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    • 专利摘要:
    EXPERIMENTAL WELDING UNICUPOM FOR A VIRTUAL WELDING SYSTEM, AND, VIRTUAL WELDING SYSTEM This is an experimental welding unit (22, ...) for a virtual welding system that includes a first outer surface and a second perpendicular surface exterior to the first exterior surface. The first outer surface and the second outer surface together provide a plurality of grooves (36, 38, 48,.) Configured for the simulation of a plurality of different types of groove welds in the experimental welding unit. A curved outer surface (42,.) Is configured for the simulation of a tube fillet weld in the experimental welding unit. The magnet source (46) is configured to generate a magnetic field around the experimental welding unit to track movements of an experimental welding tool with respect to the experimental welding unit.
    公开号:BR112016030671B1
    申请号:R112016030671-6
    申请日:2015-06-30
    公开日:2021-02-09
    发明作者:Jason Leach；Antonius Aditjandra；Deanna Postlethwaite
    申请人:Lincoln Global, Inc；
    IPC主号:
    专利说明:

    BACKGROUND FIELD OF REVELATION
    [001] The present invention relates to systems for simulating welding in a virtual welding environment and to welding coupons for use with these systems. DESCRIPTION OF RELATED TECHNIQUE
    [002] For decades, companies have been teaching welding techniques. Traditionally, welding is taught in a real-world setting, which means that welding is taught by truly opening an arc with an electrode over a piece of metal. Technically versed instructors oversee the training process making corrections in some cases as trainees perform a weld. Through instruction and repetition, a new intern learns how to weld using one or more processes. However, expenses are incurred for each welding performed, which vary according to the welding process to be taught.
    [003] More recently, more economical systems have been used for training welders. Some systems incorporate a motion analyst. The analyst includes a physical model of a weld, an experimental electrode and sensory means that track movements of the experimental electrode. A report is generated that indicates the extent to which the tip of the electrode has traveled outside an acceptable range of motion. More advanced systems incorporate the use of virtual reality, which simulates the manipulation of an experimental electrode and the resulting welds in a virtual configuration, can be observed (for example, visually, aurally, etc.) in real time by the welder.
    [004] Virtual reality welding simulators typically include several different physical weld models (for example, experimental welding coupons), where each physical model allows the welder to practice a certain type of weld. For example, an experimental welding coupon could have two perpendicular surfaces that would allow the welder to perform a fillet weld, while another experimental welding coupon could have a groove surface that would allow the welder to perform a groove weld. To switch between different types of simulated welds, the welder must reposition or relocate the experimental welding coupon. Not only is it inconvenient when the welder stops training to reposition or replace the experimental welding coupon, but repositioning or replacing the experimental welding coupon can cause the welding coupon to be improperly assembled. For example, if the virtual reality welding simulator is programmed to assume that the experimental welding coupon is located at a certain fixed location and the welder assembles the welding coupon at another inappropriate location, simulated welding data will result incorrect. BRIEF SUMMARY
    [005] The following summary provides a simplified summary to provide a basic understanding of some aspects of the devices and systems discussed here. This summary is not a vast exposition of the devices and systems discussed here. It is not intended to identify elements of paramount importance or to outline the scope of such devices and systems. Its sole purpose is to present some concepts in a simplified way as a prelude to the more detailed description that will be presented later. In particular, the invention proposes an experimental welding unit according to claim 1, and a virtual welding system according to claims 6 or 12. Preferred embodiments will be disclosed in the description, dependent claims and / or drawings. In this way, it can be preferred that the plurality of grooves include a vertical groove configured for the simulation of a vertical groove weld and a horizontal groove configured for the simulation of a horizontal groove weld or a flat groove weld and / or, if the curved outer surface includes a groove configured for simulating a pipe groove weld.
    [006] According to one aspect, an experimental welding unicupom is provided for a virtual welding system. The experimental welding unit includes a first outer surface and a second outer surface perpendicular to the first outer surface. The first outer surface and the second outer surface together provide a plurality of grooves configured for simulating a plurality of different types of groove welding in the experimental welding unit. A curved outer surface is configured to simulate pipe fillet welding in the experimental welding unit. The magnet source is configured to generate a magnetic field around the experimental welding unit to track movements of an experimental welding tool with respect to the experimental welding of a unit.
    [007] According to another aspect, a virtual welding system is provided. The virtual welding system includes an experimental welding tool to perform simulated welds. An experimental welding unicupom is configured to receive a plurality of different types of simulated welds using the experimental welding tool. The experimental welding unit includes at least one vertical grooved surface, at least one horizontal grooved surface and at least one curved surface. The plurality of different types of simulated welds include a pipe fillet weld, a vertical groove weld, a horizontal groove weld or a flat groove weld, and a horizontal fillet weld. A subsystem based on a programmable processor is operable to execute coded instructions to generate an interactive virtual reality welding environment that simulates the welding activity on a virtual welding unicupom that corresponds to the experimental welding unicupom. The interactive virtual reality welding environment includes a virtual welding pod on the virtual welding unicupom generated in real time in response to simulated welds on the experimental welding unicupom. A display device is operatively connected to the subsystem based on a programmable processor and is configured to visually describe the interactive virtual reality soldering environment, including the virtual soldering pod in the virtual soldering unit, in real time.
    [008] According to another aspect, a virtual welding system is provided. The virtual welding system includes an experimental welding tool to perform simulated welds. The experimental welding tool includes a magnetic field sensor. An experimental welding unicupom is configured to receive a plurality of different types of simulated welds using the experimental welding tool. The experimental welding unit includes a magnet source configured to generate a magnetic field around the experimental welding unit to track movements of the experimental welding tool with respect to the experimental welding unit. The experimental welding unicupon additionally comprises at least one vertical grooved surface, at least one horizontal grooved surface, and at least one curved surface. The plurality of different types of simulated welds include a pipe fillet weld, a vertical groove weld, a horizontal groove weld, a flat groove weld, a horizontal fillet weld and a pipe groove weld or a weld weld. fillet in the head position. A programmable processor-based subsystem is operable to execute coded instructions for the generation of an interactive virtual reality welding environment that simulates the welding activity on a virtual welding unicupom that corresponds to the experimental welding unicupom. The interactive virtual reality welding environment includes a virtual welding pod over the virtual welding unicupom generated in real time in response to simulated welds in the experimental welding unicupom. The virtual weld pudding includes dynamic real-time characteristics of molten metal fluidity and heat dissipation. A display device is operatively connected to the subsystem based on the programmable processor and is configured to visually describe the interactive virtual reality welding environment, including the virtual welding pod in the virtual welding unicupom, in real time. BRIEF DESCRIPTION OF THE DRAWINGS
    [009] FIG. 1 is a perspective view of a welder using a virtual welding system;
    [0010] FIG. 2 is a perspective view of a welder using a virtual welding system;
    [0011] FIG. 3 is a perspective view of a virtual welding system;
    [0012] FIG. 4 is a schematic block diagram of a virtual welding system;
    [0013] FIG. 5 is a perspective view of a welding unicupom
    [0014] The experimental; FIG. 6 is a perspective view of a welding unicupom
    [0015] The experimental; FIG. 7 is a perspective view of a welding unicupom
    [0016] The experimental; FIG. 8 is a perspective view of a welding unicupom
    [0017] The experimental; FIG. 9 is a perspective view of an experimental welding unit;
    [0018] FIG. 10 is a perspective view of an experimental welding unit;
    [0019] FIG. 11 is a perspective view of an experimental welding unit;
    [0020] FIG. 12 is a perspective view of an experimental welding unit;
    [0021] FIG. 13 is a perspective view of an experimental welding unicupon;
    [0022] FIG. 14 is a perspective view of an experimental welding unit;
    [0023] FIG. 15 is a perspective view of an experimental welding unit;
    [0024] FIG. 16 is a perspective view of an experimental welding unit; and
    [0025] FIGS. 17A to C schematically illustrate exemplary double displacement layers for the simulation of surfaces of an experimental welding unicupon in virtual reality space. DETAILED DESCRIPTION
    [0026] The present matter concerns virtual welding systems for use in training and demonstration of demonstrative welding operations and refers to experimental welding coupons for use in such systems. Details on virtual welding systems can be found in Patent Application Publication under US 2012/0189993 A1 (Kindig et al.), Entitled VIRTUAL WELDING SYSTEM, published on July 26, 2012, which is integrally incorporated into the present invention. by reference, and in the Patent Application Publication under US 2013/1089657 A1 (Wallace et al.), entitled VIRTUAL REALITY GTAW AND PIPE WELDING SIMULATOR AND SETUP, published on July 25, 2013, which is fully incorporated into this invention by reference.
    [0027] The present matter will now be described with reference to the drawings, in which similar reference numbers are used to refer to similar elements throughout the present invention. It appears that the various drawings are not necessarily drawn in scale from one figure to another, nor within a given figure, and in particular the size of the components are drawn in an arbitrary manner to facilitate the understanding of the drawings. In the following description, for illustrative reasons, several specific details are placed in order to provide a complete understanding of the present matter. It may be evident, however, that the present matter can be practiced without these specific details. In addition, other modalities of the subject are possible and the subject can be practiced and performed in other ways than what has been described. The terminology and phraseology used in the description of the subject are used for the purpose of promoting an understanding of the subject and should not be interpreted as limiting.
    [0028] Figures 1 to 3 show components of a virtual welding system, and Fig. 4 provides a block diagram of the virtual welding system 10. The virtual welding system includes a subsystem based on a programmable processor 12 which generates an interactive virtual reality welding environment to provide training for a welder or user 14 about different welding processes and techniques. The programmable processor-based subsystem 12 can simulate different welding processes, such as metal arc welding with gas (GMAW), arc welding with coated electrode (SMAW), arc welding with tungsten gas (GTAW) and the like in a virtual reality space and provide real-time comments to the user 14 regarding the progress and quality of the simulated welds. The programmable processor-based subsystem 12 may include one or more processors (for example, microprocessor, microcontroller, etc.) and associated memory (RAM, ROM, etc.) for storing and executing the coded program instructions that cause the subsystem programmable processor-based provide functionality as described here.
    [0029] The virtual welding system 10 includes a welding interface with user 16 that communicates with the subsystem based on a programmable processor. The welding user interface 16 allows user 14 to configure a welding process to be simulated. The welding user interface 16 can include input and output devices, such as video screens, keyboards, mice, video game controllers, touch screens, etc. Through the welding interface with user 16, user 14 can choose or configure various virtual or simulated welding parameters, such as welding voltage, welding current, welding polarity, welding waveforms, wire feed speed, etc. . Real-time comments on a virtual welding operation can be made to user 14 via the welding user interface 16. For example, welding progress including representations of weld quality, defects and weld puddling can be displayed to user 14 on the welding interface with user 16 in real time. Audible real-time comments on the virtual welding operation can also be made to user 14 via the welding user interface 16. Consequently, the simulated welding activity of user 14 in the real world translates into welding activity. virtual and is produced in real time. Depending on the usage in question, the expression "real time" means simultaneous perception and experience in a virtual environment that occurs in substantially the same way that an end user 14 would perceive and experience simultaneously in a real world scenario.
    [0030] Real-time feedback of the virtual welding operation can also be provided to the user via a front-mounted display device 18. The front-mounted display device 18 can be integrated into a welding helmet or alternatively be mounted separately as shown in FIG.1. The front-mounted display device 18 may include two high-contrast micro-screens capable of delivering fluid video in full motion in 2D modes and sequential video in sequential frames. Virtual images, video for example, from the virtual welding environment are provided and displayed on the front-mounted display device 18. A zoom mode can also be provided, allowing user 14 to simulate an adapter plate. The front-mounted display device 18 may additionally include speakers, allowing the user 14 to hear ambient sounds and sounds related to simulated welding. The front-mounted display device 18 operatively connects to a subsystem based on a programmable processor 12 via wired or wireless means.
    [0031] During training, user 14 performs simulated welding using an experimental welding tool 20. The experimental welding tool 20 can be shaped to be similar to a real-world welding tool, such as an electrode holder for manual welding or an arc welding torch. The experimental welding tool 20 can have the same shape, weight and / or feel as a real-world welding tool. The experimental welding tool 20 operatively connects to the subsystem based on a programmable processor 12 via wired or wireless means.
    [0032] When using the experimental welding tool 20, user 14 performs simulated welds on an experimental welding coupon, just like an experimental welding unicupom 22, 22a, 22b. As will be described in detail below, the experimental welding unicupom 22, 22a, 22b is structurally configured to receive a plurality of different types of simulated welds using the experimental welding tool 20. Conventional conventional welding coupons are configured to receive a type of welding simulated, like a horizontal fillet weld. Conversely, the experimental welding unicupons discussed here are configured to receive different types of simulated welds. Conventional experimental welding coupons must also be positioned correctly with respect to elements of a spatial tracking system, if the virtual welding system is to operate properly. Certain experimental weld unicupons 22, 22a, 22b discussed here have elements of the spatial tracking system integrated into them in a fixed positioning relationship with respect to the unicupom, so that the unicupom is inherently correctly positioned.
    [0033] As shown in Figs. 1 to 3, the virtual welding system 10 can include a case 24 for storing and transporting the components of the virtual welding system. Case 24 includes a cap 26 and a base 28. When the virtual welding system 10 is in use, the cap 26 of case 24 can be used as a support to support the experimental welding unit during simulated welding, while other components of the system, such as the subsystem based on a programmable processor or the welding interface with the user, remain on the base 28.
    [0034] Referring to Figs. 5-8, an exemplary experimental welding unit 22a is shown in several different perspectives. Experimental welding unicupom 22a allows a plurality of different welds to be simulated using the experimental welding tool. The experimental welding unit 22a includes a base 30 and first 32 and second 34 wall members that are perpendicular to the base and to each other. The base 30 and the first 32 and second 34 wall members provide outer surfaces of the experimental welding unicupom under which the welding simulation can take place. For example, a simulated linear fillet weld, such as a simulated horizontal fillet weld (for example, welding position 2F) can be performed along the intersection 33 of the base 30 and the first wall member 32. A different type Simulated linear fillet weld, like a simulated vertical fillet weld (for example, welding position 3F) can be performed along the intersection of the first 32 members of the wall and the second 34 members of the wall.
    [0035] The base 30 and the first 32 and second 34 wall members include the respective grooves 36, 38, 40 to simulate various groove welds. The base 30 forms a horizontal grooved surface that allows a flat groove weld (e.g., 1G welding position) to be simulated using the experimental welding tool. The first wall member 32 includes a horizontal groove 38 that allows a horizontal groove weld (e.g., welding position 2G) to be simulated. The second wall member 34 includes a vertical groove 40 that allows a vertical groove weld (e.g., welding position 3G) to be simulated. Therefore, the grooved base 30 and the first 32 and second 34 wall members allow at least five different types of welds to be simulated using the experimental welding tool (two types of fillet welds and three types of groove welds). In certain embodiments, additional welding operations can be simulated using the experimental welding unit 22a, such as a wear coating. Additionally, in certain embodiments, the experimental welding unicupom 22a can be repositioned (for example, turned upside down) to allow additional welding operations to be simulated, such as a linear fillet weld over head (for example, welding position 4F), a groove weld on the head (eg welding position 4G), a flat fillet weld (e.g. welding position 1F), etc.
    [0036] Experimental welding unicupom 22a may include a curved surface 42 that allows multiple pipe welds to be simulated. The base 30 of the experimental welding unit 22a projects over the curved surface 42, which allows a pipe fillet weld to be simulated along the intersection 43 of the curved surface and the base. The curved surface includes a curved groove 44, which allows a pipe groove weld (e.g., 2G weld position) to be simulated. In certain embodiments, the experimental welding unit 22a can be repositioned to allow additional pipe welds to be simulated, such as fixed horizontal welding positions (eg 5G welding position) or slanted (eg 6G welding position) .
    [0037] The experimental welding unicupom 22a includes a magnet source 46 that generates a magnetic envelope around the unicupom, so that the position of the experimental welding tool and, optionally, the front mounted display device can be traced. The experimental welding unit 22a can be made of a material, such as plastic, that will not substantially interfere with or distort the magnetic envelope. The magnet source 46 is activated by the programmable processor-based subsystem when simulated welding is performed. The magnetic envelope generated around the experimental welding unit 22a defines a three-dimensional space within which the user's activity, such as movements of the experimental welding tool and movements of the user's head (for example, viewing position) can be tracked.
    [0038] The magnet source 46 is attached to the experimental welding unit 22a in a fixed position known to the programmable processor-based subsystem, and the user does not need to manually and correctly position the experimental welding unit with respect to the magnet source 46 as in previous virtual welding systems. In the embodiment of Figs. 5 to 8, the magnet source 46 is attached to the outer surfaces of the experimental welding unit 22a. Alternatively, the experimental welding unit can form a case for the magnet source 46, and the magnet source can be located inside the experimental welding unit. In certain embodiments, the magnet source 46 may include one or more position sensors to determine the orientation of the experimental welding unit 22a. The orientation of the experimental welding unicupom 22a can be transmitted to the subsystem based on a programmable processor, so that the subsystem based on a programmable processor knows the orientation of the experimental welding unicupom 22a and which welds are being simulated. For example, based on the orientation of the experimental welding unicupom 22a, the programmable processor-based subsystem can distinguish between horizontal fillet weld and overhead fillet weld being simulated at the intersection of two surfaces (for example, at the intersection 33 of the base 30 and the first wall member 32).
    [0039] The experimental welding tool and the front-mounted display device can include sensors that react to the magnetic field generated by the magnet source 46, and can send relative position information corresponding to the subsystem based on a programmable processor. The sensors can include multiple induction coils aligned in cross spatial directions, which can be substantially and orthogonally aligned. The induction coils measure the resistance of the magnetic field in each of the three directions and thus can generate information about the position that is provided to the subsystem based on a programmable processor. The programmable processor-based subsystem can include appropriate electronics, which can be in the form of a stand-alone module, for activation and control of the magnet source 46 and reception / interpretation of the position information from the position sensors in the experimental welding tool and the front-mounted display device.
    [0040] The programmable processor-based subsystem can simulate the various surfaces of the experimental welding unit 22a in the virtual reality space and track the user's movements in the real world and translate them into corresponding movements in the virtual reality space. This interactive virtual reality welding environment can be displayed to the user according to the user's current physical visualization perspective.
    [0041] Referring to Figs. 9 to 12, another embodiment of an experimental welding unicupon 22b is shown. In the modality of the experimental welding unicupom 22b shown in Figs. 9 to 12, the experimental welding unit is located on top of the magnet source 46a, which provides a basis for the experimental welding unit. The experimental welding unicupom 22b is generally in cubic shape with several outer surfaces that have grooves or projecting portions that allow different types of welds to be simulated.
    [0042] The upper surface 50 of the experimental welding unit 22b has a horizontal groove 52 and a cylindrical portion projected upwards 54. The horizontal groove 52 allows a flat groove weld (for example, welding position 1G) to be simulated using the experimental welding tool. The cylindrical portion 54 allows a pipe fillet weld to be simulated along the intersection 55 of the cylindrical portion and the upper surface 50. The cylindrical portion 54 could include a circumferential groove (not shown) to allow a pipe groove weld. (for example, 2G welding position) is simulated.
    [0043] A first vertical surface 56 of the experimental welding unit 22b may include a horizontal tongue 58 projecting outwardly from the first vertical surface. A simulated horizontal fillet weld (for example, welding position 2F) can be performed along the intersection 59 of the upper surface of the horizontal tongue 58 and the first vertical surface 56. A fillet weld on a simulated head (for example, welding position) welding 4F) can be carried out along the intersection of the lower surface of the horizontal tongue 58 and the first vertical surface.
    [0044] A second vertical surface 60 of the experimental welding unit 22b may include a vertical tongue 62 projecting outwardly from the second vertical surface. Simulated vertical fillet welds (for example, welding position 3F) can be performed along the intersections 63 of the vertical tongue 62 and the second vertical surface, on both sides of the vertical tongue 62.
    [0045] A third vertical surface 64 of the experimental welding unit 22b may include a vertical groove 66 that allows a vertical groove weld (e.g., welding position 3G) to be simulated.
    [0046] A fourth vertical surface 68 of the experimental welding unit 22b may include a horizontal groove 70 which allows a horizontal groove weld (e.g., 2G welding position) to be simulated.
    [0047] In this way, the experimental welding unicupom 22b is configured to simulate a plurality of different types of welds (for example, flat groove weld, vertical groove weld, horizontal groove weld, tube fillet weld, horizontal fillet, and fillet weld over head) using only an experimental welding coupon. As discussed above, the magnet source 46a is attached to the experimental welding unit 22b in a fixed position known to the subsystem based on a programmable processor and the user does not need to manually and correctly position the experimental welding unit with respect to the magnet source. . In addition, the magnet source 46a is mounted at the bottom of the experimental welding unit 22b and acts as a base for the experimental welding unit. The vertical surfaces 56, 60, 64, 68 project upwardly from the magnet source 46a and are supported on top of the magnet source when the unicupom 22b is in use.
    [0048] In certain embodiments, the experimental welding unicupom 22b includes multiple grooves and / or tongues on the same surface of the unicupom, so that several different welds can be simulated using the same side of the experimental welding unicupom. For example, a vertical side of the experimental welding unicupom 22b can include both horizontal 58 and vertical 62 tongues so that the horizontal, vertical and overhead fillet tongues can be simulated on a common side of the experimental welding unicupom.
    [0049] With reference to Figs. 13 to 16, yet another embodiment of an experimental welding unicupon 22c is shown. The experimental welding unicupom 22c can include various projections, tongues and cylindrical grooves, as discussed above to simulate a plurality of different welds using an experimental welding unicupom.
    [0050] In the mode of the experimental welding unicupom 22c shown in Figs. 13 to 16, the experimental welding unicupom is removably mounted on a support 72. The support includes an arm 74, and the experimental welding unicupom 22c includes a collar 76 that slides to the end of the arm 74. The welding unicupom experimental 22c can include a fastener as a fixing screw, to attach the unicupom to arm 74. In certain embodiments, the experimental welding unicupom 22c can be rotated on arm 74, so that different welds can be simulated. For example, the experimental welding unicupom 22c can be rotated at 45 °, 90 °, 180 °, etc., which changes the orientation of several welds that can be simulated. For example, the vertical groove 75 shown in Fig. 14 can be rotated in a horizontal position as shown in Fig. 15, so that both vertical groove welds and a flat groove weld can be simulated using the same grooved surface. Similarly, the downwardly protruding tongue 77 can allow welds on heads to be simulated when the experimental welding unicupom 22c is positioned as shown in Fig. 14, and vertical fillet welds to be simulated when the experimental welding unicupom is positioned as shown in Fig. 15.
    [0051] Collar 76 and arm 74 and support 72 can be switched to ensure that the experimental welding unit 22c is always correctly positioned on the support / arm.
    [0052] In certain embodiments, as shown in Fig. 16, the experimental welding unicupom 22c can alternatively be placed on top of the support 72, in order to allow different types of welds to be simulated. That is, the experimental welding unicupom 22c can be removed from the arm 74, and from the collar 76 in order to slide through the upper cylindrical end 78 of the support 72, to reconfigure the unicupom. The repositioning of the experimental welding unicupom 22c rotates the unicupom by 90 °, which alters the orientation of several welds that can be simulated. For example, the experimental welding unicupom 22c may include a cylindrical projection 80 that is oriented in an upward direction along a vertical geometric axis when the unicupom is mounted on the arm 74 and oriented laterally along a horizontal geometric axis when the unicupom is mounted on the end 78 of the support. Different types of pipe welds can be simulated by repositioning the experimental welding unicupom 22c from arm 74 to end 78 of the support. Similarly, different types of linear fillet welds can be simulated by repositioning the experimental welding unicupom 22c from the arm 74 to the end 78 of the support 72. For example, the downwardly protruding tongue 77 in Fig. 14 can allow fillet welds over heads to be simulated when the experimental welding unicupom 22c is located on arm 74. When the experimental welding unicupom 22c is moved to the end 78 of the support 72 as shown in Fig. 16, the same tongue it will project horizontally allowing a horizontal fillet weld to be simulated. Different types of groove welding can also be simulated by repositioning the experimental welding unit 22c from the arm 74 to the end 78 of the support. For example, the vertical groove 75 shown in Fig. 14 can allow a vertical groove weld to be simulated when the experimental welding unicupom 22c is located on arm 74. When the experimental welding unicupom 22c is moved to the end 78 of the holder 72 as shown in Fig. 16, the same groove will be oriented horizontally, allowing a horizontal groove weld to be simulated.
    [0053] In addition to having grooves, projections, tongues, etc. for the simulation of different welds, the experimental welding unicupom 22c shown in Figs. 13 to 16 have holes 82, 84 of various diameters and stepped portions 86, 88. Holes 82, 84 allow plug welds to be simulated, while stepped portions 86, 88 allow overlapping welds to be simulated. It is found that the experimental welding unicupons 22a, 22b shown in Figs. 5 to 12 could have similar holes and staggered portions, if desired, to allow plug and overlap welds to be simulated.
    [0054] In the mode shown in Figs. 13 to 16, the magnet source 46b is not directly attached to the experimental welding unicupom 22c. Instead, the magnet source 46b is attached to the support 72 (for example, attached to the 74) that supports the experimental welding unit 22c. The magnet source 46b can be configured to generate a magnetic envelope that is large enough to encompass the experimental welding unicupom 22c if it is mounted on arm 74 or at the end 78 of the holder. Both the experimental welding unicupom 22c, the magnet source 46b or the holder 72 can be configured to inform the programmable processor-based subsystem about the location of the unicupom in the holder (that is, whether the unicupom is mounted on arm 74 or at the end 78), via wired or wireless communications. For example, unicupom 22c or support 72 may include limit breakers or another type of sensor to identify the position of the unicupom in the support.
    [0055] As discussed above with respect to figure 4, the virtual welding system 10 includes a programmable processor-based subsystem 12 that is operable to execute coded instructions to generate the interactive virtual reality welding environment that simulates virtual activity welding on a virtual reality welding unit that corresponds to the experimental welding unit. The interactive virtual reality welding environment includes a virtual welding pod over the virtual welding unicupom (corresponding to the experimental welding unicupom). The virtual weld pudding is generated by the subsystem based on a programmable processor 12 in real time in response to the simulated welds of the user in the experimental welding unicupom based on the current welding parameters (eg voltage, current, waveforms, polarity, etc.) .). The interactive virtual reality welding environment generated by the programmable processor-based subsystem 12, and the simulated results of the user's virtual welding activity are displayed to the user and reproduced sonically via the welding user interface 16 and / or the display device front-mounted 18. The virtual welding system can simulate a real welding operation by representing the interactive virtual reality welding environment, including the virtual welding pod in the virtual welding unit, in real time.
    [0056] Virtual weld pudding can include real-time dynamic characteristics of molten metal fluidity and heat absorption and dissipation that are displayed to the user during simulated welding. Bead and puddle images are driven by the state of a welding pixel displacement map (wexel), (that is, welding element), which is further discussed below. To simulate dynamic weld pudding and display its characteristics, the programmable processor-based subsystem 12 can employ the physical welding functionality or a physical model of the welding process and the experimental welding unicupom. The physical functionality of the welding employs a double layer displacement technique to accurately model dynamic fluidity / viscosity, solidity, heat gradient (heat absorption and dissipation), weakening of pudding and shape of the bead.
    [0057] The programmable processor-based subsystem 12 can additionally employ the bead delivery functionality to deliver a weld bead in all states from the heated molten state to the cooled solidified state. The bead delivery functionality uses information from the physical welding functionality (for example, heat, fluidity, displacement, dimensional tolerance (dime spacing) to accurately and realistically deliver a weld bead in real-time virtual reality space) .
    [0058] Additional textures (for example, acicular crystallization, slag, granulation) can be superimposed on the simulated weld bead, and various characteristics, such as sparks, speckles, smoke, arc luminescence, vapors, and discontinuities, such as recess and porosity, can be provided and displayed to the user.
    [0059] Through the simulation of welds on the experimental welding unicupom, the user can visualize the weld pudding in the virtual reality space and modify its welding technique in response to the visualization of several characteristics of the simulated weld pudding, including fluidity of molten metal (eg viscosity) and heat dissipation in real time. The user can also view and respond to other features including wake groove and dimensional tolerance (dime spacing) in real time. Visualizing and responding to the characteristics of weld pudding is like many welding operations that are actually performed in the real world. The modeling of the double displacement layer of the weld's physical functionality allows for the characteristics of heat dissipation and fluidity of the molten metal in real time to be modeled and represented to the user with precision. For example, heat dissipation determines the solidification time (for example, how long it takes for a wexel to solidify completely).
    [0060] In addition, the user can make a second pass over the weld material of the bead using the same (for example, a second) experimental welding tool, welding electrodes and / or welding process. In a second pass scenario, the simulation shows the simulated experimental welding tool, the experimental welding unicupom and the original simulated weld bead material in the virtual reality space as the simulated experimental welding tool deposits a second bead material. simulated weld in fusion with the first simulated weld bead material by forming a second simulated weld puddle in the vicinity of a simulated arc emitted from the simulated experimental welding tool. Additional and subsequent passes using the same or different welding tools or processes can be done in a similar way. In a second or subsequent pass, the previous weld bead material is merging with the new weld bead material being deposited as a new weld puddle formed in the virtual reality space by combining any of the bead materials of the previous weld, the new weld bead material and possibly the adjacent unicupom material. Such a subsequent pass can be performed to repair a weld bead formed by a previous pass, for example, or it can include a heat pass and one or more span closing passes after a root pass, as is done in the welding of pipe. According to various modalities, the weld bead and base material can be simulated to include mild steel, stainless steel and aluminum. For example, the experimental welding unicupom can be described in the virtual reality space to appear as mild steel, stainless steel and aluminum, and characteristics of virtual weld pudding (for example, heating or cooling) can be controlled properly.
    [0061] The experimental welding unicupom exists in the real world as, for example, a plastic part and also exists in the virtual reality space (for example, in the interactive virtual reality welding environment as a virtual welding unicupom). Within the programmable processor-based subsystem 12, the simulated surfaces of the virtual welding unit that correspond to the real surfaces of the experimental welding unit are broken into a grid or a set of welding elements, called weld pixels (“wexels”) forming a map of wexel. Each wexel defines a small portion of the surface of the experimental welding unit. The wexel map defines the surface resolution. Changeable channel parameter values are assigned to each wexel, allowing the values of each wexel to change dynamically in real time in the interactive virtual reality welding environment during simulated welding. Changeable channel parameter values correspond to channel puddings (molten metal fluidity / viscosity displacement), heat (heat absorption / dissipation), displacement (solid displacement), and Extra (various extra states, for example, slag, grain, acicular crystallization, primary metal). These changeable channels can be called PHED for pudding, heat, extra, and displacement, respectively.
    [0062] The puddle channel stores a displacement value for any liquefied metal at the wexel location. The displacement channel stores a displacement value for the solidified metal at the wexel location. The heat channel stores a value by assigning the heat magnitude to the wexel location. In this way, the weldable part of the unicupom may show displacement due to the welded bead, a diffuse surface puddling due to the liquid metal, coloring due to heat, etc.
    [0063] A displacement map and a particle system can be used in which the particles can interact with each other and collide with the displacement map. The particles are fluid and dynamic virtual particles and provide the liquid behavior of the weld pudding but are not delivered directly (for example, they are not viewed directly). Instead, only the effects of the particle on the displacement map are visualized. The entry of heat into a wexel affects the movement of nearby particles. There are two types of displacement involved in the simulation of a welding puddle which includes pudding and displacement. Pudding is "temporary" and only lasts as long as particles and heat are present. The displacement is “permanent”. The displacement of the pudding is the liquid metal of the weld which changes rapidly (for example, flickers) and it can be felt that it is “above” the displacement. The particles cover a portion of a virtual surface displacement map (for example, a wexel map). The displacement represents the permanent solid metal that includes both the starting base metal and the weld bead that has solidified.
    [0064] According to an exemplary modality, the simulated welding process in the virtual reality space works as follows: particles are transmitted from an emitter (emitter of the simulated experimental welding tool) in a thin cone. The particles make the first contact with the surface of the experimental welding unicupom where the surface is defined by a wexel map. The particles interact with each other and the wexel map and are constituted in real time. The closer a wexel is to the emitter, the more heat is added. Heat is modeled depending on the distance from the arc point and the amount of time that heat is admitted from the arc. Some images (for example, color, etc.) are revealed by heat. The weld pudding is loaded or delivered to the virtual reality space so that the wexels have sufficient heat. Regardless of whether it is hot enough, the wexel map liquefies, causing the displacement of the puddling to “grow” towards these wexel locations. The displacement of the pudding is determined by sampling the “tallest” particles at each wexel location. As the emitter moves along the weld path, the wexel locations left behind cool. Heat is removed from a wexel location at a particular rate. When a cooling limit is reached, the wexel map solidifies. In this way, the displacement of the pudding is gradually converted into displacement (for example, a solidified cord). The displacement added is equivalent to the stripping removed so that the overall height does not change. The particle longevity is adjusted to persist until solidification is complete. Certain properties of the particles that can be modeled include attraction / repulsion, velocity (related to heat), exhalation (related to heat dissipation) and direction (related to gravity).
    [0065] Figures 17a to 17c illustrate an exemplary modality of the concept of a double displacement or dual puddle model (displacement and particles) used by the virtual welding system. The experimental welding unicupom that has a plurality of surfaces as described above are simulated in the virtual reality welding environment. The surfaces described above (for example, horizontal grooved surface, vertical grooved surface, curved grooved surface, overlapping surfaces, etc.) are simulated in the virtual reality welding environment as double displacement layers that have a solid displacement layer and a layer of displacement of pudding. The displacement layer of the pudding is capable of modifying the solid displacement layer.
    [0066] As described here, “pudding” is defined by an area of the wexel map where the value of the pudding has increased due to the presence of particles. The sampling process is shown in Figs. 17a to 17c. A section of a wexel map is shown having seven adjacent wexels. Actual displacement values are represented by 1710 non-shaded rectangular bars at a given height (for example, a given displacement for each wexel). In Fig. 17a, particles 1720 are shown as round, shaded dots that collide with actual displacement levels and are stacked. In Fig. 17b, the heights of the highest particles 1730 are sampled at each wexel location. In figure 17c, the shaded rectangles 1740 show how many puddles have been added at the top of the displacement as a result of the particles. The height of the weld pudding is not instantly set to the sample values as long as the pudding is added at a particular liquefaction rate based on heat. Although not shown in Figs. 17a to 19c, it is possible to visualize the solidification process as the pudding (shaded rectangles) gradually shrinks and the displacement (non-shaded rectangles) gradually increases from below to exactly take the place of pudding. In this way, the fluidity characteristics of the metal in real time are precisely simulated. As a user practices a particular welding process, the user can observe the fluidity characteristics of the molten metal and the heat dissipation characteristics of the weld pudding in real time in the virtual reality space and use this information to adjust or maintain their technique. welding.
    [0067] The number of wexels representing the surface of an experimental welding unicupom is fixed. In addition, the particles of pudding that are generated by the simulation to model the fluidity are temporary, as described here. Therefore, since an initial pudding is generated in the virtual space during a simulated welding process, the number of wexels added to the pudding particles tends to remain relatively constant. This is because the number of wexels that are being processed is fixed and the number of pudding particles that exist is being processed during the welding process, it tends to remain relatively constant because the pudding particles are being "created" and "destroyed" at a similar rate (for example, the particle particles are temporary). Therefore, the processing load of the programmable processor-based subsystem remains relatively constant during a simulated welding session.
    [0068] It is evident that this revelation is by way of example and that several changes can be made by adding, modifying or deleting details without leaving the fair scope of the teaching contained in this description. The invention, therefore, is not limited to the particular details of this description as long as the following claims are not necessarily so limited. NUMERICAL REFERENCES 10 virtual welding system 12 subsystem 14 user 16 welding interface with user 18 display device 20 experimental welding tool 22 experimental welding unit 22a experimental welding unit 22b experimental welding unit 22c experimental welding unit 24 case 26 cover 26 28 base 30 base 32 first wall 33 intersection 34 second wall 36 groove 38 groove 40 groove 42 curved surface 43 intersection 44 curved groove 46 magnet source 46a magnet source 46b magnet source 50 upper surface 52 horizontal groove 54 cylindrical portion projected upwards 55 intersection 56 first vertical surface 58 horizontal tongue 60 second vertical surface 62 vertical tongue 63 intersection 64 third vertical surface 66 vertical groove 68 fourth vertical surface 70 horizontal groove 72 bracket 74 arm 75 vertical groove 76 collar 77 tongue projected down 78 upper cylindrical end 80 pr cylindrical ejection 82 orifice 84 orifice 86 staggered portion 88 staggered portion 1710 rectangular bars 1720 particles 1730 particle height 1740 shaded rectangles
    权利要求:
    Claims (16)
    [0001]
    1. EXPERIMENTAL WELDING UNICUPOM (22, ...) FOR A VIRTUAL WELDING SYSTEM, characterized by comprising: a first outer surface; a second outer surface perpendicular to the first outer surface, where the first outer surface and the second outer surface together provide a plurality of grooves (36, 38, 40, ...) configured for simulating a plurality of different types of welds of groove on the experimental welding unicupom; an outer curved surface (42, ...) configured for the simulation of a tube fillet weld in the experimental welding unicupom; and a magnet source (46) configured to generate a magnetic field around the experimental welding unit (22, ...) to track movements of an experimental welding tool with respect to the experimental welding unit.
    [0002]
    2. EXPERIMENTAL WELDING UNICUPOM, according to claim 1, characterized in that the magnet source is a base for the experimental welding unicupom, and supports the first and second outer surfaces on top of the base.
    [0003]
    3. EXPERIMENTAL WELDING UNICUPOM, according to claim 1, characterized in that the magnet source is attached to one or more outer surfaces of the experimental welding unicupom.
    [0004]
    4. UNICUPOM OF EXPERIMENTAL WELDING, according to any one of claims 1 to 3, characterized in that said and / or additional surfaces of the experimental welding unicupom are configured together to facilitate the simulation of each one of a vertical groove weld, a weld horizontal groove, flat groove weld, horizontal fillet weld and vertical fillet weld.
    [0005]
    5. EXPERIMENTAL WELDING UNICUPOM, according to any one of claims 1 to 3, characterized in that said and / or additional surfaces of the experimental welding unicupom are configured together to facilitate the simulation of each of a vertical groove weld, a weld with a flat groove and a fillet weld over the head.
    [0006]
    6. VIRTUAL WELDING SYSTEM, characterized by comprising: an experimental welding tool (20) to perform simulated welds; an experimental welding unit (22, ...) configured to receive a plurality of different types of simulated welds using the experimental welding tool, in which the experimental welding unit comprises at least one grooved surface and at least one curved surface, wherein the plurality of different types of simulated welds includes: a pipe fillet weld; a groove weld; and a linear fillet weld, a subsystem based on a programmable processor that can be operated to execute coded instructions to generate an interactive virtual reality welding environment that simulates welding activity on a virtual welding unicupom that corresponds to the experimental welding unicupom, where the interactive virtual reality welding environment includes a virtual welding pod in the virtual welding unicupom generated in real time in response to simulated welds on the experimental welding unicupom; and a display device (18) operatively connected to the subsystem based on a programmable processor and configured to visually represent the interactive virtual reality welding environment, including the virtual welding pod in the virtual welding unicupom, in real time.
    [0007]
    7. VIRTUAL WELDING SYSTEM, according to claim 6, characterized in that the experimental welding unit comprises a magnet source (46) attached to the experimental welding coupon and configured to generate a magnetic field around the experimental welding unit to track movements of the experimental welding tool with respect to the experimental welding unit during simulated welding.
    [0008]
    8. VIRTUAL WELDING SYSTEM, according to either of claims 6 or 7, characterized in that the magnet source is a base of the experimental welding unit configured to support said surfaces above the magnet source when the experimental welding unit is in operation. use.
    [0009]
    9. VIRTUAL WELDING SYSTEM, according to any one of claims 6 to 8, characterized in that the experimental welding unit includes a tongue configured to receive both a simulated horizontal fillet weld and an overhead fillet weld.
    [0010]
    10. VIRTUAL WELDING SYSTEM, according to any one of claims 6 to 9, characterized in that the experimental welding unit has a plurality of holes configured to receive simulated plug welds and / or to be additionally configured to receive a simulated superimposed weld.
    [0011]
    11. VIRTUAL WELDING SYSTEM, according to any one of claims 6 to 10, characterized in that the virtual weld pudding includes dynamic real-time characteristics of molten metal fluidity and heat dissipation that are displayed on the display device during welding simulated.
    [0012]
    12. VIRTUAL WELDING SYSTEM, characterized by comprising: an experimental welding tool (20) to perform simulated welds, in which the experimental welding tool comprises a magnetic field sensor; an experimental welding unicupom (22, ...) configured to receive a plurality of different types of simulated welds using the experimental welding tool, in which the experimental welding unicupom comprises a magnet source configured to generate a magnetic field around of the experimental welding unit for tracking movements of the experimental welding tool in relation to the experimental welding unit, in which the magnet source is attached to the unit in a fixed position, and in which the experimental welding unit additionally comprises at least a vertical grooved surface, at least one horizontal grooved surface and at least one curved surface, wherein the plurality of different types of simulated welds include: a pipe fillet weld; a vertical groove weld; a horizontal groove weld; a flat groove weld; a horizontal fillet weld; and a pipe groove weld or a head fillet weld; a subsystem based on a programmable processor that can be operated to execute coded instructions to generate an interactive virtual reality welding environment that simulates welding activity on a virtual welding unicupom that corresponds to the experimental welding unicupom, in which the welding environment of interactive virtual reality includes a virtual weld pudding in the virtual welding unicupom generated in real time in response to simulated welds on the experimental welding unicupom, and in which the virtual weld pudding includes real-time dynamic characteristics of molten metal fluidity and heat dissipation; and a display device operatively connected to the subsystem based on a programmable processor and configured to visually represent the interactive virtual reality welding environment, including the virtual welding pod in the virtual welding unicupom, in real time.
    [0013]
    13. VIRTUAL WELDING SYSTEM, according to claim 12, characterized in that the magnet source is a base of the experimental welding unicupom configured to support said surfaces above the magnet source when the experimental welding unicupom is in use.
    [0014]
    14. VIRTUAL WELDING SYSTEM, according to either of claims 12 or 13, characterized in that the experimental welding unit is additionally configured to receive a simulated vertical fillet weld.
    [0015]
    VIRTUAL WELDING SYSTEM, according to either of claims 6 or 12, characterized in that the at least one vertical grooved surface, the at least one horizontal grooved surface and at least one curved surface are respectively simulated in the working environment. interactive virtual reality welding as double displacement layers, where each double displacement layer includes a solid displacement layer and a displacement displacement layer and where the displacement displacement layer is capable of modifying the displacement layer of solid.
    [0016]
    16. VIRTUAL WELDING SYSTEM, according to any one of claims 12 to 15, characterized in that the real-time dynamic characteristics of molten metal fluidity and heat dissipation are displayed on the display device during simulated welding.
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    同族专利:
    公开号 | 公开日
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    法律状态:
    2020-05-05| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|
    2020-12-08| B09A| Decision: intention to grant|
    2021-02-09| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 30/06/2015, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US14/331,402|US8992226B1|2014-07-15|2014-07-15|Unicoupon for virtual reality welding simulator|
    US14/331,402|2014-07-15|
    PCT/IB2015/001084|WO2016009260A1|2014-07-15|2015-06-30|Unicoupon for virtual reality welding simulator|
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