Lincoln Global, Inc.

Edison Welding Institute, Inc.

Cumberland & Western Resources, LLC

Other

Path Robotics, Inc.

Paul Boulware

Christopher C Conrardy

Douglas Alan Clark

M William Forquer

Jeong K Na

Roger L Spencer

Craig Thompson Walters

Stanley Louis Ream

Jacob Cole Hay

Stanley L Ream

Victor Matthew Penrod

Constance T Reichert LaMorte

Dylan Desantis

Eric Schwenker

Scott A Newhouse

Ron Brown

Bill Colgan

Jeremy Michael Green

Travis Peterson

This disclosure provides systems, methods, and apparatuses, including computer programs encoded on computer storage media, that provide for welding techniques for manufacturing robots, such multipass welding techniques for welding robots. For example, the welding techniques may enable generation of weld instructions based on a welding fill plan. The instructions may be generated based on a bead model or a table that indicates a wire feed speed, a travel speed, or a voltage. As another example, the techniques may enable generation of weld instructions based on the one or more dimensions of a seam. As another example, the techniques may enable generation of a joint model of a cross-section of a seam to be welded. The joint model may be generated based on a combination of a plurality of feature components to generate the joint model of the seam. Other aspects and features are also claimed and described.

Techniques for multipass welding

A testing apparatus for use with a laser powder bed fusion additive manufacturing device that includes a laser for generating a non-stationary laser beam and a build plane positioned at a predetermined location relative to the non-stationary laser beam. The portable testing apparatus includes a support having an upper surface adapted to receive and absorb laser light generated by the non-stationary laser beam; a plurality of pin-hole defining structures each positioned to receive the laser light generated by the non-stationary laser beam, and such that each pin-hole is elevated at a predetermined height above the upper surface of the support and parallel thereto; a fiber optic cable disposed within each pin-hole defining structure, wherein each fiber optic cable has a proximal end at which the laser light is received through the pin-hole and a distal end to which the laser light is delivered; and a photodetector located at the distal end of each fiber optic cable, wherein the photodetector converts the laser light delivered to the photodetector into electrical voltage output signals based on intensity of the laser light received through each pin-hole.

Laser beam profiling system for use in laser powder bed fusion manufacturing

A testing apparatus adapted to be placed within a laser powder bed fusion additive manufacturing device that includes a laser for generating a non-stationary laser beam and a build plane positioned at a predetermined location relative to the non-stationary laser beam. The portable testing apparatus includes a support having an upper surface that is positioned parallel to and above the build plane of the laser powder bed fusion additive manufacturing device, and that is adapted to receive and absorb laser light generated by the non-stationary laser beam; a plurality of pin-hole defining structures mounted at predetermined locations in the support such that each pin-hole defined is positioned to receive the laser light generated by the non-stationary laser beam, and such that each pin-hole is elevated at a predetermined height above the upper surface of the support and parallel thereto; a fiber optic cable disposed within each pin-hole defining structure, wherein each fiber optic cable has a proximal end at which the laser light is received through the pin-hole and a distal end to which the laser light is delivered; and a photodetector located at the distal end of each fiber optic cable that converts the laser light delivered to the photodetector into electrical voltage output signals that are based on the intensity of the laser light received through each pin-hole.

A system for characterizing manual welding exercises and providing valuable training to welders that includes components for generating, capturing, and processing data. The data generating component further includes a fixture, workpiece, at least one calibration devices each having at least two point markers integral therewith, and a welding tool. The data capturing component further includes an imaging system for capturing images of the point markers and the data processing component is operative to receive information from the data capturing component and perform various position and orientation calculations.

System for characterizing manual welding operations

A system for characterizing manual welding exercises and providing valuable training to welders that includes components for generating, capturing, and processing data. The data generating component further includes a fixture, workpiece, at least one calibration device having at least two point markers integral therewith, and a welding tool. The data capturing component further includes an imaging system for capturing images of the point markers and the data processing component is operative to receive information from the data capturing component and perform various position and orientation calculations.

System for characterizing manual welding operations on pipe and other curved structures

A system for non-destructively characterizing laser welds that includes at least one phased array probe that includes a plurality of ultrasonic transducer elements arranged in an array at one end of the probe, wherein the transducer elements are operative to both generate ultrasonic signals and to receive reflections thereof, wherein the transducer elements are further arranged into discrete subgroups, and wherein each subgroup may be activated independently of the other subgroups and at different time intervals; a combination of materials for allowing the probe to conform to a contoured surface of a laser weld while enabling sound energy to be transferred directly into a laser weld under test conditions, wherein the combination of materials further includes a flexible membrane mounted on the end of the probe and a fluid filled chamber material disposed between the membrane and the array of ultrasonic transducer elements; and a data processor in communication with the at least one phased array probe that includes software having at least one imaging algorithm for processing data received from the probe and generating color coded ultrasonic C-scan images of a characterized laser weld.

Phased array system for inspection of laser welds

A method for manual welder training that includes providing a welding training apparatus that includes both hardware and software components and that is operative to gather and process data in real time, wherein the data is derived from an actual training exercise conducted by a welding trainee; selecting training objectives from a predetermined number of predefined objectives; initializing a curriculum, wherein the curriculum is based on the selected training objectives; performing at least one training exercise, wherein the training exercise is a component of the curriculum; providing real-time feedback to the trainee, wherein the real-time feedback is based on the performance of the trainee during the training exercise; evaluating the performance of the trainee based on data gathered and processed during the training exercise; optionally, adapting the curriculum based on the trainee's performance evaluation; and awarding credentials or certifications to the trainee following successful completion of the curriculum.

System and method for manual welder training

A method for characterizing a spot weld, including acquiring a sequence of A-scans from an ultrasonic phased array, wherein the A-scans describe individual portions of a field of view of the phased array; manually applying an interface gate and a flaw gate to each individual A-scan within the sequence of A-scans; calculating a gate ratio between a maximum amplitude under the interface gate and a maximum amplitude under the flaw gate for each individual A-scan; plotting the gate ratio for each individual A-scan as a function of location within the phased array field of view to generate a weld fusion map; using a predetermined threshold to differentiate fused locations from unfused locations on the weld fusion map; and calculating predetermined weld metrics, wherein the predetermined weld metrics include area, diameter, width, length, percent fused, or combinations thereof.

Gating methods for use in weld inspection systems

An automated system for non-destructively evaluating spot welds that includes at least one matrix phased array probe; a fixture adapted to be mounted on a robot or other mechanical actuator, wherein the fixture is further adapted to retain the at least one matrix phased array probe; and an enclosure that includes at least one input for connecting to the at least one matrix phased array probe, ultrasonic phased array transmitting and receiving circuitry in electrical communication with the at least one input, at least one data processor running software that includes at least one algorithm for processing data received from the probe and generating discrete specifications of evaluated welds, wherein the discrete specifications further include pass indications or fail indications regarding weld acceptability; and at least one output for outputting the discrete specifications of evaluated welds.

Automated weld inspection system with weld acceptability pass or fail indications

A system for training welders that includes a data generating component, a data capturing component and a data processing and visualization component. The data generating component operates in real time and derives data from an actual manually-executed weld and further includes a weld process-specific jig, a calibration block positioned on the jig, wherein the geometric configuration of the calibration block is specific to a particular type of weld joint, a weld coupon positioned on the welding process-specific jig adjacent to the calibration block, a welding gun for use by a trainee, wherein the welding gun is operative to form the weld; and at least one target mounted on the welding gun that is recognized by the data processing and visualization component for providing multidimensional position and orientation feedback to the trainee.

Growing community of inventors

Columbus, OH, United States of America

Paul Boulware