System and method of tracking a welding tool and providing feedback

Abstract

A welding system includes one or more sensing devices used to detect and/or determine a position and/or orientation of a welding tool (e.g., a welding torch). The welding tool may be tracked to determine (and/or calibrate) a shape of a welding joint and/or a path of the welding joint. The welding system may determine a virtual line representative of the welding joint. The welding tool may be tracked (and/or the virtual line used) to determine (and/or provide feedback relating to) various welding parameters, including at least a work angle of the welding tool, and/or a travel angle of the welding tool.

1 . A method, comprising:
 tracking, via processing circuitry, tool positions and a tool orientation of a welding tool using sensor data detected by a sensor system;   determining, via the processing circuitry, a joint characteristic of a welding joint based on the tool positions of the welding tool; and   identifying, via the processing circuitry, a parameter value based on the joint characteristic and the tool orientation of the welding tool.   
     
     
         2 . The method of  claim 1 , wherein the parameter value comprises a travel angle value or work angle value of the welding tool. 
     
     
         3 . The method of  claim 1 , wherein the joint characteristic comprises a shape of the welding joint, a path of the welding joint, or a virtual line representative of the welding joint. 
     
     
         4 . The method of  claim 1 , wherein the method further comprises providing feedback, via a user interface, based on the parameter value. 
     
     
         5 . The method of  claim 4 , wherein the user interface comprises a display device, an audio device, or a vibration device. 
     
     
         6 . The method of  claim 1 , wherein the sensor system comprises an inertial measurement unit comprising an accelerometer, a gyroscope, or a magnetometer, and the sensor data comprises data detected by the inertial measurement unit. 
     
     
         7 . The method of  claim 1 , wherein the sensor system comprises a depth sensor, and the sensor data comprises data detected by the depth sensor. 
     
     
         8 . The method of  claim 7 , wherein tracking the tool positions and the tool orientation of the welding tool comprises emitting a visible pattern, via the depth sensor, and observing a reflection of the visible pattern. 
     
     
         9 . The method of  claim 1 , wherein the sensor system comprise a camera sensor, and the sensor data comprises image data detected by the camera sensor, the image data representative of one or more images. 
     
     
         10 . The method of  claim 1 , wherein tracking the tool positions and the tool orientation of the welding tool comprises identifying the tool position or the tool orientation based on a rigid body model of the welding tool, and an arrangement of markers shown on the welding tool in the one or more images. 
     
     
         11 . A weld monitoring system, comprising:
 a sensor system configured to detect sensor data pertaining to a welding tool; and   processing circuitry configure to:
 track tool positions and a tool orientation of the welding tool using the sensor data detected by the sensor system, 
 determine a joint characteristic of a welding joint based on the tool positions of the welding tool, and 
 identify a parameter value based on the joint characteristic and the tool orientation of the welding tool. 
   
     
     
         12 . The system of  claim 11 , wherein the parameter value comprises a travel angle value or work angle value of the welding tool. 
     
     
         13 . The system of  claim 11 , wherein the joint characteristic comprises a shape of the welding joint, a path of the welding joint, or a virtual line representative of the welding joint. 
     
     
         14 . The system of  claim 11 , further comprising a user interface configured to provide feedback, based on the parameter value. 
     
     
         15 . The system of  claim 14 , wherein the user interface comprises a display device, an audio device, or a vibration device. 
     
     
         16 . The system of  claim 11 , wherein the sensor system comprises an inertial measurement unit comprising an accelerometer, a gyroscope, or a magnetometer, and the sensor data comprises data detected by the inertial measurement unit. 
     
     
         17 . The system of  claim 11 , wherein the sensor system comprises a depth sensor, and the sensor data comprises data detected by the depth sensor. 
     
     
         18 . The system of  claim 17 , wherein depth sensor is configured to emit a visible pattern, and the processing circuitry is configured to track the tool positions or the tool orientation using an observed reflection of the visible pattern. 
     
     
         19 . The system of  claim 11 , wherein the sensor system comprise a camera sensor, and the sensor data comprises image data detected by the camera sensor, the image data representative of one or more images. 
     
     
         20 . The system of  claim 19 , wherein the processing circuitry is configured to track the tool positions or the tool orientation based on a rigid body model of the welding tool, and an arrangement of markers shown on the welding tool in the one or more images.