U.S. patent application number 17/368935 was filed with the patent office on 2021-10-28 for system and method of exporting or using welding sequencer data for external systems.
The applicant listed for this patent is Lincoln Global, Inc.. Invention is credited to Joseph A. Daniel, Edward Enyedy, James Hearn.
Application Number | 20210331266 17/368935 |
Document ID | / |
Family ID | 1000005698928 |
Filed Date | 2021-10-28 |
United States Patent
Application |
20210331266 |
Kind Code |
A1 |
Daniel; Joseph A. ; et
al. |
October 28, 2021 |
SYSTEM AND METHOD OF EXPORTING OR USING WELDING SEQUENCER DATA FOR
EXTERNAL SYSTEMS
Abstract
The invention described herein generally pertains to a system
and method for collecting one or more welding parameters in real
time during creation of one or more welds using a welding sequence.
The one or more welding parameters can be associated with a
particular welding sequence. Moreover, based on the one or more
welding parameters collected, a modeled welding parameter can be
generated to increase quality, efficiency, and the like. A
collection component collects real time welding parameter data from
which a quality manager component creates a modeled welding
parameter. The modeled welding parameter can be employed for the
welding sequence to monitor or track the welding parameter during a
subsequent weld.
Inventors: |
Daniel; Joseph A.; (Sagamore
Hills, OH) ; Enyedy; Edward; (Eastlake, OH) ;
Hearn; James; (Brunswick, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Lincoln Global, Inc. |
Santa Fe Springs |
CA |
US |
|
|
Family ID: |
1000005698928 |
Appl. No.: |
17/368935 |
Filed: |
July 7, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13803032 |
Mar 14, 2013 |
11072034 |
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17368935 |
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11613652 |
Dec 20, 2006 |
9104195 |
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13803032 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B23K 9/0953 20130101;
G05B 2219/45135 20130101; G05B 2219/35529 20130101; G05B 2219/35528
20130101; Y02P 90/02 20151101; G05B 19/4183 20130101 |
International
Class: |
B23K 9/095 20060101
B23K009/095; G05B 19/418 20060101 G05B019/418 |
Claims
1-20. (canceled)
21. A welder system comprising: a welding job sequencer component
that is configured to identify a welding sequence for an operator
to use in a welding work cell, wherein the welding sequence defines
at least a parameter and a welding schedule for a first welding
procedure to create a first weld on a workpiece and a second
welding procedure to create a second weld on the workpiece; the
welding job sequencer component is further configured to utilize
the welding sequence in the welding work cell to automatically
configure welding equipment to perform the first welding procedure
and the second welding procedure on the workpiece without
intervention from the operator; and a collection component that is
configured to collect a real time welding parameter for at least
one of the first weld and the second weld, wherein the collection
component corresponds the real time welding parameter to the
identified welding sequence and at least one of the first weld and
the second weld.
22. The welder system of claim 1, further comprising a weld score
component that is configured to evaluate at least one of the first
weld and the second weld performed on the workpiece by the operator
based upon at least one of an image of the first weld, an image of
the second weld, an inspection of the first weld, and an inspection
of the second weld.
23. The welder system of claim 22, wherein the collection component
associates a portion of the evaluation to the identified welding
sequence and at least one of the first weld and the second
weld.
24. The welder system of claim 22, further comprising: a check
point component that is configured to monitor the operator and
creation of at least one of the first weld and the second weld in
real time using the welding sequence; and the collection component
associates a portion of the monitoring to the identified welding
sequence and at least one of the first weld and the second
weld.
25. The welder system of claim 24, further comprising: the welding
job sequencer component is further configured to communicate an
instruction to the operator of the welding work cell to assemble
the workpiece with the first welding procedure and the second
welding procedure having two separate welding schedules; and
wherein the instruction includes at least one of the portion of the
monitoring and the portion of the evaluation.
26. The welder system of claim 21, further comprising a quality
manager component that is configured to evaluate the real time
welding parameter for at least one of the first weld and the second
weld created with the welding sequence and identify a welding
parameter model.
27. The welder system of claim 26, wherein the welding parameter
model is based on an average of multiple measurements of the real
time welding parameter.
28. The welder system of claim 26, wherein the welding parameter
model is a defined range of values based on multiple measurements
of the real time welding parameter.
29. The welder system of claim 26, wherein the welding parameter
model includes a threshold tolerance based on multiple measurements
of the real time welding parameter.
30. The welder system of claim 26, wherein the collection component
associates the welding parameter model to the identified welding
sequence and at least one of the first weld and the second
weld.
31. The welder system of claim 26, wherein the quality manager
component is further configured to receive the real time welding
parameter to utilize as the welding parameter model.
32. The welder system of claim 31, further comprising a guide
component that is configured to collect a portion of media captured
during creation of the welding parameter model during at least one
of the first weld and the second weld.
33. The welder system of claim 32, wherein the guide component
displays the portion of media on an equipment of the operator as at
least one of a video, an audio clip, an image, a three-dimensional
(3D) image, and a hologram.
34. The welder system of claim 21, further comprising a
notification component that is configured to generate an alert to
the operator based on at least one of the welding sequence, a
performance of the first weld or the second weld, and a comparison
of the real time welding parameter with a welding parameter model
calculated based on historic welding parameter data for the welding
sequence.
35. The welder system of claim 34, wherein the notification
component is further configured to communicate the alert to the
operator based on an urgency of the alert or a condition within the
welding work cell.
36. A method of welding in a welding work cell, the comprising:
identifying a welding sequence for an operator to use in a welding
work cell, wherein the welding sequence defines a first welding
procedure that includes a first parameter to create a first weld on
a workpiece and a second welding procedure that includes a second
parameter to create a second weld on the workpiece; utilizing the
welding sequence to automatically modify a welding equipment within
the welding work cell without intervention from the operator
creating at least one of the first weld and the second weld;
collecting a welding parameter in real time during creation of at
least one of the first weld and the second weld; associating the
welding parameter to the welding sequence and at least one of the
first weld and the second weld; generating a welding parameter
model based on one or more welding parameters collected in real
time; and implementing the welding parameter model for the welding
sequence performed at a time after creation of at least one of the
first weld and the second weld.
37. The method of claim 36, further comprising displaying a portion
of media illustrating performance of the welding parameter
model.
38. The method of claim 37, wherein the portion of media is at
least one of an image, a video, a holographic image, a holographic
video, a three-dimensional (3D) image, and a 3D video.
39. The method of claim 36, further comprising: monitoring the
welding work cell to identify a condition related to at least one
of a noise level, an activity of the operator, and a location of
the operator; and communicating an alert to the operator based on
the condition, wherein the alert is based on at least one of the
welding sequence, a creation of an additional weld, and a real time
comparison of an additional weld created with the welding parameter
model.
40. A welder system comprising: means for identifying a welding
sequence for an operator to use in a welding work cell, wherein the
welding sequence defines a first welding procedure that includes a
first parameter to create a first weld on a workpiece and a second
welding procedure that includes a second parameter to create a
second weld on the workpiece; means for utilizing the welding
sequence to automatically modify a welding equipment within the
welding work cell without intervention from the operator creating
at least one of the first weld or the second weld; means for
collecting a welding parameter in real time during creation of at
least one of the first weld or the second weld; means for
associating the welding parameter to the welding sequence and at
least one of the first weld or the second weld; means for
generating a welding parameter model based on one or more welding
parameters collected in real time; and means for implementing the
welding parameter model for the welding sequence performed after at
least one of the first weld or the second weld.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S.
application Ser. No. 11/613,652, filed Dec. 20, 2006, and entitled
"WELDING JOB SEQUENCER." The entirety of the aforementioned
application is incorporated herein by reference.
TECHNICAL FIELD
[0002] Devices, systems, and methods consistent with the invention
relate to welding work cells.
BACKGROUND OF THE INVENTION
[0003] In the related art, work cells are used to produce welds or
welded parts. There are at least two broad categories of work
cells, including robotic work cells and semi-automatic work
cells.
[0004] In robotic work cells, the scheduling and performing of
welding operations is largely automated, with little operator
involvement. Thus, these cells generally have a relatively low
labor cost and a relatively high productivity. However, their
repeating operations cannot easily adapt to varying welding
conditions and/or sequences.
[0005] In contrast, semi-automatic work cells (i.e., work cells
involving at least some operator welding) generally provide less
automation vis-a-vis robotic work cells, and accordingly have a
relatively higher labor cost and a relatively lower productivity.
Nevertheless, there are many instances where using a semi-automatic
welding work cell can actually be advantageous over robotic work
cells. For example, a semi-automatic welding work cell can more
easily adapt to varying welding conditions and/or sequences.
[0006] Unfortunately, when welding more complex assemblies in
related art semi-automatic work cells, multiple different welding
schedules are often required for different types of welds on
different parts of an assembly. In many systems, when a different
welding schedule must be utilized, the operator is required to stop
welding operations and manually adjust the output of the
semi-automatic equipment according to the new schedule. In some
other systems, this manual adjustment is eliminated by storing
particular schedules in the work cell. Nevertheless, even in such
systems, the operator still needs to cease welding operations and
push a button to select the new welding schedule before he may
continue welding.
[0007] Neither of these practices for setting a different welding
schedule is particularly efficient. Thus, in practice, the number
of welding schedules used in a semi-automatic work cell is often
reduced in order to eliminate the need for constant adjustment of
the output of the semi-automatic equipment. While this reduction of
welding schedules makes the overall operation easier for the
welder, the forced simplification of this approach can lead to
reduced productivity and lower overall quality.
[0008] Additionally, when abiding by strict quality control
specifications, it is sometimes necessary to perform welds in a
specific sequence, verify that each weld is performed with a given
set of conditions, and monitor the output of the equipment during
the welding operations. In a robotic work cell, these requirements
are easily fulfilled. However, in a semi-automatic work cell, these
requirements are susceptible to human error, since the operator
must keep track of all of these aspects in addition to performing
the welding operations themselves.
[0009] An illustrative example of the above problems is shown in
the related art semi-automatic welding method diagrammatically
represented in FIG. 1. In this method, each of the various
scheduling, sequencing, inspection and welding operations are
organized and performed by the operator (i.e., the welder) himself.
Specifically, the operator begins the welding job at operation 10.
Then, the operator sets up the welding equipment according to
schedule A, at operation 20. Next, the operator performs weld #1,
weld #2, and weld #3 using welding schedule A at operations 22, 24
and 26. Then, the operator stops welding operations and sets up the
welding equipment according to schedule B at operation 30. Next,
the operator performs weld #4 using welding schedule B at operation
32. Then, the operator checks the dimensions of the assembly at
operation 40, and sets up the welding equipment according to
schedule C at operation 50. Next, the operator performs weld #5 and
weld #6 using welding schedule C at operations 52 and 54. After the
welding operations are completed, the operator visually inspects
the welded assembly at operation 60, and completes the welding job
at operation 70.
[0010] Clearly, the method shown in FIG. 1 depends on the operator
to correctly follow the predefined sequencing for performing welds
and inspections, to accurately change between welding schedules
(such as at operation 30), and to perform the welding itself.
Errors in any of these responsibilities can result either in rework
(if the errors are caught during inspection at operation 60) or a
defective part being supplied to the end user. Further, this
exemplary semi-automatic welding method hampers productivity,
because the operator must spend time configuring and reconfiguring
weld schedules.
[0011] The above problems demand an improvement in the related art
system.
SUMMARY OF THE INVENTION
[0012] In accordance with an embodiment of the present invention, a
welding system is provided that includes a welding job sequencer
component that is configured to identify a welding sequence for a
welding work cell, wherein the welding sequence defines at least a
parameter and a welding schedule for a first welding procedure to
create a first weld on a workpiece and a second welding procedure
to create a second weld on the workpiece. The welding job sequencer
component is further configured to utilize the welding sequence in
the welding work cell to automatically configure welding equipment
to perform the first welding procedure and the second welding
procedure on the workpiece without intervention from the operator.
In the embodiment, the welder system further includes a collection
component that is configured to collect a real time welding
parameter for at least one of the first weld or the second weld,
wherein the collection component corresponds the real time welding
parameter to the identified welding sequence and at least one of
the first weld or the second weld.
[0013] In accordance with an embodiment of the present invention, a
method of welding in a welding work cell with a welding sequence is
provided that includes at least the steps of: identifying a welding
sequence for an operator to use in a welding work cell, wherein the
welding sequence defines a first welding procedure that includes a
first parameter to create a first weld on a workpiece and a second
welding procedure that includes a second parameter to create a
second weld on the workpiece; utilizing the welding sequence to
automatically modify a welding equipment within the welding work
cell without intervention from the operator creating at least one
of the first weld or the second weld; collecting a welding
parameter in real time during creation of at least one of the first
weld or the second weld; associating the welding parameter to the
welding sequence and at least one of the first weld or the second
weld; generating a welding parameter model based on one or more
welding parameters collected in real time; and implementing the
welding parameter model for the welding sequence performed after at
least one of the first weld or the second weld.
[0014] In accordance with an embodiment of the present invention, a
welding system is provided that includes at least the following:
means for identifying a welding sequence for an operator to use in
a welding work cell, wherein the welding sequence defines a first
welding procedure that includes a first parameter to create a first
weld on a workpiece and a second welding procedure that includes a
second parameter to create a second weld on the workpiece; means
for utilizing the welding sequence to automatically modify a
welding equipment within the welding work cell without intervention
from the operator creating at least one of the first weld or the
second weld; means for collecting a welding parameter in real time
during creation of at least one of the first weld or the second
weld; means for associating the welding parameter to the welding
sequence and at least one of the first weld or the second weld;
means for generating a welding parameter model based on one or more
welding parameters collected in real time; and means for
implementing the welding parameter model for the welding sequence
performed after at least one of the first weld or the second
weld.
[0015] These and other objects of this invention will be evident
when viewed in light of the drawings, detailed description and
appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention may take physical form in certain parts and
arrangements of parts, a preferred embodiment of which will be
described in detail in the specification and illustrated in the
accompanying drawings which form a part hereof, and wherein:
[0017] FIG. 1 illustrates a welding operation of the related art
utilizing a semi-automatic welding work cell;
[0018] FIG. 2 illustrates a welding operation according to the
invention utilizing a semi-automatic welding work cell;
[0019] FIG. 3 is a block diagram illustrating a welding system that
utilizes a welding job sequencer component to configure welding
equipment for two or more weld operations to assembly a
workpiece;
[0020] FIG. 4 is a block diagram illustrating a welding system that
utilizes a welding job sequencer component;
[0021] FIG. 5 is a block diagram illustrating a distributed welding
environment with a plurality of welding work cells that interface
with a welding job sequencer component via a local, remote, or
cloud database;
[0022] FIG. 6 is a block diagram illustrating a welding system that
includes a plurality of welding work cells in which welding work
cells are managed by a cloud-based welding job sequencer
component;
[0023] FIG. 7 is a block diagram illustrating a system that
aggregates data associated with a welding operation performed with
a welding sequence;
[0024] FIG. 8 is a block diagram illustrating a system that
communicates a portion of media to an operator to facilitate
creating a weld with a welding procedure;
[0025] FIG. 9 is a block diagram illustrating a system that
communicates an alert to an operator performing one or more welds
using a welding sequence;
[0026] FIG. 10 is a block diagram illustrating a system that
delivers an alert to an operator creating a weld with a welding
sequence based on a condition within a welding work cell;
[0027] FIG. 11 is a flow diagram of identifying a welding parameter
model for a welding sequence based on one or more welding
parameters collected in real time for the welding sequence used to
create at least one weld; and
[0028] FIG. 12 is a flow diagram of creating a welding parameter
model for a welding sequence based on one or more parameters
collected from a previous welding operation that used the welding
sequence.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Embodiments of the invention relate to methods and systems
that relate to collecting one or more welding parameters in real
time during creation of one or more welds using a welding sequence.
The one or more welding parameters can be associated with a
particular welding sequence. Moreover, based on the one or more
welding parameters collected, a modeled welding parameter can be
generated to increase quality, efficiency, and the like. A
collection component collects real time welding parameter data from
which a quality manager component creates a modeled welding
parameter. The modeled welding parameter can be employed for the
welding sequence to monitor or track the welding parameter during a
subsequent weld.
[0030] According to an aspect of the invention, there is provided a
semi-automatic welding work cell including a welding job sequencer
that automatically selects a welding schedule for use by an
operator in the semi-automatic welding work cell.
[0031] According to another aspect of the invention, there is
provided a method of welding in a semi-automatic work cell,
including automatically selecting a welding schedule for use by an
operator in the semi-automatic welding work cell.
[0032] According to another aspect of the invention, there is
provided a welding production line including at least one
semi-automatic welding work cell, where the semi-automatic work
cell includes a welding job sequencer that automatically selects a
welding schedule for use by an operator therein.
[0033] According to another aspect of the invention, there is
provided a method of monitoring a welding production line,
including automatically selecting a welding schedule for use by an
operator in a semi-automatic welding work cell.
[0034] The term "component" as used herein can be defined as a
portion of hardware, a portion of software, or a combination
thereof. A portion of hardware can include at least a processor and
a portion of memory, wherein the memory includes an instruction to
execute.
[0035] The best mode for carrying out the invention will now be
described for the purposes of illustrating the best mode known to
the applicant at the time of the filing of this patent application.
The examples and figures are illustrative only and not meant to
limit the invention, which is measured by the scope and spirit of
the claims. Referring now to the drawings, wherein the showings are
for the purpose of illustrating an exemplary embodiment of the
invention only and not for the purpose of limiting same, FIG. 2 is
referenced. In an exemplary embodiment of the invention as
illustrated in FIG. 2, a welding job sequencer is provided. The
welding job sequencer improves the semi-automatic work cell of the
related art by increasing the productivity of the semi-automatic
work cell without compromising the number of weld schedules usable
therein. The welding job sequencer accomplishes this improvement by
implementing automatic changes in the semi-automatic work cell, and
by providing the operator with an array of commands and
instructions.
[0036] More specifically, in an exemplary embodiment, the welding
job sequencer automatically selects and implements a function of
the welding work cell. An example of such a function includes a
particular weld schedule to be used with the semi-automatic work
cell. In other words, the welding job sequencer may select a weld
schedule to be used for a particular weld, and modify the settings
of the semi-automatic work cell in accordance with the selected
weld schedule, automatically for the operator (i.e., without the
operator's specific intervention).
[0037] Additionally, in the exemplary embodiment, the welding job
sequencer may automatically indicate a sequence of operations that
the operator should follow to create a final welded assembly. In
conjunction with the automatic selection of welding schedules, this
indicated sequence allows an operator to follow the sequence to
create a final welded part, without having to spend time adjusting,
selecting, or reviewing each individual weld schedule and/or
sequence.
[0038] Accordingly, since the welding job sequencer sets up the
welding equipment and organizes the workflow, and since the
operator only performs the welding operations themselves, the
chance for error in the welding operation is greatly reduced, and
productivity and quality are improved.
[0039] The exemplary embodiment is diagrammatically represented in
FIG. 2. In FIG. 2, at operation 110, the welding job sequencer
begins operation, and immediately sets the welding equipment to use
weld schedule A (operation 120) and instructs the operator to
perform welds #1, #2 and #3. Then, the operator performs welds #1,
#2 and #3 using weld schedule A (operations 122, 124 and 126).
Next, the welding job sequencer sets the welding equipment to use
weld schedule B (operation 130), and instructs the operator to
perform weld #4. Then the operator performs weld #4 using weld
schedule B (operations 132). After completion of weld schedule B,
the welding job sequencer sets the welding equipment to use weld
schedule C (operation 150), and instructs the operator to perform
welds #5 and #6, and to inspect the part. Then, the operator
performs welds #5 and #6 (operations 152, and 154) using weld
schedule C, and inspects the completed part to confirm that it is
correct (operation 160). This inspection may include dimensional
verification, visual defect confirmation, or any other type of
check that might be needed. Further, operation 160 may include a
requirement that the operator affirmatively indicate that the
inspection is complete, such as by pressing an "OK" button, before
it is possible to proceed to the next operation. Lastly, the
welding job sequencer indicates that the welding operation is at an
end (operation 170), and re-sets for the next operation.
[0040] Accordingly, as noted above, the sequencing and scheduling
of welding operations is completed by the sequencer, and frees the
operator to focus on performing welds according to instruction.
[0041] The welding job sequencer may select and implement a new
function, such as the selection and implementation of weld
schedules A, B and C shown in FIG. 2, based upon various variables
or inputs. For example, the welding job sequencer may simply select
new weld schedules based upon a monitoring of elapsed time since
the beginning of the welding operations, or since the cessation of
welding (such as the time after weld #3 in FIG. 2 above).
Alternatively, the welding job sequencer may monitor the actions of
the operator, compare the actions to the identified sequence of
welds, and select new weld schedules appropriately. Still further,
various combinations of these methods, or any other effective
method, may be implemented, as long as the end effect is to provide
an automatic selection and implementation of a function, such as
the weld schedule, for use by the operator.
[0042] Parameters of the selected weld schedule may include such
variables as welding process, wire type, wire size, WFS, volts,
trim, which wire feeder to use, or which feed head to use, but are
not limited thereto.
[0043] While the above description focuses on the selection of a
weld schedule as a function which is automatically selected and
implemented, the welding job sequencer is not limited to using only
this function.
[0044] For example, another possible function that may be selected
and implemented by the welding job sequencer is a selection of one
of multiple wire feeders on a single power source in accordance
with the weld schedule. This function provides an even greater
variability in welding jobs capable of being performed by the
operator in the semi-automatic work cell, since different wire
feeders can provide a great variance of, for example, wire sizes
and types.
[0045] Another example of a function compatible with the welding
job sequencer is a Quality Check function. This function performs a
quality check of the weld (either during welding or after the weld
is completed) before allowing the job sequence to continue. The
quality check can monitor various welding parameters and can pause
the welding operation and alert the operator if an abnormality is
detected. An example of a welding parameter measurable by this
function would be arc data.
[0046] Another example of such a function would be a Repeat
function. This function would instruct the operator to repeat a
particular weld or weld sequence. An example of the use of this
function includes when the Quality Check function shows an
abnormality, or when multiple instances of the same weld are
required.
[0047] Another example of such a function would be a Notify Welder
function, which communicates information to the welder. This
function would display information, give an audible signal, or
communicate with the welder by some other means. Examples of use of
this function include an indication to the operator that he is free
to begin welding, or an indication that the operator should check
some portion of the welded part for quality purposes.
[0048] Another example of such a function would be a Enter Job
Information function. This function will require the welder to
enter information, such as the part serial number, a personal ID
number, or other special conditions before the job sequencer can
continue. This information could also be read from a part or
inventory tag itself through Radio Frequency Identification (RFID),
bar code scanning, or the like. The welding job sequencer could
then utilize the entered information for the welding operations. An
example of the use of this function would be as a predicate to the
entire welding operation, so as to indicate to the welding job
sequencer which schedules and/or sequences should be selected.
[0049] A further example of such a function would be a Job Report
function. This function will create a report on the welding job,
which could include information such as: the number of welds
performed, total and individual arc timing, sequence interruptions,
errors, faults, wire usage, arc data, and the like. An example of
the use of this function would be to report to a manufacturing
quality department on the efficiency and quality of the welding
processes.
[0050] A still further example of such a function would be a System
Check function. This function will establish whether the welding
job can continue, and could monitor such parameters as: wire
supply, gas supply, time left in the shift (as compared to the
required time to finish the job), and the like. The function could
then determine whether the parameters indicate that there is enough
time and/or material for the welding job to continue. This function
would prevent down-time due to material depletion, and would
prevent work-in-process assemblies from being delayed, which can
lead to quality problems due to thermal and scheduling issues.
[0051] Further, as mentioned above, the welding job sequencer may
select and implement a new function, based upon various variables
or inputs. These variables and inputs are not particularly limited,
and can even be another function. For example, another function
compatible with the welding job sequencer is a Perform Welding
Operation function. This function is designed to detect the actual
welding performed by the operator, and to report that welding so
that the welding job sequencer can determine whether to proceed
with further operations. For example, this function can operate by
starting when the operator pulls the trigger to start the welding
operation, and finishing when the operator releases the trigger
after the welding is complete, or after a predetermined period of
time after it starts. This function could end when the trigger is
released or it could be configured to automatically turn off after
a period of time, a quantity of wire, or an amount of energy is
delivered. This function may be used to determine when to select a
new function, such as a new weld schedule, as discussed above.
[0052] Still further, various semi-automatic and/or robotic work
cells can be integrated together on a single network, and the
sequencing of welding steps at a single work-cell can be fully
integrated into a complete production schedule, which itself can be
modified as needed to track variations in the production schedule.
Sequencing and/or scheduling information can also be stored in a
database, be stored by date as archival information, and be
accessed to provide various production reports
[0053] In an embodiment, a semi-automatic welding work cell for
welding an assembly defined by a plurality of welds can be
provided, the plurality of welds being defined by at least two weld
schedules can include welding equipment for use by a welding
operator to perform said plurality of welds and complete the
assembly with said welding equipment having a plurality of
functions. In the embodiment, the work cell can include a welding
job sequencer that automatically selects a welding schedule for use
by an operator in the semi-automatic welding work cell. In the
embodiment, the welding job sequencer can select the welding
schedule according to an elapsed time. In an embodiment, the
welding job sequencer can detect when the operator is conducting a
welding operation, and selects the welding schedule based upon that
detection. In the embodiment, the welding job sequencer can detect
when the operator is conducting a welding operation, and the
welding job sequencer selects the welding schedule according to an
amount of welding wire supplied for the welding operation. In the
embodiment, the welding job sequencer can detect when the operator
is conducting a welding operation, and the welding job sequencer
selects the welding schedule according to an amount of energy
supplied for the welding operation. In the embodiment, the welding
schedule includes information about at least one of a welding
process, wire type, wire size, WFS, volts, trim, wire feeder to
use, or feed head to use.
[0054] In an embodiment, the welding work cell can include the
welding job sequencer which select and implements at least one of a
plurality of functions to define at least a first weld schedule and
a second weld schedule from the at least two weld schedules so as
to organize a workflow for creating the welded assembly and
indicate to the welding operator a sequence of working operations
for completing the assembly. In the embodiment, the welding job
sequencer can automatically modify the welding equipment in
accordance with the workflow and sequence of the welding operations
without the welding operator intervening.
[0055] In the embodiment, the second weld schedule is defined
according to an elapsed time of the first weld schedule. In the
embodiment, the at least one function detects completion of said
first weld schedule by said operator and automatically changes from
said first weld schedule to said second weld schedule. In the
embodiment, at least one function detects when the operator is
conducting said first weld schedule, and said second weld schedule
is defined according to an amount of welding wire supplied for said
first weld schedule. In the embodiment, at least one function
detects when the operator is conducting said first weld schedule,
and said second weld schedule is defined according to an amount of
energy supplied for said first weld schedule. In the embodiment,
the at least one first weld set up parameter and said at least one
second weld set up parameter comprise at least one of a welding
process, wire type, wire size, WFS, volts, trim, wire feeder to
use, or feed head to use. In the embodiment, at least one first
weld set up parameter and said at least one second weld set up
parameter comprise a feeder for use by an operator in the
semi-automatic welding work cell. In the embodiment, at least one
function monitors quality measurables of said weld assembly,
wherein the quality measureables comprise at least information
about an arc used to form the weld created by the operator In the
embodiment, at least one function indicates information to the
operator in the semiautomatic welding work cell. In the embodiment,
at least one function accepts job information comprising at least a
part ID number, operator ID number, or welding instructions. In the
embodiment, at least one function produces a job report comprising
at least one of a number of welds preformed, total arc time,
individual arc time, sequence interruptions, errors, faults, wire
usage, arc data. In the embodiment, at least one function includes
a system check of said cell, the system check comprising at least a
detection of wire supply, gas supply, and time.
[0056] In the embodiment, the welding job sequencer can select a
welding sequence for use by the operator in the semi-automatic
welding work cell. In the embodiment, the welding job sequencer can
indicate the selected welding sequence to the operator in the
semi-automatic welding work cell. In the embodiment, the welding
job sequencer can select a wire feeder for use by an operator in
the semi-automatic welding work cell. In the embodiment, the
welding job sequencer can monitor quality measurables of a weld
created by the operator, wherein the quality measureables comprise
at least information about an arc used to form the weld created by
the operator. In the embodiment, the welding job sequencer can
indicate information to the operator in the semi-automatic welding
work cell. In the embodiment, the welding job sequencer can accept
job information comprising at least a part ID number, operator ID
number, or welding instructions. In the embodiment, the welding job
sequencer can produce a job report comprising at least one of a
number of welds preformed, total arc time, individual arc time,
sequence interruptions, errors, faults, wire usage, arc data. In
the embodiment, the welding job sequencer can perform a system
check comprising at least a detection of wire supply, gas supply,
and time.
[0057] In an embodiment, a method of welding in a semi-automatic
work cell can be provided that includes automatically selecting a
welding schedule for use by an operator in the semi-automatic
welding work cell. In the embodiment, the automatic selection can
be performed after an elapsed time. In the embodiment, the method
can include detecting when the operator is conducting a welding
operation, wherein the automatic selection is performed based upon
that detection. In the embodiment, the method can include detecting
when the operator is conducting a welding operation, wherein the
automatic selection is performed according to an amount of welding
wire supplied for the welding operation. In the embodiment, the
method can include detecting when the operator is conducting a
welding operation, wherein the automatic selection is performed
according to an amount of energy supplied for the welding
operation. In the embodiment, the welding schedule can include
information about at least one of a welding process, wire type,
wire size, WFS, volts, trim, wire feeder to use, or feed head to
use.
[0058] In the embodiment, the method can include selecting a
welding sequence for use by the operator in the semi-automatic
welding work cell. In the embodiment, the method can include
indicating the selected welding sequence to the operator in the
semi-automatic welding work cell. In the embodiment, the method can
include selecting a wire feeder for use by an operator in the
semi-automatic welding work cell. In the embodiment, the method can
include monitoring quality measurables of a weld created by the
operator, wherein the quality measureables comprise at least
information about an arc used to form the weld created by the
operator. In the embodiment, the method can include indicating
information to the operator in the semi-automatic welding work
cell. In the embodiment, the method can include accepting job
information comprising at least a part ID number, operator ID
number, or welding instructions. In the embodiment, the method can
include producing a job report comprising at least one of a number
of welds performed, total arc time, individual arc time, sequence
interruptions, errors, faults, wire usage, arc data. In the
embodiment, the method can include performing a system check
comprising at least a detection of wire supply, gas supply, and
time.
[0059] In an embodiment, a welding production line is provided with
at least one semi-automatic welding work cell, wherein the
semi-automatic work cell that includes a welding job sequencer that
automatically selects a welding schedule for use by an operator
therein. In the embodiment, the welding production line includes a
monitoring system that communicates with the welding job sequencer
to direct the welding job sequencer to automatically select the
welding schedule for use by the operator therein.
[0060] In an embodiment, a method of monitoring a welding
production line is provided that includes automatically selecting a
welding schedule for use by an operator in a semi-automatic welding
work cell. In the embodiment, the method can include directing the
welding job sequencer to automatically select the welding schedule
for use by the operator therein.
[0061] In an embodiment, a semi-automatic welding work cell is
provided that includes a welding job sequencer that automatically
selects a welding schedule for use by an operator in the
semi-automatic welding work cell. The automatic selection may be by
way of elapsed time, a detection of welding operations, a detection
of the amount of welding wire supplied for the welding operation,
or a detection of the amount of energy supplied for the welding
operation.
[0062] In an embodiment, a method of welding in a semi-automatic
work cell having welding equipment and a welding job sequencer to
complete an assembly defined by a plurality of welds can be
provided in which the plurality of welds can be defined by at least
two weld schedules. The embodiment can include at least the steps
of the following: implementing a welding equipment function with
the welding job sequencer to define from the at least two weld
schedules a first weld schedule having at least one first weld set
up parameter and at least one first weld instruction and a second
weld schedule having at least one second weld set up parameter and
at least one second weld instruction, at least one of the said
second weld set up parameter and said second weld instruction is
different from said first weld set up parameter and said first weld
instruction; indicating to a welding operator a sequence of welding
operations for completing the assembly based on said first and
second weld schedules; and automatically modifying said welding
equipment in accordance with said sequence of welding operations
for completing the assembly based on said first and second weld
schedules.
[0063] In the embodiment, the method can include defining said
second weld schedule is performed after an elapsed time defined by
said first weld schedule. In the embodiment, the method can include
detecting when the operator is conducting said first weld schedule,
wherein defining said second schedule is based upon that detection.
In the embodiment, defining said first and second weld schedules
can include defining an amount of welding wire supplied for the
welding operation. In the embodiment, defining said second weld
schedule is according to an amount of energy supplied for the
welding operation for said first weld schedule. In the embodiment,
defining at least one of the first and second weld schedules can
include selecting at least one of a welding process, wire type,
wire size, WFS, volts, trim, wire feeder to use, or feed bead to
use. In an embodiment, defining at least one of the first and
second weld schedules can include selecting a wire feeder for use
by an operator in the semi-automatic welding work cell. In an
embodiment, the method can include monitoring quality measurables
of a weld created by the operator, wherein the quality measureables
comprise at least information about an arc used to form the weld
created by the operator. In an embodiment, the method can include
indicating information to the operator in the semi-automatic
welding work cell. In an embodiment, the method can include
accepting job information comprising at least a part ID number,
operator ID number, or welding instructions. In an embodiment, the
method can include producing a job report comprising at least one
of a number of welds performed, total arc time, individual arc
time, sequence interruptions, errors, faults, wire usage, arc data
performing a system check comprising at least a detection of wire
supply, gas supply, and time.
[0064] In an embodiment, a welding production line is provided that
includes at least one semi-automatic welding work cell for welding
an assembly defined by a plurality of welds, the plurality of welds
being defined by at least weld schedules, the semi-automatic
welding work cell including welding equipment for use by a welding
operator to perform the plurality of welds and complete the
assembly, the welding equipment having a plurality of functions. In
the embodiment, the production line can include a welding job
sequencer which selects and implements at least one of the
plurality of functions to define at least a first and a second weld
schedule in a sequence of welding operations from the at least two
weld schedules to be used by said welding operator for completing
the weld assembly. In an embodiment, the production line can
include said first weld schedule contains at least one first weld
set up parameter and at least one first weld instruction for said
welding operator and said second weld schedule contains at least
one second weld set up parameter and at least one second weld
instruction for said welding operator, at least one of said first
weld set up parameter and said first weld instruction is different
from said second weld set up parameter and said second weld
instruction, said welding job sequencer automatically modifying
said welding equipment in accordance with said sequence of
operations without said welding operator intervention. In an
embodiment, the production line can include a monitoring system in
communication with the welding job sequencer to monitor completion
of the at least one weld instruction of each of the first and
second weld schedule.
[0065] In an embodiment, a method for monitoring a welding
production line in at least one semi-automatic welding work cell
for use by a welding operator to complete an assembly defined by a
plurality of welds, the plurality of welds being defined by at
least two weld schedules, the semi-automatic welding work cell
including welding equipment and a welding job sequencer. The method
can include at least the following steps: defining at least a first
and a second weld schedule in a sequence of welding operations from
the at least two weld schedules with the welding job sequencer said
first weld schedule having at least one first weld set up parameter
and at least one first weld instruction and said second weld
schedule defining at least one second weld set up parameter and at
least one second weld instruction with at least one of said second
weld set up parameter and said second weld instruction being
different from said first weld set up parameter and said first weld
instruction; determining completion of said first weld schedule by
said welding operator; automatically modifying the welding
equipment in accordance with said second weld schedule without said
welding operator intervention; and monitoring the welding
operations. In the embodiment, the method can include automatically
modifying the welding equipment in accordance with said second weld
schedule is based on said completion of said first weld
schedule.
[0066] In an embodiment, a semi-automatic welding work cell for use
by an operator is provided. The embodiment can include welding
equipment having a plurality of functions for performing welds by
the operator and a welding job sequencer selecting from the
plurality of functions to set up and organize the welding equipment
for the operator. The embodiment can include the plurality of
functions including: a weld schedule function defined by a sequence
of weld operations; a notify function to instruct the operator to
perform the weld schedule; and a quality check function to monitor
at least one weld operation of the sequence of weld operations.
[0067] In the embodiment, the quality check function performs a
quality check on a weld completed by the at least one weld
operation. In the embodiment, the quality check function monitors
the at least one weld operation during the at least one weld
operation. In the embodiment, the quality check function monitors
the at least one weld operation after completion of the at least
one weld operation. In the embodiment, the weld schedule function
defines a plurality of weld schedules, each weld schedule having a
first weld operation and at least a second weld operation. In the
embodiment, the quality check function monitors the at least one
weld operation before allowing the sequence of weld operations to
continue. In the embodiment, the quality check function detects an
abnormality, the sequencer pauses the sequence of weld operations
and the notify function alerts the operator of the abnormality.
[0068] FIG. 3 is a schematic block diagram of an exemplary
embodiment of welding system 300 that utilizes welding job
sequencer component 302 to configure welding equipment for two or
more weld operations to assembly a workpiece. Welding job sequencer
component 302 that is configured to implement a welding sequence
that includes settings, configurations, and/or parameters to
perform two or more welding procedures on a workpiece. In
particular, welding job sequencer component 302, as discussed above
as welding job sequencer, automatically configures welding
equipment to create two or more welds that include two or more
welding schedules. Moreover, welding job sequencer component 302
utilizes the welding sequence to aid an operator to perform the two
or more welds. As discussed above, welding job sequencer component
302 can be utilized with welding work cell 304 that is
semi-automatic. However, it is to be appreciated and understood
that welding job sequencer component 302 can be implemented in a
suitable welding environment or system that includes at least
welding equipment and an operator to facilitate creating one or
more welds.
[0069] Welding system 300 further includes check point component
306 that is configured to monitor a welding process and/or a
welding operator in real time. For instance, the welding process is
monitored in real time to detect at least one of a welding
parameter (e.g., voltage, current, among others), a welding
schedule parameter (e.g., welding process, wire type, wire size,
WFS, volts, trim, wire feeder to use, feed head to use, among
others), a weld on a workpiece as the weld is created, a movement
of an operator, a position of a welding tool, a position or
location of a welding equipment, a position or location of an
operator, sensor data (e.g., video camera, image capture, thermal
imaging device, heat sensing camera, temperature sensor, among
others), and the like. Check point component 306 includes an alert
system (not shown) that can communicate an alert or notification to
indicate a status of the real time monitoring. In an embodiment,
check point component 306 can utilize thresholds, ranges, limits,
and the like for the real time monitoring to precisely identify a
abnormality with welding system 300. Furthermore, check point
component 306 can communicate an alert or notification to welding
work cell 304 or the operator to at least one of stop the welding
procedure, continue with the welding procedure, pause the welding
procedure, terminate the welding procedure, or request approval of
the welding procedure. In an embodiment, check point component 306
can store monitoring data (e.g., video, images, results, sensor
data, and the like) in at least one of a server, a data store, a
cloud, a combination thereof, among others.
[0070] Weld score component 308 is included with welding system 300
and is configured to evaluate a weld created by an operator within
welding work cell 304 upon completion of such weld. Weld score
component 308 provides a rating or score for the completed weld to
facilitate implementing a quality control on the workpiece and/or
assembly of the workpiece. For instance, weld score component 308
can alert a quality inspection upon completion, provide data
collection of a job (e.g., assembly of workpiece, weld on
workpiece, among others), and the like. In an embodiment, an
in-person quality inspection can be performed upon completion of a
portion of the assembly (e.g., completion of a weld, completion of
two or more welds, completion of assembly, among others). In
another embodiment, weld score component 308 can utilize a sensor
to collect data (e.g., video camera, image capture, thermal imaging
device, heat sensing camera, temperature sensor, among others) to
determine approval of the job. For instance, a quality inspection
can be performed remotely via video or image data collected upon
completion of a job.
[0071] It is to be appreciated that welding job sequencer component
302 can be a stand-alone component (as depicted), incorporated into
welding work cell 304, incorporated into check point component 306,
incorporated into weld score component 308, or a suitable
combination thereof. Additionally, as discussed below, welding job
sequencer component 302 can be a distributed system,
software-as-a-service (SaaS), a cloud-based system, or a
combination thereof. Further, it is to be appreciated and
understood that check point component 306 can be a stand-alone
component (as depicted), incorporated into welding work cell 304,
incorporated into welding job sequencer component 302, incorporated
into weld score component 308, or a suitable combination thereof.
Additionally, check point component 306 can be a distributed
system, software-as-a-service (SaaS), a cloud-based system, or a
combination thereof. Moreover, it is to be appreciated and
understood that weld score component 308 can be a stand-alone
component (as depicted), incorporated into welding work cell 304,
incorporated into welding job sequencer component 302, incorporated
into check point component 306, or a suitable combination thereof.
Additionally, weld score component 308 can be a distributed system,
software-as-a-service (SaaS), a cloud-based system, or a
combination thereof.
[0072] FIG. 4 illustrates a schematic block diagram of an exemplary
embodiment of welding system 400 including welding circuit path
405. It is to be appreciated that welding system 400 is also
referred to as the welding work cell, wherein the welding work cell
and/or welding system 400 can produce welds or welded parts.
Welding system 400 includes welder power source 410 and display 415
operationally connected to welder power source 410. Alternatively,
display 415 may be an integral part of welder power source 410. For
instance, display 415 can be incorporated into welder power source
410, a stand-alone component (as depicted), or a combination
thereof. Welding system 100 further includes welding cable 120,
welding tool 430, workpiece connector 450, spool of wire 460, wire
feeder 470, wire 480, and workpiece 440. Wire 480 is fed into
welding tool 430 from spool 460 via wire feeder 470, in accordance
with an embodiment of the present invention. In accordance with
another embodiment of the present invention, welding system 400
does not include spool of wire 460, wire feeder 470, or wire 480
but, instead, includes a welding tool comprising a consumable
electrode such as used in, for example, stick welding. In
accordance with various embodiments of the present invention,
welding tool 430 may include at least one of a welding torch, a
welding gun, and a welding consumable.
[0073] Welding circuit path 405 runs from welder power source 410
through welding cable 420 to welding tool 430, through workpiece
440 and/or to workpiece connector 450, and back through welding
cable 420 to welder power source 110. During operation, electrical
current runs through welding circuit path 405 as a voltage is
applied to welding circuit path 405. In accordance with an
exemplary embodiment, welding cable 420 comprises a coaxial cable
assembly. In accordance with another embodiment, welding cable 420
comprises a first cable length running from welder power source 410
to welding tool 430, and a second cable length running from
workpiece connector 450 to welder power source 410.
[0074] Welding system 400 includes welding job sequencer component
302 (as described above). Welding job sequencer component 302 is
configured to interact with a portion of welding system 400. For
instance, welding job sequencer component 302 can interact with at
least the power source 410, a portion of welding circuit path 405,
spool of wire 460, wire feeder 470, or a combination thereof.
Welding job sequencer component 302 automatically adjusts one or
more elements of welding system 400 based on a welding sequence,
wherein the welding sequence is utilized to configure welding
system 400 (or an element thereof) without operator intervention in
order to perform two or more welding procedures with respective
settings or configurations for each welding procedure.
[0075] In an embodiment, welding job sequencer component 302
employs a welding sequence to automatically configure welding
equipment. It is to be appreciated that welding system 400 or
welding work cell can employ a plurality of welding sequences for
assembly of one or more workpieces. For instance, a workpiece can
include three (3) welds to complete assembly in which a first
welding sequence can be used for the first weld, a second welding
sequence can be used for the second weld, and a third welding
sequence can be used for the third weld. Moreover, in such example,
the entire assembly of the workpiece including the three (3) welds
can be referenced as a welding sequence. In an embodiment, a
welding sequence that includes specific configurations or steps can
further be included within a disparate welding sequence (e.g.,
nested welding sequence). A nested welding sequence can be a
welding sequence that includes a welding sequence as part of the
procedure. Moreover, the welding sequence can include at least one
of a parameter, a welding schedule, a portion of a welding
schedule, a step-by-step instruction, a portion of media (e.g.,
images, video, text, and the like), a tutorial, among others. In
general, the welding sequence can be created and employed in order
to guide an operator through welding procedure(s) for specific
workpieces without the operator manually setting welding equipment
to perform such welding procedures. The subject innovation relates
to creating a welding sequence and/or modifying a welding
sequence.
[0076] One or more welder power source(s) (e.g., welder power
source 410) aggregates data respective to a respective welding
process to which the welder power source is providing power to
implement. Such collected data relates to each welder power source
and is herein referred to as "weld data." Weld data can include
welding parameters and/or information specific to the particular
welding process the welder power source is supplying power. For
instance, weld data can be an output (e.g., a waveform, a
signature, a voltage, a current, among others), a weld time, a
power consumption, a welding parameter for a welding process, a
welder power source output for the welding process, and the like.
In an embodiment, weld data can be utilized with welding job
sequencer component 302. For example, weld data can be set by a
welding sequence. In another example, weld data can be used as a
feedback or a feedforward loop to verify settings.
[0077] In one embodiment, welding job sequencer component 302 is a
computer operable to execute the disclosed methodologies and
processes, including methods 1100 and 1200 described herein. In
order to provide additional context for various aspects of the
present invention, the following discussion is intended to provide
a brief, general description of a suitable computing environment in
which the various aspects of the present invention may be
implemented. While the invention has been described above in the
general context of computer-executable instructions that may run on
one or more computers, those skilled in the art will recognize that
the invention also may be implemented in combination with other
program modules and/or as a combination of hardware and/or
software. Generally, program modules include routines, programs,
components, data structures, etc., that perform particular tasks or
implement particular abstract data types.
[0078] Moreover, those skilled in the art will appreciate that the
inventive methods may be practiced with other computer system
configurations, including single-processor or multiprocessor
computer systems, minicomputers, mainframe computers, as well as
personal computers, hand-held computing devices,
microprocessor-based or programmable consumer electronics, and the
like, each of which may be operatively coupled to one or more
associated devices. The illustrated aspects of the invention may
also be practiced in distributed computing environments where
certain tasks are performed by remote processing devices that are
linked through a communications network. In a distributed computing
environment, program modules may be located in both local and
remote memory storage devices. For instance, a remote database, a
local database, a cloud-computing platform, a cloud database, or a
combination thereof can be utilized with welding job sequencer
302.
[0079] Welding job sequencer 302 can utilize an exemplary
environment for implementing various aspects of the invention
including a computer, wherein the computer includes a processing
unit, a system memory and a system bus. The system bus couples
system components including, but not limited to the system memory
to the processing unit. The processing unit may be any of various
commercially available processors. Dual microprocessors and other
multi-processor architectures also can be employed as the
processing unit.
[0080] The system bus can be any of several types of bus structure
including a memory bus or memory controller, a peripheral bus and a
local bus using any of a variety of commercially available bus
architectures. The system memory can include read only memory (ROM)
and random access memory (RAM). A basic input/output system (BIOS),
containing the basic routines that help to transfer information
between elements within welding job sequencer 302, such as during
start-up, is stored in the ROM.
[0081] Welding job sequencer 302 can further include a hard disk
drive, a magnetic disk drive, e.g., to read from or write to a
removable disk, and an optical disk drive, e.g., for reading a
CD-ROM disk or to read from or write to other optical media.
Welding job sequencer 302 can include at least some form of
computer readable media. Computer readable media can be any
available media that can be accessed by the computer. By way of
example, and not limitation, computer readable media may comprise
computer storage media and communication media. Computer storage
media includes volatile and nonvolatile, removable and
non-removable media implemented in any method or technology for
storage of information such as computer readable instructions, data
structures, program modules or other data. Computer storage media
includes, but is not limited to, RAM, ROM, EEPROM, flash memory or
other memory technology, CD-ROM, digital versatile disks (DVD) or
other magnetic storage devices, or any other medium which can be
used to store the desired information and which can be accessed by
welding job sequencer 302.
[0082] Communication media typically embodies computer readable
instructions, data structures, program modules or other data in a
modulated data signal such as a carrier wave or other transport
mechanism and includes any information delivery media. The term
"modulated data signal" means a signal that has one or more of its
characteristics set or changed in such a manner as to encode
information in the signal. By way of example, and not limitation,
communication media includes wired media such as a wired network or
direct-wired connection, and wireless media such as acoustic, Radio
Frequency (RF), Near Field Communications (NFC), Radio Frequency
Identification (RFID), infrared, and/or other wireless media.
Combinations of any of the above should also be included within the
scope of computer readable media.
[0083] A number of program modules may be stored in the drives and
RAM, including an operating system, one or more application
programs, other program modules, and program data. The operating
system in welding job sequencer 302 can be any of a number of
commercially available operating systems.
[0084] In addition, a user may enter commands and information into
the computer through a keyboard and a pointing device, such as a
mouse. Other input devices may include a microphone, an IR remote
control, a track ball, a pen input device, a joystick, a game pad,
a digitizing tablet, a satellite dish, a scanner, or the like.
These and other input devices are often connected to the processing
unit through a serial port interface that is coupled to the system
bus, but may be connected by other interfaces, such as a parallel
port, a game port, a universal serial bus ("USB"), an IR interface,
and/or various wireless technologies. A monitor (e.g., display
415), or other type of display device, may also be connected to the
system bus via an interface, such as a video adapter. Visual output
may also be accomplished through a remote display network protocol
such as Remote Desktop Protocol, VNC, X-Window System, etc. In
addition to visual output, a computer typically includes other
peripheral output devices, such as speakers, printers, etc.
[0085] A display (in addition or in combination with display 415)
can be employed with welding job sequencer 302 to present data that
is electronically received from the processing unit. For example,
the display can be an LCD, plasma, CRT, etc. monitor that presents
data electronically. Alternatively or in addition, the display can
present received data in a hard copy format such as a printer,
facsimile, plotter etc. The display can present data in any color
and can receive data from welding job sequencer 302 via any
wireless or hard wire protocol and/or standard. In another example,
welding job sequencer 302 and/or system 400 can be utilized with a
mobile device such as a cellular phone, a smart phone, a tablet, a
portable gaming device, a portable Internet browsing device, a
Wi-Fi device, a Portable Digital Assistant (PDA), among others.
[0086] The computer can operate in a networked environment using
logical and/or physical connections to one or more remote
computers, such as a remote computer(s). The remote computer(s) can
be a workstation, a server computer, a router, a personal computer,
microprocessor based entertainment appliance, a peer device or
other common network node, and typically includes many or all of
the elements described relative to the computer. The logical
connections depicted include a local area network (LAN) and a wide
area network (WAN). Such networking environments are commonplace in
offices, enterprise-wide computer networks, intranets and the
Internet.
[0087] When used in a LAN networking environment, the computer is
connected to the local network through a network interface or
adapter. When used in a WAN networking environment, the computer
typically includes a modem, or is connected to a communications
server on the LAN, or has other means for establishing
communications over the WAN, such as the Internet. In a networked
environment, program modules depicted relative to the computer, or
portions thereof, may be stored in the remote memory storage
device. It will be appreciated that network connections described
herein are exemplary and other means of establishing a
communications link between the computers may be used.
[0088] Alternatively or in addition, a local or cloud (e.g., local,
cloud, remote, among others) computing platform can be utilized for
data aggregation, processing, and delivery. For this purpose, the
cloud computing platform can include a plurality of processors,
memory, and servers in a particular remote location. Under a
software-as-a-service (SaaS) paradigm, a single application is
employed by a plurality of users to access data resident in the
cloud. In this manner, processing requirements at a local level are
mitigated as data processing is generally done in the cloud,
thereby relieving user network resources. The software-as-a-service
application allows users to log into a web-based service (e.g., via
a web browser) which hosts all the programs resident in the
cloud.
[0089] Turning to FIG. 5, system 500 illustrates a welding
environment with a plurality of welding work cells via a local,
remote, or cloud database. System 500 includes a plurality of
welding work cells such as first welding work cell 515, second
welding work cell 520 to Nth welding work cell 530, where N is a
positive integer. In an embodiment, each welding work cell includes
a welding job sequencer component 535, 540, and 545, that is used
to implement a welding schedule(s) to each welding work cell as
well as or in the alternative to an enterprise-wide welding
operation(s) and/or enterprise-wide welding work cell. Welding
sequence(s) from each welding job sequencer component 535, 540, and
545 is received from the local or cloud database (e.g., local
database, cloud database, remote database, among others) computing
platform 510.
[0090] In an embodiment, each welding work cell further includes a
local data store. For instance, first welding work cell 515
includes welding job sequencer component 535 and data store 550,
second welding work cell 520 includes welding job sequencer
component 540 and data store 555, and Nth welding work cell 530
includes welding job sequencer component 545 and data store 560. It
is to be appreciated that system 500 includes welding job sequencer
302 hosted by computing platform 510 in which each welding work
cell includes a distributed and respective welding job sequencer
component. Yet, it is to be understood that welding job sequencer
302 (and distributed welding job sequencer components 535, 540, and
545) can be a stand-alone component in each welding work cell or a
stand-alone component in the computing platform 510.
[0091] Each welding work cell can include a respective data store
that stores a portion of at least one welding sequence. For
instance, welding sequences related to a welding process A is
employed at one or more welding work cell. The welding sequence is
stored in a respective local data store (e.g., data stores 550,
555, and 560). Yet, it is to be appreciated and understood that
each welding work cell can include a local data store (as
depicted), a collective and shared remote data store, a collective
and shared local data store, a cloud data store hosted by computing
platform 510, or a combination thereof. A "data store" or "memory"
can be, for example, either volatile memory or nonvolatile memory,
or can include both volatile and nonvolatile memory. The data store
of the subject systems and methods is intended to comprise, without
being limited to, these and other suitable types of memory. In
addition, the data store can be a server, a database, a hard drive,
a flash drive, an external hard drive, a portable hard drive, a
cloud-based storage, a solid-state drive, and the like.
[0092] For instance, welding job sequencer component 302 can manage
each welding job sequencer component 535, 540, 545 in each welding
work cell 515, 520, 530. In another embodiment, the communications
can be transmitted from the welding job sequencer 302 to each
welding work cell (e.g., each welding job sequencer component). In
another embodiment, the communications can be received from each
welding work cell (e.g., each welding job sequencer component) from
the welding job sequencer component 302. For instance, a welding
sequence can be used with 1.sup.st welding work cell 515 and
communicated directly to a disparate welding work cell or via
computing platform 510.
[0093] FIG. 6 illustrates welding system 600 that includes a
plurality of welding work cells in which welding job sequencer
component 302 is hosted with computing platform 510 to utilize one
or more welding sequences to configure welding equipment within one
or more welding systems, welding environments, and/or welding work
cells. Welding system 600 includes a local or cloud-based welding
job sequencer component 302 hosted in computing platform 510.
Welding job sequencer component 302 can utilize a welding sequence
with a number of welding work cell. For instance, welding system
600 can a number of welding work cells such as, but not limited to,
1.sup.st welding work cell 620, 2.sup.nd welding work cell 630, to
Nth welding work cell, where N is a positive integer. It is to be
appreciated that the locality of the welding job sequencer
component 302 is in relation to each 1.sup.st welding work cell
620, 2.sup.nd welding work cell 630, and/or Nth welding work cell
640.
[0094] In an embodiment, welding job sequencer 302 communicates one
or more welding sequence to a target welding work cell, wherein the
target welding work cell is a welding work cell that is to utilize
the communicated welding sequence. Yet, in another embodiment,
welding job sequencer 302 utilizes memory 650 hosted by computing
platform 510 in which one or more welding sequences are stored.
Yet, the stored welding sequence can be related or targeted to one
or more welding work cells regardless of a storage location (e.g.,
local, cloud, remote, among others).
[0095] FIG. 7 illustrates system 700 that aggregates data
associated with a welding operation performed with a welding
sequence. As discussed above, welding sequence is used by welding
job sequencer component 302 to perform two or more welds with two
or more respective welding parameters (e.g., welding schedules,
parameters, configurations, settings, and the like) within welding
work cell 304. In particular, one or more welding sequences are
employed to automatically configure welding equipment without
operator intervention to perform a first welding operation with a
first welding schedule and a second welding operation with a second
welding schedule. It is to be appreciated that a welding sequence
can include additional steps or procedures to implement within
welding work cell 304 (as discussed below). Welding job sequencer
component 302 is configured to implement one or more welding
sequence(s) to perform a welding operation, wherein the welding
sequence(s) can be stored on welding sequence data store 706.
Welding sequence(s) can be identified or selected and loaded or
used from welding sequence data store 706.
[0096] It is to be appreciated that the welding sequence(s) can be
executed from welding sequence data store 706, downloaded and
executed locally (e.g., local in reference to where a weld is
performed with the welding sequence), or a combination thereof. As
discussed above, data store (here, welding sequence data store 706)
can be, for example, either volatile memory or nonvolatile memory,
or can include both volatile and nonvolatile memory. The data store
(here, welding sequence data store 706) of system 700 is intended
to comprise, without being limited to, these and other suitable
types of memory. In addition, the data store can be a server, a
database, a hard drive, a flash drive, an external hard drive, a
portable hard drive, a cloud-based storage, a solid-state drive,
and the like. It is to be appreciated that input data received or
registered (discussed below) can be stored in a dedicated data
store for such data, welding sequence data store, a remote data
store, a cloud-based environment, a combination thereof, among
others.
[0097] System 700 further includes collection component 702 that is
configured to collect real time data from a welding operation that
uses a welding sequence. In general, collection component 702
collects, receives, and/or aggregates a welding parameter from a
weld being performed with use of a portion of a welding sequence.
For instance, a welding parameter is aggregated, received, or
collected in real time for a welding sequence that is used to
perform one or more welds. By way of example and not limitation,
the welding parameter can be at least one of a parameter for the
weld (e.g., voltage, current, among others), a welding schedule
parameter (e.g., welding process, wire type, wire size, wire feed
speed (WFS), volts, trim, wire feeder to use, feed head to use,
among others), a movement of an operator, a position of a welding
tool, a position or location of a welding equipment, a position or
location of an operator, a location or position of a body part of
an operator, sensor data (e.g., video camera, image capture,
thermal imaging device, heat sensing camera, temperature sensor,
among others), physical weld appearance (e.g., weld size, weld
shape, weld dimension(s), and the like), welding equipment
configurations (e.g., power source settings, waveforms, wire feed
speed, and the like), welder setup (e.g., workpiece type, wire
type, material type, weld to perform, and the like), a time to
create a weld, a fixture location, a cost to create the weld (e.g.,
cost includes electricity, electrode, gas, employee pay, among
others), a speed for a welding tool, among others. By way of
example and not limitation, a fixture secures the workpiece from
movement during the first weld or the second weld. For instance, a
fixture can be a clamp, a temporary weld (e.g., a tack weld), among
others. Still, it is to be appreciated and understood that any
welding parameter can be selected with sound engineering judgment
without departing from the intended scope of coverage of the
embodiments of the subject invention.
[0098] The real time welding parameter is stored and associated
with a welding sequence that was utilized while creating a weld by
collection component 702. In other words, welding parameter(s) can
be tracked and monitored for each welding sequence used in order to
evaluate data and configure welding equipment, welding technique of
the operator, among others. The welding parameter aggregated can be
associated to the corresponding welding sequence (e.g., where
corresponding refers to the welding sequence that was used while
collecting the welding parameter) by metadata, metadata tags, data
storage techniques, data store management, naming conventions,
among others. It is to be appreciated that any suitable technique
can be employed to ensure that a welding sequence is matched or
corresponded to real time collected welding parameter(s).
[0099] System 700 further includes quality manager component 704
that is configured to collect quality assurance data and create a
modeled welding parameter (e.g., also referred to as welding
parameter model). In an embodiment, quality manager component 704
collects quality assurance data during a performance of a weld for
a specific welding sequence. Tracking the quality assurance data
for each welding sequence allows for evaluation of each weld during
each portion of the welding sequence, wherein such tracking allows
for increased results, quality, and the like. In an embodiment,
quality manager component 704 is further configured to interact or
communicate with the weld score component (discussed in FIG. 3)
and/or the check point component (discussed in FIG. 3). For
instance, quality assurance data can be collected by quality
manager component 704 on a periodic time frequency, at a particular
point or step during the welding sequence, at a beginning and/or
end of a welding sequence, among others. In an example, snapshots
can be collected on a timely basis, wherein quality assurance data
is collected and reviewed in real time. If the quality assurance
data is not up to a defined standard, the welding sequence can be
halted, stopped, restarted, eliminated, among others.
[0100] Quality manager component 704 leverages real time welding
parameter(s) for each welding sequence and generates a modeled
welding parameter based thereon. This modeled welding parameter is
used for the corresponding welding sequence to maintain quality of
welding operations performed with welding sequences. In an
embodiment, the modeled welding parameter can be based on real time
collected welding parameter(s) for each welding sequence. In
another embodiment, the modeled welding parameter can be based on a
real time collected welding parameter during a welding training
session, a virtual welding session, a welding simulation, or a
specific welding session to create a modeled welding parameter. For
instance, a welding parameter A can be monitored in real time and
collected for each instance that welding sequence W is used. After
a duration of time or two or more welds, this data collected for
welding parameter A can be evaluated to create a modeled welding
parameter A'. The modeled welding parameter A' can be used for
welding operations that employ the welding sequence W so as to
maintain consistency and/or quality. In another example, more than
one welding parameter can be collected in real time to create one
or more welding parameter models. For instance, data for welding
parameters A and B can be used with welding sequence W from which
modeled welding parameter AB' can be generated for use with welding
sequence W. It is to be appreciated that any suitable number of
welding parameters can be used to create a welding parameter model
and the above discussion is provided for example.
[0101] The term "modeled welding parameter'" and/or "welding
parameter model" as used herein can be defined as a targeted value
for a measurement or reading of a welding parameter in real time,
wherein the targeted value is based on two or more real time
measurements (e.g., welding parameter real time measurements) for a
specific welding sequence and created weld. It is to be appreciated
that the "modeled welding parameter" and/or "welding parameter
model" can be user-defined, identified with statistical analysis of
two or more real time welding parameters, identified via a user
performance of a weld with a welding sequence to detect a real time
welding parameter, or a combination thereof. By way of example and
not limitation, the statistical analysis can be an average of two
or more real time welding parameter, a range based on two or more
real time welding parameters, a threshold tolerance based on one or
more real time welding parameter, a weighted average of two or more
real time welding parameters, a median, a standard deviation, among
others. Still, it is to be appreciated and understood that a
modeled welding parameter and/or a welding parameter model can be
employed with any formula using two or more real time welding
parameters can be selected with sound engineering judgment without
departing from the intended scope of coverage of the embodiments of
the subject invention.
[0102] It is to be appreciated that real time collection of a
welding parameter for a welding sequence can be utilized in one or
more environments independent of a source or collection of the
welding parameter (e.g., independent of where a welding sequence is
used and where the data collection takes place). For instance, an
operator can perform two or more welds with welding sequence W in
welding environment A and further utilize welding parameters
collected from the two or more welds with welding sequence W to
create a welding parameter model in welding environment B. In
another example, real time data for welding parameters can be
collected (while using welding sequence W) across welding
environment A and welding environment B to create a welding
parameter model for the welding sequence W for use in welding
environment A, welding environment B, and/or welding environment
C.
[0103] In an example, a welding sequence can include a quality
assurance collection (e.g., also referred to as collection quality
assurance data). The welding sequence can be created, edited, or
modified to include a quality assurance collection for at least one
of a welding work cell, a welding equipment, or one or more welds.
By way of example and not limitation, the quality assurance
collection can be a data capture of at least one of welding
equipment (e.g., settings, physical location, consumable amount,
and the like), the operator (e.g., physical location of person,
location of arms, location of hands, and the like), or a weld
(e.g., dimensions, size, location of weld, among others). It is to
appreciated that the data collection can be video, audio, images,
settings, welding equipment settings, physical location of the
operator, movements from the operator, and the like. For instance,
a quality assurance collection can be included with a welding
sequence as a step therein in which the collection is on a
particular frequency, duration of time, or a point in a welding
procedure (e.g., middle of weld, end of weld, and the like). Thus,
a welding environment, welding system, and/or welding work cell can
have quality assurance data collected in real time. In an example,
a quality assurance collection can be a step in a welding sequence
at a particular point in the welding procedure. In a particular
example, the welding sequence can be evaluated over time to
identify specific parts or areas a weld includes an error. In such
example, the quality assurance collection can be configured to
gather data at a point in time prior to the particular point in
order to avoid the error.
[0104] In an example, a welding sequence can include a
replenishment of a consumable. The welding sequence can be created
or edited to include a replenishment of a consumable for at least
one of a welding work cell, a welding equipment, among others. For
instance, a replenishment of a consumable can be included with a
welding sequence after a period of time, wherein the period of time
is estimated based on the duration the welding equipment is used
(e.g., estimate the use of consumables). Thus, a welding
environment, welding system, and/or welding work cell can be
evaluated in real time or from collected real time data and
identify data to determine a replenishment of a consumable.
[0105] In another example, a welding sequence can include an
inspection or a repair. The welding sequence can be created or
edited to include an inspection request or a repair request based
on a factor such as, but not limited to, a time, a duration, among
others. A welding work cell can have a maintenance period for a
particular time and if a welding sequence is created for such
welding work cell, a repair or maintenance can be included with the
created welding sequence. Thus, a welding environment, welding
system, and/or welding work cell can be evaluated in real time or
from collected real time data and identify data to determine
inspections or repairs.
[0106] In another example, a welding sequence can include a
pre-shift routine that is performed prior to a welding operation.
For instance, a shift can be part of a scheduling of operators or
employees, wherein the shift is a duration of time when operators
are working. As an example, a shift can be from seven (7) am to
three (3) pm. Based on gathered historic welding data or real time
welding data, an estimation of welding time can be calculated to
facilitate determining maintenance to perform on welding equipment.
In an embodiment, at least one of gas flow, tip condition, tip
replacement, nozzle inspection, nozzle replacement, among others
can be included within a welding sequence based on the estimation
of welding time.
[0107] Furthermore, it is to be appreciated and understood that
collection component 702 can be a stand-alone component (as
depicted), incorporated into welding job sequencer component 302,
incorporated into welding equipment (not shown), incorporated into
quality manager component 704, incorporated into welding work cell
304, or a combination thereof. Additionally, welding job sequencer
component 302 can be a stand-alone component (as depicted),
incorporated into collection component 702, incorporated into
welding equipment (not shown), incorporated into quality manager
component 704, incorporated into welding work cell 304, or a
combination thereof. Further, welding sequence data store 706 can
be a local data store, a remote data store, a cloud-based data
store, a computing platform, and/or any other network or computing
environment configuration discussed above in regards to the welding
job sequencer component.
[0108] FIG. 8 illustrates system 800 that communicates a portion of
media to an operator to facilitate creating a weld with a welding
procedure. System 800 further includes guide component 802 that is
configured to provide data to welding work cell 304 to facilitate
creation of a weld using a welding sequence, wherein the data is
related to a portion of media (e.g., audio, video, image, and the
like). In an example, the portion of media can be of a weld (e.g.,
physical appearance), a welding torch (e.g., orientation, location,
etc.), a workpiece (e.g., fixture location, etc.), a body part of
the operator (e.g., hand location, body location, among others), or
a combination thereof. In an embodiment, guide component 802
receives a portion of media corresponding to a welding sequence or
a portion of a welding sequence (e.g., a step, a part, etc.) and
provides such portion of media to an operator performing a welding
using the welding sequence or the portion of the welding sequence.
In another embodiment, guide component collects the portion of
media via quality manager component 704. For instance, a portion of
media can be stored for a weld performed (with a welding sequence)
that has one or more welding parameters identified for the modeled
welding parameter. In another instance, a pre-defined portion of
media can be assigned to each portion of the welding sequence. In
general, a portion of media is presented to the operator, wherein
the portion of media is based at least in part upon a modeled
welding parameter, a welding parameter model, a user-defined
portion of media, a simulated welding operation, a virtual welding
operation, among others.
[0109] Guide component 802 is further configured to communicate the
portion of media that corresponds to the welding sequence being
used. By way of example and not limitation, the portion of media
can be communicated via a device (e.g., smartphone, speaker,
display, handheld, portable gaming device, tablet, laptop, monitor,
television, among others). Moreover, the portion of media can be
displayed onto or using an equipment of the operator. By way of
example and not limitation, equipment of the operator can be a
helmet, a visor, a pair of glasses, a glove, an apron, a jacket, a
welding sleeve, an identification badge of the operator, an
earpiece, a pair of headphones, an ear plug, a headband, a bandana,
a watch, an item of jewelry (e.g., ring, necklace, bracelet, among
others), and the like.
[0110] In an embodiment, guide component 802 can display a hologram
(e.g., holographic images, 3D images, 3D video, holographic video,
and the like) onto at least one of an equipment of the user, a
workpiece, or a surface that the workpiece is situated. The
hologram can be a "ghosting" that shows a performance of a weld
with the welding sequence so as to communicate or show to the
operator the positions (e.g., operator physical location, fixture
location, welding torch angle/position, workpiece location, etc.),
motions (e.g., welding torch motions to create weld, and the like),
rate (e.g., speed of which to make the weld, and the like), weld
dimensions (e.g., weld size, look of weld, and the like), among
others.
[0111] In another embodiment, guide component 802 can display a
location to the operator on where to weld for the welding sequence,
wherein the location is displayed via indicator (e.g., a light, a
target, a graphic, an image, among others). For instance, a visor
on the operator can have an indicator displayed thereon such that
from the view of the operator, the indicator is positioned on a
location to where the weld for the welding sequence should be
performed.
[0112] FIG. 9 illustrates system 900 that communicates an alert to
an operator performing one or more welds using a welding sequence.
System 900 includes notification component 902 that communicates an
alert to welding work cell 304. In particular, notification
component 902 can communicate an alert to at least one of workpiece
904, operator 906, and/or equipment 908. It is to be appreciated
that the alert can be communicated in order to relay
information/notification related to at least one of the welding
sequence being used, a quality assurance condition (e.g., real time
monitoring compared to modeled welding parameter(s), not within a
range or tolerance level, motion or movement making weld is
improper, among others), a work environment condition (e.g., a
lunch break, a break time, a time of the day, an end of shift, a
public address (PA) announcement, an evacuation announcement, a
fire alarm, an emergency alarm, start of shift, an end of a break,
an end of lunch, among others), welding equipment (e.g., welding
torch at improper position, among others), welding consumable
(e.g., replenishment warning, amount/level of consumable, stick-out
is too short, stick-out is too long, among others), safety concerns
(e.g., proximity to welding torch, proximity to welding equipment,
among others), or a combination thereof.
[0113] For instance, notification component 902 can display a red
light on workpiece 904 to alert operator 906 to halt performing the
weld based on a detected issue (e.g., See above examples). In
another instance, an audio signal can be used to communicate to
operator 906 that welding for a specific workpiece is complete or
has passed a quality check. In another instance, a green light can
illuminate equipment 908 that requires replenishment of a
consumable. For example, alerts can provide guidance to operator
906 for a sequence on how to replace a consumable. In another
example, a vibration or haptic feedback alert can be communicated
to operator 906.
[0114] In another example, background music can be played for
operator 906 which is interrupted based on an alert or other
communication. In a particular example, the background music can be
modified (e.g., increase tempo, reduce tempo, change genre of
music, change category of music, change artist, among others) to
correspond to the alert communicated to operator 906. For instance,
if operator is performing a weld with a welding sequence at a
faster pace, a tempo of the background music can be changed (e.g.,
increased to communicate the pace is too fast, slowed to
communicate the operator should slow pace, difference artist set
for a too fast detection, among others).
[0115] FIG. 10 illustrates system 1000 that delivers an alert to an
operator creating a weld with a welding sequence based on a
condition within a welding work cell. System 1000 includes
notification component 902 that further includes manager component
1002 that is configured to evaluate a condition in welding work
cell 304. Manager component 1002 can select one or more alert(s)
1004 to communicate to welding work cell 304 based on a detected
condition therein. For instance, if sound levels within welding
work cell 304 are high, a visual alert or haptic alert can be
communicated. In another example, if operator 906 is positioned
away from a display or not in view of the display, an audio alert
and/or haptic alert can be communicated. In another example, if
operator 908 is away from welding work cell 304 (out of range for
an audio alert and/or visual alert), a haptic alert can be
communicated via a wireless device or portable device (e.g., worn
on operator 906, incorporated into equipment of the operator, among
others). For instance, a haptic feedback (e.g., a motion,
vibration, movement, and the like) to the operator can communicate
to the operator by notification component 902.
[0116] In another embodiment, an urgency of the alert can determine
which alert (e.g., audio, visual, haptic, and/or combination
thereof) to communicate. For instance, an evacuation alert can be
communicated with an audio alert, a visual alert, and a haptic
alert. A less urgent alert can be communicated with a haptic alert
as such alert does not disrupt or distract other operators other
than the receiving operator. It is to be appreciated that manager
component 1002 can include pre-defined settings for alerts,
conditions, among others. Moreover, manager component 1002 can
collect real time data and automatically adjust based on operator
preferences.
[0117] In view of the exemplary devices and elements described
supra, methodologies that may be implemented in accordance with the
disclosed subject matter will be better appreciated with reference
to the flow charts and/or methodologies of FIGS. 11 and 12. The
methodologies and/or flow diagrams are shown and described as a
series of blocks, the claimed subject matter is not limited by the
order of the blocks, as some blocks may occur in different orders
and/or concurrently with other blocks from what is depicted and
described herein. In an embodiment, a first input can be received
prior to a second input (as described below). In another
embodiment, a second input can be received prior to a first input.
In an embodiment, the a first input and a second input can be
received at substantially the same time. Moreover, not all
illustrated blocks may be required to implement the methods and/or
flow diagrams described hereinafter.
[0118] Sequentially, the following occurs as illustrated in the
decision tree flow diagram 1100 of FIG. 11 which is a flow diagram
1100 that identifies a welding parameter model for a welding
sequence based on one or more welding parameters collected in real
time for the welding sequence used to create at least one weld.
Methodology 1100 collects data (e.g., welding parameter) during a
welding operation using a welding sequence in order to generate a
welding parameter model (e.g., also referred to as a modeled
welding parameter) used with the welding sequence (e.g., at a later
point in time), wherein the welding parameter model is based on the
collected data. A welding sequence for an operator to use in a
welding work cell is identified, wherein the welding sequence
defines a first welding procedure that includes a first parameter
to create a first weld on a workpiece and a second welding
procedure that includes a second parameter to create a second weld
on the workpiece (reference block 1102). The welding sequence is
utilized to automatically modify a welding equipment within the
welding work cell without intervention from the operator creating
at least one of the first weld or the second weld (reference block
1104). A welding parameter is collected in real time during
creation of at least one of the first weld or the second weld
(reference block 1106). The welding parameter is associated to the
welding sequence and at least one of the first weld or the second
weld (reference block 1108). A welding parameter model is generated
based on one or more welding parameters collected in real time
(reference block 1110). The welding parameter model is implemented
for the welding sequence performed at a time after creation of at
least one of the first weld or the second weld (reference block
1112).
[0119] The following occurs as illustrated in the flow diagram 1200
of FIG. 12. Flow diagram 1200 relates to creating a welding
parameter model for a welding sequence based on one or more
parameters collected from a previous welding operation that used
the welding sequence. A welding sequence is utilized to
automatically modify a welding equipment within a welding work cell
without intervention from an operator creating at least one of the
first weld or the second weld, wherein the welding sequence defines
a first welding procedure that includes a first parameter to create
a first weld on the workpiece and a second welding procedure that
includes a second parameter to create a second weld on the
workpiece (reference block 1202). A welding parameter is collected
in real time during creation of at least one of the first weld or
the second weld with the welding sequence (reference block 1204). A
welding parameter model is generated based on one or more welding
parameters collected in real time for the welding sequence
(reference block 1206). The welding parameter model is utilized for
a new welding operation that uses the welding sequence (reference
block 1208).
[0120] In an embodiment, the method can include at least the steps
of displaying a portion of media illustrating performance of the
welding parameter model, wherein the portion of media is at least
one of a video, an image, a picture, a holographic image, a
holographic video, a 3 dimensional (3D) image, or a 3D video. In an
embodiment, the method can include at least the steps of monitoring
the welding work cell to identify a condition related to a noise
level, an activity of the operator, or a location of the operator;
and communicating an alert to the operator based on the condition,
wherein the alert is based on at least one of the welding sequence,
a creation of an additional weld, or a real time comparison of an
additional weld created with the welding parameter model.
[0121] By way of example and not limitation, welding equipment
(e.g., controller for a welder power source, wire feeder, welder
power source, among others) can include one or more steps related
to a particular welding process for a specific workpiece, wherein a
step can include a respective setting or configuration for at least
one welding equipment. For instance, a first workpiece can include
steps A, B, C, and D based on welding parameters desired, the
welding process used, and/or the workpiece. In another example, a
second workpiece can include steps B, C, A, E, and F. With the
employment of a welding sequence, the controller implementing the
steps for the welding process via the welder power source and/or
welding equipment can be managed and/or instructed. For instance,
the welding sequence can indicate at least one of the following:
which steps to perform, redo a step, skip a step, pause a sequence
of steps, among others. Furthermore, a controller (e.g., or other
suitable component) can control one or more welder power sources,
parameters, welding schedules, among others associated with one or
more welding processes, wherein each welding process can have a
corresponding welding sequence(s).
[0122] In an embodiment, a system can include a weld score
component that is configured to evaluate at least one of the first
weld or the second weld performed on the workpiece by the operator
based upon at least one of an image of the first weld or the second
weld or a user inspection. In an embodiment, the collection
component associates a portion of the evaluation to the identified
welding sequence and at least one of the first weld or the second
weld. In an embodiment, the system can include a check point
component that is configured to monitor the operator and creation
of at least one of the first weld or the second weld in real time
using the welding sequence and the collection component that
associates a portion of the monitoring to the identified welding
sequence and at least one of the first weld or the second weld.
[0123] In an embodiment, the system can include the welding job
sequencer component that is further configured to communicate an
instruction to the operator of the welding work cell to assemble
the workpiece with the first welding procedure and the second
welding procedure having two separate welding schedules, wherein
the instruction includes at least one of the portion of the
monitoring or the portion of the evaluation.
[0124] In an embodiment, the system can include a quality manager
component that is configured to evaluate the real time welding
parameter for at least one of the first weld or the second weld
created with the welding sequence and identify a welding parameter
model. In an embodiment, the welding parameter model is based on an
average measurement of the real time welding parameter. In an
embodiment, the welding parameter model is a defined range of
values based on the real time welding parameter. In an embodiment,
the welding parameter model includes a threshold tolerance based on
the real time welding parameter. In an embodiment, the collection
component associates the welding parameter model to the identified
welding sequence and at least one of the first weld or the second
weld. In an embodiment, the quality manager component is further
configured to receive the real time welding parameter to utilize as
the welding parameter model.
[0125] In an embodiment, the system can include a guide component
that is configured to collect a portion of media captured during
creation of the welding parameter model during at least one of the
first weld or the second weld. In an embodiment, the guide
component displays the portion of media on an equipment of the
operator as at least one of a video, a portion of audio, a 3
dimensional (3D) image, a hologram, or an image.
[0126] In an embodiment, the system can include a notification
component that is configured to generate an alert to the operator
based on at least one of the welding sequence, a performance of the
first weld or the second weld, or a comparison of the real time
welding parameter with a welding parameter model calculated based
on historic welding parameter data for the welding sequence. In an
embodiment, the notification component is further configured to
communicate the alert to the operator based on an urgency of the
alert or a condition within the welding work cell.
[0127] The above examples are merely illustrative of several
possible embodiments of various aspects of the present invention,
wherein equivalent alterations and/or modifications will occur to
others skilled in the art upon reading and understanding this
specification and the annexed drawings. In particular regard to the
various functions performed by the above described components
(assemblies, devices, systems, circuits, and the like), the terms
(including a reference to a "means") used to describe such
components are intended to correspond, unless otherwise indicated,
to any component, such as hardware, software, or combinations
thereof, which performs the specified function of the described
component (e.g., that is functionally equivalent), even though not
structurally equivalent to the disclosed structure which performs
the function in the illustrated implementations of the invention.
In addition although a particular feature of the invention may have
been disclosed with respect to only one of several implementations,
such feature may be combined with one or more other features of the
other implementations as may be desired and advantageous for any
given or particular application. Also, to the extent that the terms
"including", "includes", "having", "has", "with", or variants
thereof are used in the detailed description and/or in the claims,
such terms are intended to be inclusive in a manner similar to the
term "comprising."
[0128] This written description uses examples to disclose the
invention, including the best mode, and also to enable one of
ordinary skill in the art to practice the invention, including
making and using any devices or systems and performing any
incorporated methods. The patentable scope of the invention is
defined by the claims, and may include other examples that occur to
those skilled in the art. Such other examples are intended to be
within the scope of the claims if they have structural elements
that are not different from the literal language of the claims, or
if they include equivalent structural elements with insubstantial
differences from the literal language of the claims.
[0129] The best mode for carrying out the invention has been
described for purposes of illustrating the best mode known to the
applicant at the time. The examples are illustrative only and not
meant to limit the invention, as measured by the scope and merit of
the claims. The invention has been described with reference to
preferred and alternate embodiments. Obviously, modifications and
alterations will occur to others upon the reading and understanding
of the specification. It is intended to include all such
modifications and alterations insofar as they come within the scope
of the appended claims or the equivalents thereof.
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