WO2014184710A2

WO2014184710A2 - Virtual reality based welding simulator

Info

Publication number: WO2014184710A2
Application number: PCT/IB2014/061240
Authority: WO
Inventors: Sudarshan RAMACHANDRAIAH
Original assignee: Virtual Logic Systems Pvt.Ltd.
Priority date: 2013-05-11
Filing date: 2014-05-06
Publication date: 2014-11-20
Also published as: WO2014184710A3

Abstract

The inventive subject matter of the present disclosure provides apparatus, systems, and methods for conducting welding simulation. Systems and method further relate to virtual welding environments that emulate welding of a three-dimensional work piece created virtually on a monitor.

Description

VIRTUAL REALITY BASED WELDING SIMULATOR

Field of the Invention

[0001] The present disclosure pertains to systems for emulating a virtual welding environment, and more particularly to virtual welding environments that emulate welding of a three- dimensional work piece created virtually on a monitor.

Background of the Invention

[0002] The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

[0003] Welding is a value added operation in various industries such as automobile industries, equipment production, small part fabrication, etc. For decades companies have been teaching welding skills. Traditionally, welding has been taught in a real world setting, that is to say that welding has been taught by actually striking an arc with an electrode on a piece of metal. Instructors, skilled in the art, oversee the training process making corrections in some cases as the trainee performs a weld. By instruction and repetition, a new trainee learns how to weld using one or more processes. However, costs are incurred with every weld performed, which varies depending on the welding process being taught.

[0004] In more recent times, cost saving systems for training welders have been employed, where virtual reality (VR) is used as a welding training tool. Unlike classroom training, virtual reality training provides hands on experience to the trainee. By this method, new techniques can be learned without risk of injury. Moreover, material costs incurred during classroom training can be eliminated. Known in prior art is a welding simulator that makes use of head mounted display (HMD) that provides VR environment for welding. The weld piece is virtual, and is placed near the mock-up table or is placed in a virtual position visible in HMD. Also known in prior art is a programmable processer based welding system for providing training in simulated virtual or augmented reality environments. However, the currently used welding training systems are expensive, lack mechanisms to provide training in different positions, are limited in their training focus, and do not provide the trainee the experience of a real weld piece.

[0005] There is therefore a need for a welding simulation system/architecture that enables more accurate and cost-effective welding to take place.

[0006] All publications herein are incorporated by reference to the same extent as if each

individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.

[0007] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term "about." Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

[0008] As used in the description herein and throughout the claims that follow, the meaning of "a," "an," and "the" includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of "in" includes "in" and "on" unless the context clearly dictates otherwise. [0009] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. "such as") provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

[0010] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.

Objects of the Invention

[0011] It is an object of the present disclosure to provide cost-effective training to trainees

intending to learn welding operations.

[0012] It is an object of the present disclosure to provide a welding simulator system for welding using techniques such as gas metal arc welding, gas tungsten arc welding, stick metal arcs, among other like welding technologies known in the art.

[0013] It is an object of the present disclosure to provide a welding simulator for welding of work piece that is created virtually on a monitor/display unit, wherein the work piece can be rendered in three dimensions. [0014] It is an object of the present disclosure to provide a welding simulator that presents the

3D view of the work piece on the monitor/display based on the perspective/orientation of the user and/or welding gun held by the user.

[0015] It is another object of the present disclosure to provide a welding simulator that updates the 3D rendering of the virtual work piece in real-time based on position and/or orientation of the user and/or head thereof.

[0016] It is yet another object of the present disclosure to provide a welding simulator that presents 3D rendering of the virtual work piece to enable user to perceive true size of the work piece.

Summary of the Invention

[0017] The inventive subject matter of the present disclosure provides apparatus, systems, and methods for conducting welding simulation. Systems and method further relate to virtual welding environments that emulate welding of a three-dimensional work piece created virtually on a monitor.

[0018] According to one embodiment of the present disclosure, welding simulator, also

completely or partially interchangeably referred to as system hereinafter, can include a camera based tracking means and a mechanical linkage means, wherein the mechanical linkage means is mounted on a support and is operatively coupled with a welding gun configured to enable a user to hold the gun in hand. According to another embodiment, the mechanical linkage means include a plurality of sensors configured to assess movement/position/orientation of the user's hand.

[0019] According to another embodiment, welding simulator apparatus of the present disclosure can include a monitor/display unit configured on a motorized mechanism in order to adjust the height/orientation/position of the monitor. A work piece to be welded can be rendered in a three-dimensional (3D) representation on the monitor, wherein a user can, using 3D compatible goggles such as stereoscopic goggles, view the 3D rendered work piece on the display unit. The display can appear as if the weld piece is placed on the surface of the monitor and is projecting outwards giving illusion of a 3D work piece. [0020] According to yet another embodiment, welding simulator apparatus of the present disclosure can be configured to incorporate a perspective correction

algorithm/means/mechanism/technique that, based on the position and/or orientation of the trainee user and/or of the welding gun, changes/modifies the rendering of the weld piece. Such 3D rendering of the weld piece can be modified by means of the camera based tracking means that tracks the position and/or orientation of the user, and enables modification/adaptation in the 3D rendering of the weld piece. Such perspective correction enables the user to get the feel of actual weld piece rather than of a dummy weld piece.

[0021] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

Brief Description of the Drawings

[0022] FIGs. 1(a) and 1(b) illustrate an exemplary representation 100 of a welding simulation architecture in accordance with an embodiment of the present disclosure.

[0023] FIG. 2 illustrates horizontal welding position of the system in accordance with an

embodiment of the present disclosure.

[0024] FIG. 3 illustrates vertical welding position of the system in accordance with an

embodiment of the present disclosure.

[0025] FIG. 4 illustrates overhead welding position of the system in accordance with an

embodiment of the present disclosure.

Detailed Description of the Invention

[0026] The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.

[0027] The inventive subject matter of the present disclosure provides apparatus, systems, and methods for conducting welding simulation. Systems and method further relate to virtual welding environments that emulate welding of a three-dimensional work piece created virtually on a monitor.

[0028] FIGs. 1(a) and 1(b) illustrate an exemplary representation 100 of a welding simulation architecture in accordance with an embodiment of the present disclosure. According to one embodiment of the present disclosure, welding simulator, also completely or partially interchangeably referred to as system hereinafter, can include a camera based tracking means 1 and a mechanical linkage means 2, wherein the mechanical linkage means 2 can be mounted on a support 4 and can be operatively coupled with a welding gun 3 that is configured to enable a user to hold the gun 3 in hand. According to another embodiment, the mechanical linkage means 2 can include a plurality of sensors configured to assess movement/position/orientation of the user's hand. In another embodiment, a plurality of mechanical linkage means 2 can be configured, so that both hands, for instance, can use two or more mechanical linkage means 2 for the welding operation. Similarly, a plurality of different or same supports can configured for the two or more mechanical linkage means 2 to enable a user to, for instance, conduct TIG (GTAW) welding where the user uses the left hand to feed the filler material, and the right hand to use the welding gun. Therefore, means for tracking both the hands and the positions and/or orientations of the filler material and the welding gun can be performed/required. In another aspect, multiple mechanism linkage means 2 and supports 4 can also be configured so as to track multiple people welding on the same virtual weld piece. In yet another embodiment, mechanical linkage system 2 can have a provision for interchanging welding gun 3 for different types of welding. In another aspect, this interchanging provision could have sensors that detect which welding gun is loaded. [0029] According to another embodiment, welding simulator apparatus 100 of the present disclosure can include a monitor/display unit 5 configured on a motorized mechanism in order to adjust the height/orientation/position of the monitor. According to one embodiment, with reference to FIG. 1(a) and FIG. 1(b), the motorized mechanism can include a plurality of motors 6, screw rods 7, bushing assembly 8, guide 9, and a link assembly 10 for tilting and moving the monitor/display unit 5 in various positions, including but not limited to, horizontal, vertical, overhead, among other orientations. The monitor 5 can therefore be rotated from 0 degrees at horizontal to 180 degree when rotated at flipped down position, and 90 degrees for vertical positions. According to one embodiment, for height adjustment, forklift type of mechanism can be used whereas for lifting the monitor 5, crank and slider mechanism can be used.

[0030] According to one embodiment, a work piece to be welded can be rendered in a three- dimensional (3D) representation on the monitor 5, wherein a user can, using 3D compatible goggles such as stereoscopic goggles, view the 3D rendered work piece on the display unit 5. The display 5 can appear as if the weld piece is placed on the surface of the monitor and is projecting outwards giving illusion of a 3D work piece.

[0031] According to yet another embodiment, welding simulator apparatus 100 of the present disclosure can be configured to incorporate a perspective correction

algorithm/means/mechanism/technique that, based on the position and/or orientation of the trainee user and/or of the welding gun, changes/modifies the rendering of the weld piece. Such 3D rendering of the weld piece can be modified by means of the camera based tracking means 1 that tracks the position and/or orientation of the user, and enables modification/adaptation in the 3D rendering of the weld piece. Such perspective correction enables the user to get the feel of actual weld piece rather than of a dummy weld piece. During the welding operation, one or a combination of beads, sparks, and flames can also be virtually produced to give a real-life experience as the flame/sparks can be aligned to the position and/or orientation of the real welding gun. According to one embodiment, the perspective correction means of the present disclosure enable the welder to move closer or away from the monitor, as well as look around the virtual object to see, for instance, the rear, bottom, sides, among other portions of the virtual object. [0032] FIG. 2 illustrates horizontal welding position 200 of the system in accordance with an embodiment of the present disclosure. Horizontal position 200 relates to the position of the monitor/display unit 5 that can be provided to the user at the beginning of the training session. In this position, various work pieces can be placed horizontally upon the monitor/display and the user can perform welding by standing horizontally or in a seated position.

[0033] FIG. 3 illustrates vertical welding position 300 of the system in accordance with an

embodiment of the present disclosure. In vertical position, the welding piece can be placed perpendicular to the monitor/display unit facing the user, which is different from the horizontal position and is comparatively difficult. This exercise can be provided to the user after completion of welding in horizontal position.

[0034] FIG. 4 illustrates overhead welding position 400 of the system in accordance with an embodiment of the present disclosure. This is a difficult and different position when compared with the horizontal and vertical positions and can be provided to the user after practicing welding in horizontal and vertical positions.

[0035] According to one embodiment, in all the above positions, welding can be performed on standard work pieces with various joints like butt joint, fillet joint, T joint, etc. According to another embodiment, the virtual welding technique can include one or a combination of flux cored arc welding (FCAW), gas metal arc welding (GMAW), gas tungsten arc welding (GTAW), and shielded metal arc welding (SMAW). According to another embodiment, display 5 of the present disclosure can be touch-sensitive display, which can be operatively coupled with a memory for storing at least one welding application providing at least one welding process/technique.

[0036] According to another embodiment, sensors of the mechanical linkage means 2 can be configured to detect position of the welding gun 3 with respect to the 3D rendering of the work piece on the display 5. In an implementation, the sensor can include a magnetic sensor to detect proximity of the welding gun to the simulated surface on the display. According to another embodiment, implementation of a simulated work-piece and sensors allows for the user to practice in three dimensions, and be accordingly assessed following the processing and presentation of the sensor data. In another aspect, the sensors can include one or more Hall Effect sensors that allow the welding simulator to ascertain location of an object by the strength of its magnetic field. Thus, there can be no need for supplementary location sensors. Hall Effect sensors can be particularly appropriate sensors for use in magnetic tracking. In another embodiment, sensors can include one or more optical encoder sensors that allow the welding simulator to ascertain location of an object by measuring the angles between mechanical linkages. Thus, in an implementation, there can be no need for supplementary location sensors. Optical encoder sensors can be particularly appropriate sensors for use in locations where there is magnetic interferrence.

[0037] According to one embodiment, welding gun can be telescopic, wherein such a gun may be used to simulate a consumable electrode of the sort used in Stick or MIG welding. The rate at which the consumable electrode is fed into the welding site is of importance to the strength of the weld, and it is important that the trainee welder has the opportunity to practice feeding the electrode into the weld at the correct speed and in the correct manner. Thus, this feature can further enhances the realism of the simulator. In yet another embodiment, welding gun 3 of the present disclosure can further include an inclinometer, wherein the provision of an inclinometer can allow for the monitoring and/or production of data relating to the angle at which the simulating welding gun is held. There is a desirable angle at which to hold a welding rod, and this can be analysed and corrected through the use and observation of the inclinometer.

[0038] According to one embodiment, the proposed welding simulation architecture enables seamless integration of virtual world and physical world, wherein the virtual world comprises of 3D rendering of work pieces/objects to be welded, which may be vizualized with or without 3D stereo, on a monitor/TV 5, and wherein the physical world comprises of real welding torch/gun 3 help by the trainee. Based on the movement of the gun the physical world, virtual objects can be welded with a weld bead being formed in the virtual environment. [0039] In another embodiment, as the proposed simulation environment does not use the typically used head mounter displays (HMD), there is neither a restricted field of view nor does the virtual object appear at a distance greater than that of the physical world. Furthermore, there is no additional weight on the user's head. In addition, HMDs completely cover the user's eye, and prevent the user from establishing references to the physical world, causing loss of balance, increased changes of simulator sickness, among other issues. The proposed architecture further enables the welder to have the welding gun to be in the line of sight while performing the welding action.

[0040] According to another embodiment, mechanical linkage system 2 of the present disclosure can have six degrees of freedom (DOF), which can be used to track the position and orientation of the welding gun/user's arm and allow movement and easy rotation in defined three dimensional work space. In an implementation, sensors in the mechanical linkage system 2 can be configured on the joints between individual linkages. In another embodiment, an end effector can be fitted with artificial smoke generating device or compressed air nozzle to simulate real world effects of welding operation. In yet another implementation, the end effector can be fitted with any kind of force generating actuators or motors to generate real world forces and vibrations that are felt by the user during actual welding or any other real world operation of any equipment. Therefore, smoke, pressure, forces, and vibration can be generated as per the simulation.

[0041] System of the present disclosure can also include means to evaluate the type of

simulation done, compliance with expectations, degree to compliance so that the trainee can be given feedback in real time on the mistakes done, reasons of mistakes, and the mode/manner in which the mistakes can be rectified. Trainees can therefore, say on a user interface, view his/her performance and see the progress/decline in the learning curve.

[0042] As used herein, and unless the context dictates otherwise, the term "coupled to" is

intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms "coupled to" and "coupled with" are used synonymously. Within the context of this document terms "coupled to" and "coupled with" are also used euphemistically to mean "communicatively coupled with" over a network, where two or more devices are able to exchange data with each other over the network, possibly via one or more intermediary device.

[0043] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms "comprises" and "comprising" should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C ... . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.

Advantages of the Invention

[0044] The present disclosure provides cost-effective training to trainees intending to learn welding operations.

[0045] The present disclosure provides a welding simulator system for welding using techniques such as gas metal arc welding, gas tungsten arc welding, stick metal arcs, among other like welding technologies known in the art.

[0046] The present disclosure provides a welding simulator for welding of work piece that is created virtually on a monitor/display unit, wherein the work piece can be rendered in three dimensions.

[0047] The present disclosure provides a welding simulator that presents the 3D view of the work piece on the monitor/display based on the perspective/orientation of the user and/or welding gun held by the user. [0048] The present disclosure provides a welding simulator that updates the 3D rendering of the virtual work piece in real-time based on position and/or orientation of the user and/or head thereof.

[0049] The present disclosure provides a welding simulator that presents 3D rendering of the virtual work piece to enable user to perceive true size of the work piece.

Claims

CLAIMS What is claimed is:

1. A welding simulation system comprising: a camera-based tracking means; a mechanical linkage means operatively coupled with said camera-based tracking means, wherein said mechanical linkage means comprises a plurality of sensors and is operatively coupled with a welding gun to enable a user to hold said gun and perform welding operation on a three-dimensional object rendered on a display monitor.

2. The system of claim 1, wherein said system further comprises at least one support for supporting said mechanical linkage means.

3. The system of claim 1, wherein said plurality of sensors are configured to assess position and/or orientation of said user's hand and/or said welding gun, and automatically adjust said display monitor based on said position and/or orientation.

4. The system of claim 1, wherein said display monitor is supported by means of a plurality of motors configured to adjust one or a combination of height, position, and orientation of said display monitor.

5. The system of claim 1, wherein said display monitor is moveable in one or a combination of horizontal, vertical, and overhead positions.

6. The system of claim 1, wherein said system incorporates perspective correction

configured to assess position and/or orientation of user's hand and/or welding gun and modify the work piece based on said assessed position and/or orientation.

7. The system of claim 1, wherein said system is viewable from any position.

8. The system of claim 1, wherein said system enables one or a combination of flux cored arc welding (FCAW), gas metal arc welding (GMAW), gas tungsten arc welding

(GTAW), and shielded metal arc welding (SMAW).

9. The system of claim 1, wherein said mechanical linkage means has six degrees of freedom (DOF).

10. The system of claim 1, wherein said mechanical linkage means is operatively coupled with an end effector, wherein said effector is fitted with one or a combination of an artificial smoke generating device, force generating actuators, motors, and a compressed air nozzle to simulate real world effects of welding operation.

11. A virtual reality (VR) based rendering of objects in three-dimensional space comprising configuring a virtual object to scale on a monitor display in a three-dimensional space to enable said virtual object to be interacted with by means of physical object so as to give an impression of physical existence of said virtual object.