as sensor 168 described herein.In embodiments, body 620 is grouped into by two half-unit, and described two half-unit is divided and such as, kept together via securing member 640 (e.g., screw, bolt, rivet etc.).Rigid line cable 630 extends so that the communicating of niche seat 600 and PPS 110 from body 620.

The recess 616 that interface 610 is included in the abutment (landing) 614 on the opposite side of interface 610 and is arranged in described abutment.Abutment and recess combination can be used as the removable interlocking structure of complementary part in the interface of exemplary adapter 300,400,500.But, substantially any mechanical interface be considered come convenient adapter effectively removing and replacing to pedestal 600.It is at effective bond pattern that the button 618 be arranged in teat 636 can be used to refer to the user when button 618 is pressed.At least with reference to adapter 400, complementary shape factor can be included in adapter the cover coordinated on as button 618, and wherein user can press the button via the shape factor feature on adapter.For this purpose, adapter shape factor the flip flop equipment in the simulating realistic world or similar device can give user the look and feel of the real world for welding operation.

Fig. 7 is the broken-open perspective view of pedestal 600, to represent the sensor 652 be arranged in pedestal 600.Sensor 652 communicates via cable 654 parts different from one or more (such as PPS 110), and to be arranged in pedestal 600 with preposition and to be maintained at appropriate location via securing member 658.Impeller 672 runs through body 620 for pedestal 600 provides support structure.In embodiments, sensor 652 utilizes known non-contact technology, such as capacitive transducer, piezoelectric sensor, eddy current sensor, inductance sensor, sonac, hall effect sensor and/or infrared proximity sensor technology.Such technology can be used to other sensors described herein, comprises the sensor 142 and 168 used in the helmet 146 and pedestal 166 respectively.Fig. 8 illustrates simulation soldering appliance 800, and wherein adapter 400 is coupled to pedestal 600 removedly, is used for using in virtual welding system 100.

Fig. 9 illustrates support 700, and described support 700 is used to the known location be arranged on by welded specimen 758 in space relative to magnet 710.Support 700 comprises the arm 714 and base 724 that are coupled via column 722.In embodiments, column 722 is removably coupled base 724, resolves into single parts for packaging and transport to allow support 700.In addition, base 724 and column 722 can have one or more architectural feature (such as impeller), and described architectural feature is that such parts increase support structure keeps relatively low weight simultaneously.Plunger 732 can be opened from arm 714, to allow sample removing and replacing on support 700 on repeatably locus.

The size of arm 714 and welded specimen 758 are all known relative to the position of the magnet 710 be arranged in abutment 738, the simulation soldering appliance of contiguous welded specimen 758 will have known and repeatably export, thus provides suitable real-time virtual welding surroundings for user.Pin 762,764 can remove from support 700 and allow arm 714 as described in Figure 10 around pin 764 pivotable.In this embodiment, pin 762, from hole 766, removes in 768, thus allows arm 714 to rotate to the second place around pin 764.By this way, user can know from experience and each nuance be associated in a large amount of plane (such as level with vertical) emulation welding.It should be noted that the design of support 700 guarantees that magnet 710 is maintained at any one position in two positions relative to the locus of welded specimen 758, the establishment emulated for real-time welding surroundings to provide accurate repeatably result and display.

Figure 11 illustrates Portable welding suite, and described Portable welding suite can be transported from a position easily to another position.Suite can be fabricated in any position being substantially close to power supply, and described power supply can comprise battery, A/C or other power supplys.Container 810 can be formed welding robot housing substantially, and wherein inside comprises multiple shell, platform and other storage areas to hold WUI 130, support 700, simulation soldering appliance 800 and the helmet 900.Container may further include wheel, with effective transport of convenient container 810.

Figure 12 illustrates exemplary user interface 830, and described user interface 830 shows the module that multiple and typical welding system is associated.Interface 830 comprises selector switch 832, to identify the type of the adapter for the welding system emulated.Temperature measuring equipment 836, current measuring device 838 and voltage measuring apparatus 842 can for user provide Real-time Feedback during welding operation.Similarly, 854 and 856 display additional informations and allow user to input to change described information.Figure 13 illustrates the interchangeable user interface 860 at hardware welding system interface, the simulating realistic world.In embodiments, user can use Touch Screen or other peripheral input methods described herein to provide input for display 860.

Figure 14 and Figure 15 illustrates the helmet 900 worn by user when operating virtual welding system.Figure 14 illustrates the forward perspective view of the helmet 900, the described helmet 900 can be in real-world application and, as described above, be adapted as the actual welding helmet comprising FMDD.By this way, user can wear the welding helmet, as they under the sight of real world, wherein virtual environment is shown to user in real time via FMDD 140.Figure 15 illustrates the exemplary of the FMDD 140 being integrated into the welding helmet 900.FMDD 140 is via non-wireless means or be operably connected to PPS 110 and ST 120 wirelessly.According to various embodiments of the present invention, the sensor 142 of ST 120 can be attached to FMD 140 or be attached to welding the helmet 900, allow FMDD 140 and/or welding the helmet 900 relative to the 3d space framework created by ST 120 with reference to tracked.

Figure 16 illustrates the exemplary of the subsystem block scheme of the subsystem based on programmable processor (PPS) 110 of the virtual welding system 100 of Fig. 1.According to embodiment of the present invention, PPS 110 comprises CPU (central processing unit) (CPU) 111 and one or more Graphics Processing Unit (GPU) 115.In one embodiment, a GPU 115 is used to provide monoscopic vision on FMDD 140.In another embodiment, two GPU115 are programmed and provide stereoscopic vision on FMDD 140.In either case, according to embodiment of the present invention, user checks the virtual reality emulation in the molten bath (being again weldpool (weld pool)) with real-time molten metal flow and heat absorption and heat dissipation characteristics.

Figure 17 illustrates the exemplary of the block scheme of the Graphics Processing Unit (GPU) 115 of the PPS 110 of Figure 10.The realization of each GPU 115 supported data parallel algorithm.According to embodiment of the present invention, each GPU 115 provides two video frequency output 118 and 119 that can provide two virtual reality views.Two in video frequency output can be transferred into FMDD 140, provide the visual field of welding person, and the 3rd video frequency output such as can be routed to ODD 150, provide the visual field of welding person or some other the visual field.The 4th remaining video frequency output such as can be routed to projector.Two GPU 115 perform identical weld physics and calculate, but can present reality environment from the identical or different visual field.GPU 115 comprises unified calculation equipment framework (CUDA) 116 and tinter 117.CUDA 116 is software developer's computing engines by the spendable GPU 115 of industry standard programming language.CUDA 116 comprises parallel core and is used to run the physical model of molten bath described herein emulation.CPU 111 provides the data of welding input in real time to the CUDA 116 on GPU 115.Tinter 117 is responsible for drawing and applying whole emulated interfaces.Welding bead and molten bath picture are driven by the state of the weldering unit dislocation figure described after a while herein.According to embodiment of the present invention, physical model runs with the speed of 30 times about per second and upgrades.

Figure 18 illustrates the exemplary of the functional-block diagram of the virtual welding system 100 of Fig. 1.The various functional block major parts of virtual welding system 100 as shown in figure 12 realize via the software instruction operated on PPS 110 and module.The various functional blocks of virtual welding system 100 comprise physical interface 1201, welding torch and fixture model 1202, environmental model 1203, sound-content function 1204, welding sound 1205, support/tables' model 1206, inside structure function 1207, calibration function 1208, welded specimen model 1210, weld physics 1211, internal physical adjustment means (adjusting gear (tweaker)) 1212, graphical user interface function 1213, drawing function 1214, student's function of reporting 1215, present device 1216, welding bead presents 1217, 3D texture 1218, visual cues function 1219, scoring and tolerance function 1220, tolerance editing machine 1221 and special-effect 1222.

Inside structure function 1207 provides the more high-grade software computing of the process of virtual welding system 100, comprises such as load document, maintenance information, management thread, enables physical model and trigger menu.According to embodiment of the present invention, inside structure function 1207 operates on CPU 111.During implementation-specific for PPS 110, input comprises arc position, welding torch position, FMDD or helmet position, welding gun enables/state (Yes/No) that produces of closed condition and contact.

Graphical user interface function 1213 allows user to use the operating rod 132 at physics user interface 130 to arrange welding sight by ODD 150.According to embodiment of the present invention; the setting of welding sight comprises selection language; input user name; select practice plate (i.e. welded specimen); select welding technology (such as FCAW, GMAW, SMAW) and the axis injection be associated, pulse or short arc method; select gas type and flow rate, select the type (such as 6010 or 7018) of stick electrode, and select the type (such as self-shield, gas shield) of flux-cored wires.The setting of welding sight also comprises tables' height of selection support 170, arm height, arm position and arm and rotates.Arranging of sight of welding comprises Environment (background environment in such as virtual reality space) further, arranges feed rate of welding wire, arranges voltage level, arrange amperage, selects polarity and enables or close particular visual prompting.

During the welding sight of emulation, drawing function 1214 is collected user and is showed parameter and described user is showed parameter and be provided to graphical user interface function 1213, carries out in a graphic format showing (such as on ODD 150).From the tracked information feed-in drawing function 1214 of ST 120.Drawing function 1214 comprises simple analysis module (SAM) and shake (whip)/swing (weave) analysis module (WWAM).SAM is by comparing welding parameter and being stored in the data analysis user welding parameter in welding bead form, and described user's welding parameter comprises welding travel angle, gait of march, soldering angle, position and end to workpiece gap distance.WWAM analyzes user's jitter parameter, comprises coin shape body interval, shaky time and molten bath time.WWAM also analyzes user and swings parameter, comprises swing width, swings interval and swing timing.Former input data (such as position and directional data) are interpreted as functionally spendable data, for drawing by SAM and WWAM.For each parameter analyzed by SAM and WWAM, tolerance window limits (parameter limits) around using tolerance editing machine 1221 to input the best of welding bead form or ideal set value limits by parameter, and scoring and tolerance function 1220 are performed.

Tolerance editing machine 1221 comprises welding tolerance meter (weldometer) estimating materials'use, electrically use and weld interval.In addition, when special parameter out-of-size, may occur to weld discontinuous (i.e. weld defects).The incoherent state of any welding is processed by drawing function 1214 and presents in a graphic format via graphical user interface function 1213.Such welding is discontinuous comprises unsuitable weld seam size, not good welding bead is arranged, recessed welding bead, too evagination, undercut, porous, lack of penetration, slag inclusion (slag entrapment), excessively fill, burn and excessively splash.According to embodiment of the present invention, incoherent grade or amount depend on the degree of the set point that specific user's parameter drift-out is best or desirable.

Different parameter restrictions can be limited in advance for different classes of user's (such as welding beginner, welding expert and the people in transaction exhibition).Scoring and tolerance function 1220 are according to the close degree for the best (ideal) value of special parameter of user and provide digit score according to the grade of the discontinuous or defect appeared in welding.Described optimum value obtains from real world data.From scoring and tolerance function 1220 and can being used by student's function of reporting 1215 from the information of drawing function 1214, create performance report for instructing personnel and/or student.

The result of virtual welding activity can be analyzed and show to virtual welding system 100.By analyzing described result, mean that virtual welding system 100 can be determined when to be during this welding stroke and to be where along solder joint, user departs from the acceptable limited range of welding technology.Scoring can owing to the performance of user.In one embodiment, scoring can be in multiple margin tolerance, simulate the function that depart from of soldering appliance 160 in position, orientation and speed, and this can extend to critical or unacceptable welding activity from desirable welding stroke.According to the selection for marking to the performance of user, any gradient of multiple scope all can be included in virtual welding system 100.Scoring can show with the mode of numeral or alphanumeric mode.In addition, the performance of user can graphically show, in time and/or along the position of solder joint illustrating how described simulation soldering appliance closely crosses solder joint.Such as travel angle, machining angle, speed and the parameter from the distance of solder joint are the examples of content that can be measured, but all can be analyzed for any parameter of object of scoring.The margin tolerance of described parameter takes from the welding data of real world, thus provides the accurate feedback that will how to show in real world about user.In another embodiment, the analysis of corresponding with the performance of user defect also can be included and be presented on ODD 150.In this embodiment, can describe to illustrate that cause by measuring the various parameter monitored between virtual welding active stage discontinuous is the figure of which kind of type.Although " occlusion (occlusions) " may not be visual on ODD 150, due to the performance of user, defect still may occur, and the performance results of user still may correspondingly be shown (namely graphical).

Visual cues function 1219, by showing color and the cue mark of covering on FMDD 140 and/or ODD 150, provides feedback immediately to user.Visual cues is provided for each in welding parameter 151, welding parameter 151 comprises position, end to workpiece gap distance, soldering angle, travel angle, gait of march and arc length (such as manual welding), and if should be conditioned based on some aspect of the welding skill and technique of the restriction limited in advance or tolerance user, then visually indicate described user.Such as, visual cues can also be provided for shake/swing skill and technique and welding bead " coin shape body " interval.Visual cues can be set up independently or with the combination of any expectation.

Calibration function 1208 provides the ability that the parts in kind in real space (3D reference frame) are mated with the visual part in virtual reality space.By WC being installed on the arm 173 of support 170, and the point (such as being indicated by three scrobiculas on WC) utilizing the calibration pen (stylus) being operably connected to ST 120 to contact WC to limit in advance, often kind of dissimilar welded specimen (WC) is calibrated in the factory.The magnetic field intensity at the some place limited in advance described in ST 120 reads, provides positional information to PPS 110, and PPS 110 uses described positional information to carry out described calibration (conversion namely from real world space to virtual reality space).

The WC of arbitrary particular type can load the arm 714 of support 170 by repetitive mode with identical within very strict tolerance.In one embodiment, the distance on arm 714 between sample 758 and magnet 710 as above in fig. 2 what set forth is known distance 178.Thus, once specific WC type is calibrated, this WC type is without the need to by recalibration (namely the calibration of the WC of particular type is disposable event).The WC of identical type is interchangeable.Calibration guarantee user's institute's perception during welding technology physical feedback coupling in virtual reality space to the content that described user shows, make emulation look truer.Such as, if user is around the end of the turning slip MWT 160 of actual WC 180, described user will see on FMDD 140 that described end slides around the turning of virtual WC, the described end felt just as described user slides around the turning of described reality.According to embodiment of the present invention, MWT 160 is placed on pre-aligned shelf (jig) and goes up and be also calibrated based on known rack location.

According to the interchangeable embodiment of the present invention, provide " intelligence " sample such as on the turning of sample with sensor.ST 120 can follow the trail of the turning of " intelligence " welded specimen, thus virtual welding system 100 knows the position of " intelligence " welded specimen in real world 3d space continuously.According to another replaceable embodiment of the present invention, provide license key " unblock " welded specimen.When specific WC is purchased, provide license key, allow user that described license key is inputted virtual welding system 100, unlock the software be associated with this WC.According to another embodiment of the present invention, the real world CAD based on parts charts, and can provide special non-standard welded specimen.User even before in fact parts are generated in real world, can train welding CAD parts.

Sound-content function 1204 and welding sound 1205 provide the welding sound of particular type, described welding sound according to specific weld parameter whether in tolerance or out-of-size and changing.Sound adjusts according to various welding technology and parameter.Such as, spray in arc welding process at MIG, provide crack sound when user does not make MWT 160 correctly locate, and the sound of neighing is provided when MWT 160 is properly oriented.In short arc welding process, provide stable crack or " fry " sound (frying sound) for suitable welding skill and technique, and can the sound of neighing be provided when there is undercut.These sound imitates (mimic) and corresponds to correctly and the sound of the real world of mis-welds skill and technique.

According to various embodiments of the present invention, high-fidelity sound-content can use various electronics and mechanical hook-up to take from the real world recording of actual welding.According to embodiment of the present invention, the volume of the sound of institute's perception and directivity change relative to the position of the electric arc of the emulation between MWT 160 and WC 180, orientation and distance according to the head (supposing that user is just wearing the FMDD 140 followed the trail of by ST 120) of user.Such as, sound can be provided to user via the earplug speakers in the helmet 900 or via the loudspeaker be configured in control desk 135 or support 170.

There is provided environmental model 1203 to provide the various background scene in virtual reality space (static with motion).Such background environment can comprise, such as indoor welding shop, outdoor runway, garage etc., and can comprise the vehicle of movement, people, bird, cloud and various ambient sound.According to embodiment of the present invention, background environment can be mutual.Such as, user can before starting welding, and (such as safely) welds to guarantee that environment is suitable for need close examination (survey) background area.Welding torch and fixture model 1202 are provided to the various MWT of modeling in virtual reality space 160 (comprise such as rifle, have the bracket etc. of stick electrode).

Sample model 1210 is provided to the various WC 180, WC 180 of modeling in virtual reality space and comprises such as plane plate specimen, T-joint samples, docking-joint samples, groove welding bead sample and tubulose sample (pipe of such as 2 inch diameters and the pipe of 6 inch diameters).Alternatively or additionally, welded specimen model can comprise miscellaneous editions, and wherein sample is included in the one or more of welded specimen types in single shape factor.Such as, exemplary multiple welded specimen can comprise T-joint, docking-joint and groove welding bead at single parts.Support/tables' model 1206 is provided to the various parts of modeling support 170 in virtual reality space, the various parts of T/S 170 comprise as virtual reality space the adjustable arm 714, the base 724 that use and be used to adjustable arm to be coupled to the column 174 of base.Physical interface model 1201 is provided to the various parts of in virtual reality space modeling welding user interface 130, control desk 135 and ODD 150.

According to embodiment of the present invention, achieve the emulation of molten bath in virtual reality space or weldpool, the molten bath of wherein said emulation has real-time molten metal flow and heat dissipation characteristics.According to embodiment of the present invention, what be positioned at the center of molten bath emulation is the weld physics function 1211 (being physical model again) operated on GPU 115.Weld physics function employing two-track is put a layer technology and is come the dynamic flow characteristics/glutinousness of modeling exactly (viscosity), coagulability, thermal gradient (heat absorption and heat radiation), molten bath vestige (wake) and weld bead shape, and composition graphs 14A-14C is described in more detail this herein.

Weld physics function 1211 and welding bead present function 1217 and are communicated with, show welding bead from motlten metal state to cooling curing state whole states.Welding bead presents function 1217 and uses information (such as heat, mobility, dislocation, coin shape body interval) from weld physics function 1211, comes exactly and in virtual reality space, presents welding bead in real time realistically.Texture maps (texture maps) is provided to welding bead and presents function 1217 by 3D texture function 1218, and the texture (such as burnt trace (scorching), slag, particle (grain)) added is covered on the welding bead of emulation.Such as, in welding process or welding process just terminate, slag can be illustrated and comes across on welding bead and be then moved the welding bead that exposes below.Presenting apparatus function 1216 for using the specific features in the various non-molten bath of Informational Expression from special effects module 1222, comprising Mars (sparks), splashing (spatter), flue dust, arclight, smoke and gas body and specific incoherence (such as undercut and porous).

Internal physical adjustment means 1212 is the adjusting gears allowing various weld physics parameter to be defined for various welding technology, to upgrade and to revise.According to embodiment of the present invention, internal physical adjustment means 1212 to operate on CPU 111 and regulate or the parameter that upgrades be downloaded in GPU 115.The parameter type that can be conditioned via internal physical adjustment means 1212 comprise be associated with welded specimen parameter, allow technique to be changed and without the need to reset welded specimen (allowing formation second welding bead (pass)) technological parameter, can be changed and the various global parameter of whole emulation and other parameters various can not be reset.

Figure 19 is the process flow diagram of the embodiment of the training method 1300 of the virtual welding system 100 using Fig. 1.In step 1310, simulation soldering appliance is moved according to welding skill and technique relative to welded specimen.In step 1320, position and the orientation of virtual reality system tracing simulation soldering appliance in three dimensions is used.In step 1330, watch the display frame of described virtual reality welding system, form by the immediate vicinity in the emulation penetrated from the simulation soldering appliance of described emulation the molten bath emulated at the simulation soldering appliance of emulation, by emulation welding bead material stacking to the welded specimen of described emulation at least one emulation surface on time, described display frame illustrate described simulation soldering appliance and described welded specimen in virtual reality space real-time virtual reality emulation.In step 1340, described display frame is watched real-time molten metal flow and the heat dissipation characteristics in the molten bath of described emulation.In step 1350, change at least one aspect of described welding skill and technique in real time in response to the described real-time molten metal flow in molten bath of the described emulation of viewing and heat dissipation characteristics.

Method 1300 illustrates user and how can watch the molten bath in virtual reality space and change its welding skill and technique in response to the various features (comprising real-time molten metal flow (such as glutinousness) and heat radiation) of watching the molten bath emulated.User can also watch and in response to other features, comprise real-time molten bath vestige and coin shape body interval.Viewing be most welding operation in response to the feature in molten bath be how to be in fact performed in real world.The two-track of weld physics function 1211 is put layer model and is operated on GPU 115, allows so real-time molten metal flow and heat dissipation characteristics are accurately modeled and show to user.Such as, set time (namely weldering unit needs how long to solidify up hill and dale) is determined in heat radiation.

In addition, user can use identical or different (such as second) simulation soldering appliance and/or welding technology, and welding bead material completes the second welding bead.In the second such welding bead sight, the molten bath forming the second emulation at the immediate vicinity of the emulation of the simulation soldering appliance injection from emulation is passed through at the simulation soldering appliance of emulation, pile up be combined with the first welding bead material emulated second emulate welding bead material time, described emulation illustrates the simulation soldering appliance of the described emulation in virtual reality space, welded specimen and original emulation welding bead material.The additional subsequent passes using identical or different soldering appliance or technique can be formed in a similar fashion.According to particular of the present invention, when be combined in virtual reality world by previous welding bead material, new welding bead material and any likely in sample material below form new molten bath time, in arbitrary second or subsequent passes, previous welding bead material is combined with stacked new welding bead material.Such subsequent passes may be needed to form large filler weld or groove weld, such as can be performed to repair the welding bead formed by previous welding bead, or high temperature welding bead (hot pass) and one or more filling and capping (cap) welding bead complete root run in pipe welding after can be comprised.According to various embodiments of the present invention, welding bead and base material can comprise mild steel, stainless steel, aluminium, based on the alloy of nickel or other materials.

Figure 20 A-20B illustrates the concept of welding unit (weldering unit) dislocation Figure 142 0 according to embodiment of the present invention.Figure 20 A illustrates the side view of the smooth welded specimen (WC) 1400 with flat top surface 1410.Welded specimen 1400 is present in real world with the form of such as plastic components, and can be present in virtual reality space with the form of the welded specimen of emulation.Figure 20 B illustrates the sign of the top surface 1410 of the WC 1400 of emulation, and described top surface 1410 is broken down into grid or the array of the welding unit (namely welding unit) forming the first Figure 142 0 of weldering.Each weldering unit (such as, weldering unit 1421) limits the sub-fraction on the surface 1410 of welded specimen.Weld first figure and define surface resolution.Changeable passage (channel) parameter value is assigned to each weldering unit, allows the value of each weldering unit during the welding technology of emulation, dynamically changes in real time in virtual reality weld seam space.Described changeable channel parameters value corresponds to passage molten bath (molten metal flow/glutinousness dislocation), heat (heat absorption/heat radiation), dislocation (solid dislocation) and extra content (various additional state, such as slag, particle, Jiao Hen, original metal (virgin metal)).These changeable passages are called PHED herein, PHED is corresponding molten bath, heat, extra content and dislocation respectively.

Figure 20 illustrates the welded specimen space of smooth welded specimen (WC) 1400 and the exemplary in weld seam space of the Figure 14 emulated in the virtual welding system 100 of Fig. 1.Point O, X, Y and Z limit 3D welded specimen space, local.Generally speaking, per sample (p.s.) type-restriction is from 3D sample space to the mapping in 2D virtual reality weld seam space.Weldering unit Figure 142 0 of Figure 20 is for being mapped to the two-dimensional matrix of the value in virtual reality weld seam space.As shown in Figure 20, user will weld from a B to an E.In fig. 20, shown in both 3D welded specimen space and 2D weld seam space from a B to the trajectory of an E.

The welded specimen of every type limits the direction of dislocation for each position in the first figure of weldering.For the smooth welded specimen of Figure 21, the dislocation direction of the whole positions in weldering unit figure (that is, in z-direction) is identical.For illustrating described mapping, in both 3D welded specimen space and 2D weld seam space, the texture coordinate of the first figure of weldering is shown for S, T (being sometimes referred to as U, V).Weld first figure to be mapped to and the square surface 1410 characterizing welded specimen 1400.

Figure 22 illustrates the welded specimen space of turning (T connector) welded specimen (WC) 1600 and the exemplary in weld seam space that emulate in the virtual welding system 100 of Fig. 1.Turning WC 1600 has two surfaces 1610 and 1620 in 3D welded specimen space, and described two surfaces 1610 and 1620 as being mapped to 2D weld seam space shown in Figure 22.Equally, O, X, Y and Z limit 3D welded specimen space, local.For illustrating described mapping, in both 3D welded specimen space and 2D weld seam space, the texture coordinate of the first figure of weldering is shown for S, T.As shown in Figure 22, user will weld from a B to an E.In fig. 22, shown in both 3D welded specimen space and 2D weld seam space from a B to the trajectory of an E.But the direction of dislocation is towards the lines X'-O' such as shown in 3D welded specimen space, as illustrated in fig. 22 towards relative turning.

Figure 23 illustrates the welded specimen space of tubular weldment sample (WC) 1700 and the exemplary in weld seam space that emulate in the virtual welding system 100 of Fig. 1.Tubulose WC 1700 has curved surface 1710 in 3D welded specimen space, and described surperficial 1710 are mapped to 2D weld seam space as illustrated in fig. 23.Equally, O, X, Y and Z limit 3D welded specimen space, local.For illustrating described mapping, in both 3D welded specimen space and 2D weld seam space, the texture coordinate of the first figure of weldering is shown for S, T.As shown in Figure 23, user welds from a B along bending track to an E.In fig 23, illustrate from a B to the geometric locus of an E and line in 3D welded specimen space and 2D weld seam space respectively.The direction of dislocation is away from lines Y-O (namely away from the center of pipe).

Can be mapped to the similar fashion of the rectangular surface area of geometry with texture maps, the square surface that first figure can be mapped to welded specimen can be welded.Be referred to as in the identical meaning of pixel (abbreviation of image primitive) with each unit of image, each unit can welding figure is referred to as weldering unit.Pixel comprises the information channel limiting color (such as red, green, blue etc.).Weldering unit comprises that be limited in virtual reality space can the information channel (such as P, H, E, D) of face of weld.

According to embodiment of the present invention, the form of weldering unit is summed up as the passage PHED (molten bath, heat, extra content, dislocation) comprising four floating numbers.Extra passage is used as one group of binary number of the logical message (such as, whether there is any slag in the first position of described weldering) stored about weldering unit.Molten bath passage stores the dislocation value for the metal of any liquefaction of the first position of described weldering.Dislocation passage stores the dislocation value for the metal of the solidification of the first position of described weldering.The passage of heat stores the value being given in the heat level of the first position of described weldering.By this way, welded specimen the dislocation produced because of soldered welding bead, the surface " molten bath " of the flicker produced because of liquid metal, Yin Re and the color etc. produced can be shown welding portion.All these effects are all realized by the vertex shader and pixel tinter that are applied to welding surface.

According to embodiment of the present invention, use dislocation figure and particIe system, wherein particle can be interact with each other and collide dislocation figure.Described particle is virtual dynamic fluid particle and provides the liquid behavior in molten bath, but is not directly present (not namely being directly visible).On the contrary, the particle effect only on described dislocation figure is visually visible.Be input to the motion of the heat affecting proximate particle of weldering unit.Relate to the dislocation having two types in emulation molten bath, the dislocation of this two type comprises molten bathwith dislocation. molten bathbe " interim " and only continue in time there is particle and occur heat. dislocation" permanent ". molten bathdislocation is the weld seam liquid metal of Rapid Variable Design (such as glimmering) and can be considered to be at dislocation" top ".Particle covers a part of virtual surface dislocation figure (i.e. weldering unit figure).Dislocation characterizes permanent solid metal, both welding beads that described permanent solid metal comprises initial base metal and solidified.

According to embodiment of the present invention, the welding technology emulated in virtual reality space works in the following manner: particle flows out from the transmitter (transmitter of the MWT 160 of emulation) slim taper parts.The surface of the welded specimen of described particle first time contact emulation, wherein said surface limits by welding unit figure.Described particle interact with each other and with weldering unit scheme to interact, and in real time accumulate get up.Weldering unit is the closer to transmitter, then the heat added is more.The time quantum that heat inputs from electric arc according to the Distance geometry heat with electric arc point is modeled.Special pattern part (such as color etc.) is by thermal drivers.For the weldering unit of sufficiently high temperature, draw in virtual reality space or present molten bath.As long as anywhere enough hot, weldering unit figure liquefaction, causes welding first position for these molten bathdislocation " rise ".By determining at the first position sampling of each weldering " the highest " particle molten bathdislocation.When transmitter advances along seam track, the weldering unit position cooling stayed.Heat is removed from the first position of weldering with special speed.When reaching cooling threshold value, weldering unit figure solidification.Like this, molten bathdislocation is converted into gradually dislocation(welding bead namely solidified).The dislocation increased equals the molten bath of removing, thus whole height does not change.The life-span of adjustment or adjustment particle is to be retained before curing is completed.The specified particle characteristic be modeled in virtual welding system 100 comprises attraction/repulsion, speed (relative to heat), wetting (relative to heat radiation), direction (relative to gravity).

Figure 24 A-24C illustrates the exemplary that the concept of (dislocation and particle) molten bath model is put in the two-track of the virtual welding system 100 of Fig. 1.In virtual reality space, emulation has the welded specimen at least one surface.In virtual reality space, emulate the surface of welded specimen, form the two-track comprising solid dislocation layer and molten bath dislocation layer and put layer.Molten bath dislocation layer can change solid dislocation layer.

As described herein, " molten bath " is limited by a region of the first figure of weldering, and wherein molten bath value improves due to the existence of particle.Sampling process is characterized in Figure 24 A-24C.Illustrate that one of the first figure of weldering has the first section of seven contiguous welderings.Current dislocationvalue is characterized by the unblanketed rectangular strip 1910 with assigned altitute.In Figure 24 A, particle 1920 is illustrated as the unblanketed point of circle that collides with current dislocation surface level and is heaped.In Figure 24 B, " the highest " particle height 1930 is sampled in the first position of each weldering.In Figure 24 C, the rectangle 1940 of band shade illustrates the cause due to particle, move puttop on increase how many molten bath.Due to molten bathbe increased with the particular fluid rate based on heat, weld seam melt pool height can not be set to the value of sampling immediately.Although not shown in Figure 24 A-24C, it is possible for making described solidification process visual, as molten baththe rectangle of shade (band) reduce gradually and dislocation(unblanketed rectangle) is from described in increasing gradually below just in time to replace molten bath.By this way, real-time molten metal flow feature is emulated exactly.When user practises specific weld technique, user can observe the molten metal flow characteristic sum heat dissipation characteristics in molten bath in real-time virtual realistic space, and uses this information to regulate or keep its welding skill and technique.

The number characterizing the weldering unit on the surface of welded specimen is fixing.In addition, as described herein, it is interim for generating the molten bath particle of modeling mobility by emulation.Thus, once use virtual welding system 100 to generate original bath in virtual reality space during the welding technology of emulation, weldering unit adds that the number of molten bath particle keeps relative constancy often.This is because during welding technology, the number of processed weldering unit is fixing, and because molten bath particle to be just created and " destructions " with similar speed (namely molten bath particle is interim), existence and the number of processed molten bath particle is tending towards maintenance relative constancy.Therefore, during the welding stage of emulation, the process load of PPS 110 keeps relative constancy.

According to the interchangeable embodiment of the present invention, molten bath particle can be created in the surface of welded specimen or in the lower face of welded specimen.In such embodiments, dislocation can be modeled in the mode being forward or negative sense relative to the initial surface dislocation of initial (namely not soldered) welded specimen.By this way, molten bath particle can not only be set up on the surface of welded specimen, can also penetration welded specimen.But the number of weldering unit is still fixing, and the molten bath particle being created and destroying is still relative constancy.

According to the interchangeable embodiment of the present invention, can provide and there is mobility instead of the modeling particle that the first dislocation figure of more multichannel weldering comes modeling molten bath.Or, can the dense volume elements figure (voxel map) of modeling instead of modeling particle.As used herein, volume elements (such as volume pixel) is volume element, characterizes the value on regular grid in three dimensions.Or, can a modeling be sampled and the particle disappeared never, instead of modeling weldering unit figure.But so replaceable embodiment may not provide the process load of relative constancy for system.

In addition, according to embodiment of the present invention, (blowthrough) or open-work (keyhole) is penetrated by being removed by material to emulate.Such as, if electric arc to be remained on same position in real world excessively long-time for user, material will fire and fall to cause hole.It is simulated in virtual welding system 100 that such real world penetrates through the first decimation technique of weldering (decimation techniques).If the heat absorbed by a weldering unit is defined as too high by virtual welding system 100, this weldering unit can be labeled or be designated as by burn and carry out presenting (being such as rendered as hole) with this.But next, can weld unit for specific weld technique (such as pipe welding) and rebuild, wherein after being burnt at first, material is added back.In a word, virtual welding system 100 emulates weldering unit's selection (being removed by material) and welds unit and rebuilds (add by material and go back).In addition, in root run welding, the operation of removing materials is suitably emulated in virtual welding system 100.

In addition, in root run welding, the operation of removing materials is suitably emulated in virtual welding system 100.Such as, in real world, before carrying out follow-up welding stroke, the polishing of root run can be performed.Similarly, virtual welding system 100 can emulate the polishing stroke operation removed from virtual solder joint by material.It being understood that the material be removed can be modeled as the negative sense dislocation on the first figure of weldering.That is, the polishing welding bead operation of removing materials, by the modeling of virtual welding system 100, causes the welding bead profile changed.The emulation of polishing stroke operation can be automatic, this that is, virtual welding system 100 removes one and pre-determines the material of thickness, and the material of described predefined thickness can be the welding bead surface of corresponding root run.

In interchangeable embodiment, actual milling tools or grinding machine (grinder) can be simulated as the activation by simulating soldering appliance 160 or another input media and enable or close.It is noted that milling tools can the simulated grinding machine imitating (resemble) real world.In this embodiment, user handles (maneuver) milling tools to respond the motion of described milling tools and removing materials along root run.It being understood that user can be allowed to remove too much material.In a similar way as described above, if user polishes off too much material, hole or other (above-mentioned) defects may be caused.Force spacing further, (being namely programmed) can be realized or stop, preventing user from removing too much material or point out when too much material is just removed.

According to embodiment of the present invention, except not visible " molten bath " particle described herein, virtual welding system 100 also uses the visual particle of other three types to characterize electric arceffect, flameeffect and marseffect.The particle of these types can not with other particle interactions of any type, and only to interact with dislocation figure.Although these particles collide with the face of weld of emulation really, they can not interact each other.According to embodiment of the present invention, only have molten bathparticle can be interact with each other. mars particlephysical features be arranged such, thus Mars particle is jumped everywhere and is altered and be rendered as luminous point (glowing dots) in virtual reality space.

arc particelsphysical features be arranged such, thus arc particelsclash into (hit) specimen surface of emulating or welding bead and stay for some time. arc particelslarger dark bluish white color dot is rendered as in virtual reality space.Adopt such point of many superpositions to form any one visual image.Net result is the white luminous ring of light (nimbus) with blue edge.

flame particlephysical features be modeled and upwards rise lentamente. flame particlebe rendered as medium sized dark red yellow dots will.Adopt such point of many superpositions to form any one visual image.Net result upwards to rise and (the fading out) that fade out has the orange red flame group of red edge.According to a further embodiment of the present invention, the non-molten bath particle of other types can be implemented in virtual welding system 100.Such as, smoke particle can be emulated with the mode modeling similar with flame particle.

The vertex shader that in the visualization process of emulation, last step is provided by the tinter 117 of GPU 115 and pixel tinter process.Vertex shader and pixel tinter provide molten bathwith dislocationand the surface color of the change due to heat and emissivity etc.Extra (E) passage welded in first form of PHED as described earlier in this article comprises all extraneous informations that the first place of each weldering uses.According to embodiment of the present invention, extraneous information comprises non-initial position (true=welding bead, false=initial iron and steel), slag position, undercut value is (in the amount of this weldering unit place's undercut, wherein zero equals without undercut), porous value is (in the amount of this weldering unit place's porous, wherein zero equals without porous), and described welding bead vestige (wake) value of coding solidifying weld beads time.There is one group of image mapped be associated from different welded specimen picture, comprise initial iron and steel, slag, welding bead and porous.These image mapped are used in both bump mapping and texture.The amount that these image mapped merge (blending) is controlled by various mark described herein and value.

1D image mapped and each weldering unit welding bead vestige value is used to realize welding bead vestige effect, the time being cured to certain portions (a given bit) of described each weldering first welding bead vestige value coding welding bead.Once high temperature molten-bath arc welding unit position is no longer the sufficiently high temperature being called as " molten bath ", the time is stored in this position and is called as " welding bead vestige ".Net result is that shader code can use 1D texture to draw " ripple mark (ripples) ", and described " ripple mark " provides the outward appearance of the uniqueness of portraying the direction that (portray) described welding bead is laid.According to the interchangeable embodiment of the present invention, virtual welding system 100 can emulate and show welding bead in virtual reality space, and described welding bead has the real-time welding bead indication character caused to solidification transition by the real-time mobility in the molten bath of described emulation when the molten bath of described emulation is moved along seam track.

According to the interchangeable embodiment of the present invention, virtual welding system 100 can be instructed user how butt welding machine device carries out fault and be mediated (troubleshoot).Such as, the fault of system mediate pattern can train user guarantee its correctly (such as correct specific gas flow rate, connect correct power lead etc.) described system is set.According to another interchangeable embodiment of the present invention, virtual welding system 100 can record and welding process of resetting (or a part at least welding process, such as N frame).The frame of trace ball (track ball) video that rolls can be provided, allow user or instruct individuals review's welding process.Playback can also be provided with selectable speed (such as full speed, Half Speed, 1/4th speed).According to embodiment of the present invention, split screen (split-screen) can be provided to reset, such as, allow on ODD 150 (side-by-side) abreast to watch two welding processes.Such as the object of contrast, " good " welding process can be watched near " difference " welding process.

Generally speaking, disclose a kind of real-time virtual reality welding system, described system comprises based on the subsystem of Programmable Logic Controller, spatial pursuit device, at least one simulation soldering appliance and at least one display device, described spatial pursuit device is operably connected to the described subsystem based on Programmable Logic Controller, at least one simulation soldering appliance described spatially can be followed the trail of by described spatial pursuit device, and at least one display device described is operably connected to the described subsystem based on Programmable Logic Controller.Virtual reality welding system is designed to provide portable use, and wherein compact support is used to welded specimen to keep in space, to use together with simulation soldering appliance.Simulation soldering appliance comprises the common base that can be coupled to multiple adapter, wherein each adapter emulation one specific welds types.By this way, described system can emulate the molten bath with real-time molten metal flow and heat dissipation characteristics in virtual reality space.Described system can also show the molten bath of described emulation on said display means in real time.

Embodiment just illustrates several possible embodiment of the various aspect of the present invention above, and wherein those skilled in the art are according to reading and understand the change and/or modification that this instructions and accompanying drawing can expect being equal to.Especially, relative to the various functions performed by above-described parts (assembly, equipment/device, system and circuit etc.), term (comprise and relating to " device (means) ") intention being used for describing such parts is corresponding with any parts (such as hardware, software or combination wherein) that execution is described the concrete function of parts (being functionally such as equivalent parts), unless be otherwise noted, even if structure is not equal to the open structure of the function performed in the implementation that illustrates of the present invention.In addition, although special characteristic of the present invention may be disclosed relative in just several implementation, when for any that provide or specific application be expect and favourable time, such feature can with one or more other integrate features of other implementations.Also have, to a certain degree, term " comprises (including) ", " comprising (includes) ", " having (having) ", " having (has) ", " with (with) " or distortion are wherein used in detailed description book and/or claim, and such term is intended that in the mode " comprised (comprising) " similar in appearance to term comprising property.As employed herein, term " benchmark " and " reference point " refer to and carry out the reference of measuring from it.

This printed instructions uses the open the present invention of embodiment, comprises best Implementation Modes, and also enables those of ordinary skill in the art carry out the present invention, comprise and make and use any device or system and perform any method be incorporated to.The scope that the present invention can patent is defined by the claims, and can comprise other embodiments that those skilled in the art expect.Other embodiments intention like this in the scope of claims, if they have is not the textural element of the written language being different from claim, if or they comprise with the written language of claims without the different equivalent structural elements of essence.

reference number:

100 virtual welding system 318 interfaces

110 based on the subsystem 400 manual welding instrument of programmable processor

The stick electrode that 111 CPU (central processing unit) 410 emulate

112 storer 422 clampers

114 processor 500 combustible gas welding torches

115 Graphics Processing Unit 510 mouths

116 unified calculation equipment framework 518 interfaces

117 tinter 520 buttons

118 video frequency output 522 neck rings

119 video frequency output 600 pedestals

120 spatial pursuit device 610 interfaces

130 welding user interface 614 abutment

132 operating rod 616 recesses

140 are placed on facial display device 618 button

142 sensor 620 bodies

146 helmet 630 rigid line cables

150 display device 640 securing members

160 simulation soldering appliance 652 sensors

162 adapter 654 cables

166 pedestal 658 securing members

168 sensor 672 impeller

170 support 700 supports

172 magnet 710 magnets

178 preset distance 714 arms

180 welded specimen 722 columns

200 system 724 bases

300 welding gun 732 plungers

310 mouth 738 abutment

312 pipe 758 welded specimens

762 pin 1217 welding beads present

764 pin 1218 3D textures

766 hole 1219 visual cues functions

Mark/tolerance function in 768 holes 1220

800 simulation soldering appliance 1221 tolerance editing machines

810 container 1222 special-effects

830 user interface 1300 methods

832 selector switch 1310 steps

836 temperature measuring equipment 1320 steps

838 current measuring device 1330 steps

842 voltage measuring apparatus 1340 steps

854 step 1350 steps

The smooth welded specimen of 856 step 1400

860 interchangeable user interface 1410 flat top surface

900 helmet 1420 dislocation figure

1201 physical interfaces 1421 weld unit

1202 welding torches/fixture model 1600 welded specimen

1203 environmental model 1610 surfaces

1204 sound-content function 1620 surfaces

1205 welding sound 1700 pipe welded specimens

1206 supports/tables' model 1710 curved surface

1207 inside structure function 1910 rectangular strips

1208 calibration function 1920 particles

1210 welded specimen model 1930 particle height

The rectangle of 1211 weld physics 1940 with shade

1212 internal physical adjustment means 6010 stick electrodes

1213 user's interface function 7018 stick electrodes

1214 drawing functions

1215 student's function of reporting B points

1216 present device D information channel

E point/information channel

H information channel

O point

O' line

P information channel

S texture coordinate

T texture coordinate

U texture coordinate

V texture coordinate

X point

X' line

Y point

Z point

Claims (15)

1. a virtual welding system (100), described virtual welding system (100) comprising:

Based on the subsystem (110) of programmable processor;

Spatial pursuit device (120), described spatial pursuit device (120) is operably connected to the described subsystem (110) based on programmable processor;

Simulation soldering appliance (160), described simulation soldering appliance (160) spatially can be followed the trail of by described spatial pursuit device (120), and described simulation soldering appliance (160) comprises,

One or more adapter (162), wherein each adapter (162) emulates the real world outward appearance of a specific weld type; And

Pedestal (166), described pedestal (166) is each by what be coupled in described one or more adapter (162) removedly.

2. virtual welding system as claimed in claim 1, also comprises:

Be arranged on one or more sensor (168) in described pedestal (166); And

Have the magnet (172) of locus, described magnet (172) is identified the relative position of described simulation soldering appliance (160) to described magnet (172) by the tracking of described one or more sensor (168).

3. virtual welding system as claimed in claim 2, also comprises:

Welded specimen (180), described welded specimen (180) has at least one surface and soldered real world parts are wanted in emulation, described welded specimen (180) is set to from described magnet (172) known distance, at least one surface described of wherein said welded specimen (180) is simulated as the two-track comprising solid dislocation layer and molten bath dislocation layer and puts layer in described virtual reality space, and wherein said molten bath dislocation layer can change described solid dislocation layer;

Its medium-height trestle (170) can be provided to support described magnet (172) and described welded specimen (180) with predetermined spatial relationship.

4. the virtual welding system as described in claims 1 to 3, also comprises:

By the helmet (146) that user wears; And

Be arranged on the display device (150) being placed on face in the described helmet (146), the described display device (150) being placed on face shows real-time molten metal flow and the heat dissipation characteristics of the welding pool of described emulation, to be that the user of described simulation soldering appliance (160) provides real-time visual feedback when the display device (150) being placed on face described in being displayed on is upper, to allow described user to adjust oneself in real time in response to described real-time visual feedback or keep welding skill and technique.

5. system as claimed in claim 4, the wherein said helmet (146) position is determined by described spatial pursuit device (120) and is sent to the described subsystem (110) based on programmable processor.

6. the system as described in claim 4 or 5, also comprises:

Be arranged on one or more sensor (168) in the described helmet (146), to follow the trail of the locus of the described helmet (146) relative to described magnet (172);

Wherein said sensor be preferably in capacitive transducer, piezoelectric sensor, infrared proximity sensor, hall effect sensor, eddy current sensor, inductance sensor and sonac one or more.

7. the simulation soldering appliance (160) used in virtual welding system (100), described simulation soldering appliance (160) comprising:

One or more adapter (162), each adapter (162) emulates the physical features of a specific weld type; And

Pedestal (166), described pedestal (166) is each by what be coupled in described one or more adapter (162) removedly, and described pedestal (166) identifies the real-time spatial position of described simulation soldering appliance (160) relative to reference position.

8. system as claimed in claim 7, wherein reference point is welded specimen (180), described welded specimen (180) has at least one surface when emulating and wanting soldered real world parts, described welded specimen (180) has at least one surface and soldered real world parts are wanted in emulation, at least one surface described of wherein said welded specimen (180) is simulated as the two-track comprising solid dislocation layer and molten bath dislocation layer and puts layer in described virtual reality space, and wherein said molten bath dislocation layer can change described solid dislocation layer.

9. system as claimed in claim 8, also comprises:

Magnet (172), described magnet (172) is set up with preposition relative to described welded specimen (180);

Its medium-height trestle (170) can be provided, and the fixing described magnet (172) of described support (170) is relative to the locus of described welded specimen (180);

One of them or more sensor (168) can be arranged in described pedestal (166), the position of described pedestal (166) relative to described magnet (172) determined by one or more sensor described;

Their position is preferably sent to the described subsystem (110) based on programmable processor by wherein said sensor.

10. the system as described in claim 7 to 9, also comprises:

Be arranged on the interface of the first end of described pedestal (166), described interface facility and the removable mechanical couplings of in described one or more adapter (162).

11. systems as claimed in claim 10, wherein said interface comprises at least one first mechanical features, at least one second mechanical features at least one first mechanical features described and described adapter (162) is complementary, with the removable mechanical couplings of each adapter of facility (162) to described pedestal (166).

12. systems as described in claim 7 to 11, wherein said pedestal (166) also comprises flip flop equipment, and described flip flop equipment is used to indicate effective weld seam state in virtual welding system (100),

Wherein preferably described flip flop equipment is bonded in each adapter via cover, and described cover mechanically to be handled via described adapter by user and started effective weld seam state.

13. 1 kinds use the method simulating soldering appliance (160) in virtual welding system (100), and described method comprises:

Removedly the first adapter (162) is connected to pedestal (166), described first adapter (162) is associated with the first welds types;

Described first adapter (162) is removed from described pedestal (166); And

Removedly the second adapter (162) is connected to described pedestal (166), described second adapter (162) is associated with the second welds types;

Wherein said pedestal (166) comprises sensor (168), the locus of described simulation soldering appliance (160) relative to welded specimen (180) determined by described sensor (168), and the position of wherein said pedestal (166) is updated to display in real time.

14. methods as claimed in claim 13, also comprise:

Magnet (172), described magnet (172) is arranged on a known position relative to described welded specimen (180), wherein said sensor (168) determine described magnet (172) position and at least based on described magnet (172) described position calculation described in the position of welded specimen (180).

15. methods as described in claim 13 or 14, also comprise:

According to the first welding skill and technique described simulation soldering appliance (160) with described first adapter (162) mobile relative to welded specimen (180);

Use described virtual reality welding system (100) to follow the trail of in three dimensions to have the described simulation soldering appliance (160) of described first adapter (162);

Watch the display of described virtual reality welding system (100), described emulation the simulation soldering appliance (160) with described first adapter (162) by the emulation of launching from the described simulation soldering appliance (160) with described first adapter (162) immediate vicinity formed emulation welding pool and by first emulate welding bead material deposition to the welded specimen (180) of described emulation at least one emulate surface on time, described display illustrates described simulation soldering appliance (160) and described welded specimen (180) the real-time virtual reality emulation in virtual reality space with described first adapter (162),

Watch the first real-time molten metal flow and heat dissipation characteristics of the welding pool of described first emulation on the display; And

At least one aspect that described first welds skill and technique is changed in real time in response to the described first real-time molten metal flow of welding pool of described first emulation of viewing and heat dissipation characteristics,

And preferably also comprise:

According to the second welding skill and technique described simulation soldering appliance (160) with described second adapter (162) mobile relative to welded specimen (180);

Use described virtual reality welding system (100) to follow the trail of in three dimensions to have the described simulation soldering appliance (160) of described second adapter (162);

Watch the display of described virtual reality welding system (100), described emulation the simulation soldering appliance (160) with described second adapter (162) by formed at the immediate vicinity of the emulation of launching with described second adapter (162) simulation soldering appliance (160) from described emulation emulation welding pool and by the second welding bead material deposition emulated at least one surface emulated of the welded specimen (180) of described emulation time, described display illustrates described simulation soldering appliance (160) and described welded specimen (180) the real-time virtual reality emulation in virtual reality space with described second adapter (162),

Watch the second real-time molten metal flow and heat dissipation characteristics of the welding pool of described second emulation on the display; And

At least one aspect that described second welds skill and technique is changed in real time in response to the described second real-time molten metal flow of welding pool of described second emulation of viewing and heat dissipation characteristics.