Welding simulator

Abstract

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

1 . A welding training device comprising:
 an input device which is manipulated by a user in three-dimensional space during a welding training exercise;   a tracking unit that tracks a position and orientation of said input device in said three-dimensional space, where said tracking unit includes at least one sensor which senses a movement of said input device, where said at least one sensor generates a sensor output which represents said position and orientation;   a processor based computing device which contains at least one predetermined welding performance parameter, said processor based computing device receives said sensor output and generates each of a visually represented weld bead and a visually represented welding tool based on said sensor output, and said processor based computing device uses said sensor output to generate a sensed welding parameter and compares said sensed welding parameter to said predetermined welding performance parameter to generate a performance guide for said user in real-time, where said sensed welding parameter is one of a pitch of said input device, a roll angle of said input device, a travel speed of said input device, or a contact tip to work distance of said input device;   a display coupled to said processor based computing device which displays said visually represented weld bead, said visually represented welding tool and said performance guide during said welding training exercise, where said performance guide is visually changed on said display device based on said comparison between said sensed welding parameter and said predetermined welding performance parameter; and   a weld coupon which is displayed on said display device as a visually represented workpiece for guiding said user during said welding training exercise while said user manipulates said input device in said three-dimensional space with respect to said welding coupon, and where said display device displays said visually represented weld bead on said visually represented workpiece during said welding training exercise.   
     
     
         2 . The welding training device of  claim 1 , wherein said input device resembles a welding tool. 
     
     
         3 . The welding training device of  claim 1 , wherein said input device comprises a switch that initiates and stops said welding training exercise. 
     
     
         4 . The welding training device of  claim 1 , wherein said at least one sensor is an optical sensor. 
     
     
         5 . The welding training device of  claim 1 , wherein said tracking unit is separate from said input device. 
     
     
         6 . The welding training device of  claim 1 , wherein said at least one sensor is positioned on said input device. 
     
     
         7 . The welding training device of  claim 1 , wherein said performance guide is visually changed in real-time based on said comparison. 
     
     
         8 . The welding training device of  claim 1 , wherein said performance guide changes color based on said comparison. 
     
     
         9 . The welding training device of  claim 1 , wherein said processor based computing device contains a plurality of predetermined welding performance parameters, said processor based computing device uses said sensor output to generate a plurality of sensed welding parameters and compares said sensed welding parameters to said predetermined welding performance parameters, respectively, to generate a plurality of performance guides in real-time, where said performance guides indicate, respectively, said pitch of said input device, said roll angle of said input device, said travel speed of said input device, and said contact tip to work distance of said input device. 
     
     
         10 . The welding training device of  claim 1 , wherein said processor based computing device generates a score based on said comparison. 
     
     
         11 . The welding training device of  claim 1 , wherein said display displays said visually represented workpiece in a completed weld state after said welding training exercise. 
     
     
         12 . The welding training device of  claim 1 , wherein a shape of said visually represented weld bead is determined by said processor based computing device based on said sensor output. 
     
     
         13 . The welding training device of  claim 1 , wherein said welding training device has a first mode of operation in which said at least one performance guide is visually displayed on said display and a second mode of operation where said performance guide is not display on said display during operation. 
     
     
         14 . The welding training device of  claim 1 , wherein said welding training device has a first weld training capability where said weld coupon is a lap joint weld coupon and a second weld training capability where said weld coupon is a pipe joint weld coupon. 
     
     
         15 . The welding training device of  claim 1 , wherein said processor based subsystem determines an overall score for said welding training exercise based on said comparison between said sensed welding parameter and said predetermined welding performance parameter. 
     
     
         16 . The welding training device of  claim 1 , wherein said processor based computing device further comprises a predetermined acceptable range of performance for said at least one predetermined welding performance parameter and determines whether said sensed welding parameter is within said predetermined acceptable range, and wherein said processor based computing device calculates a score for said sensed welding parameter based on said determination. 
     
     
         17 . The welding training device of  claim 1 , wherein said processor based computing device records and stores information regarding said welding training exercise, and associates said information to a specific user. 
     
     
         18 . The welding training device of  claim 1 , wherein said user can input a plurality of weld settings for said weld training exercise prior to initiation of said weld training exercise. 
     
     
         19 . The welding training device of  claim 18 , wherein said plurality of weld settings includes at least one of, or a combination of: electrode type, material type for said welding coupon, and weld joint type. 
     
     
         20 . A welding training device comprising:
 an input device which resembles a welding tool and which is manipulated by a user in three-dimensional space during a welding training exercise, said input device comprising a switch which initiates and stops said welding training exercise;   a tracking unit that tracks a position and orientation of said input device in said three-dimensional space, where said tracking unit includes at least one optical sensor which senses a movement of said input device, where said at least one optical sensor generates a sensor output which represents said position and orientation, and said tracking unit is separate from said input device;   a processor based computing device which contains at least one predetermined welding performance parameter, said processor based computing device receives said sensor output and generates each of a visually represented weld bead and a visually represented welding tool based on said sensor output, and said processor based computing device uses said sensor output to generate a sensed welding parameter and compares said sensed welding parameter to said predetermined welding performance parameter to generate a performance guide for said user in real-time, where said sensed welding parameter is one of a pitch of said input device, a roll angle of said input device, a travel speed of said input device, or a contact tip to work distance of said input device;   a display coupled to said processor based computing device which displays said visually represented weld bead, said visually represented welding tool and said performance guide during said welding training exercise, where said performance guide is visually changed on said display device based on said comparison between said sensed welding parameter and said predetermined welding performance parameter; and   a weld coupon which is displayed on said display device as a visually represented workpiece for guiding said user during said welding training exercise while said user manipulates said input device in said three-dimensional space with respect to said welding coupon, and where said display device displays said visually represented weld bead on said visually represented workpiece during said welding training exercise,   wherein said performance guide is visually changed in real-time based on said comparison.   
     
     
         21 . The welding training device of  claim 20 , wherein said performance guide changes color based on said comparison. 
     
     
         22 . The welding training device of  claim 20 , wherein said processor based computing device contains a plurality of said predetermined welding performance parameters, said processor based computing device uses said sensor output to generate a plurality of said sensed welding parameters and compares said sensed welding parameters to said predetermined welding performance parameters, respectively, to generate a plurality of said performance guides in real-time, where said performance guides indicate, respectively, said pitch of said input device, said roll angle of said input device, said travel speed of said input device, and said contact tip to work distance of said input device. 
     
     
         23 . The welding training device of  claim 20 , wherein said processor based computing device generates a plurality of scores for each of said sensed welding parameters based on said comparisons. 
     
     
         24 . The welding training device of  claim 20 , wherein said display displays said visually represented workpiece in a completed weld state after said welding training exercise is stopped with said switch. 
     
     
         25 . The welding training device of  claim 20 , wherein a shape of said visually represented weld bead is determined by said processor based computing device based on said sensor output. 
     
     
         26 . The welding training device of  claim 20 , wherein said welding training device has a first mode of operation in which said at least one performance guide is visually displayed on said display and a second mode of operation where said performance guide is not display on said display during operation. 
     
     
         27 . The welding training device of  claim 20 , wherein said welding training device has a first weld training capability where said weld coupon is a lap joint weld coupon and a second weld training capability where said weld coupon is a pipe joint weld coupon. 
     
     
         28 . The welding training device of  claim 20 , wherein said processor based subsystem determines an overall score for said welding training exercise based on said comparison between said sensed welding parameter and said predetermined welding performance parameter. 
     
     
         29 . The welding training device of  claim 20 , wherein said processor based computing device further comprises a predetermined acceptable range of performance for said at least one predetermined welding performance parameter and determines whether said sensed welding parameter is within said predetermined acceptable range, and wherein said processor based computing device calculates a score for said sensed welding parameter based on said determination. 
     
     
         30 . The welding training device of  claim 20 , wherein said processor based computing device records and stores information regarding said welding training exercise, and associates said information to a specific user. 
     
     
         31 . The welding training device of  claim 20 , wherein said user can input a plurality of weld settings for said weld training exercise prior to initiation of said weld training exercise. 
     
     
         32 . The welding training device of  claim 31 , wherein said plurality of weld settings includes at least one of, or a combination of: electrode type, material type for said welding coupon, and weld joint type. 
     
     
         33 . The welding training device of  claim 22 , wherein said processor based subsystem determines an overall score for said welding training exercise based on said comparison between said sensed welding parameters and said predetermined welding performance parameters.