CN105209993B - System and method for creating or changing welding sequences - Google Patents

Abstract

The invention described herein generally relates to systems and methods for welder systems that involve creating a weld sequence for a welding environment, wherein the weld sequence is based on real-time data collected from an ongoing or previously performed welding process. Welding process information is collected and utilized to create a weld sequence to perform two or more welds, wherein at least one parameter is based on the collected welding process information (e.g., a real-world welding process).

Description

System and method for creating or changing welding sequences

CROSS REFERENCE TO RELATED APPLICATIONS: This application is a continuation-in-part of US Application Serial No. 11/613,652, filed December 20, 2006 and entitled "Welding Job Sequencer." The entire contents of the aforementioned applications are incorporated herein by reference.

technical field

Apparatus, systems and methods consistent with the present invention relate to welding work cells. More particularly, the invention relates to a welding machine system and a method of welding in a welding work cell according to the preambles of claims 1 and 11 respectively.

Background of the Invention

In the related art, work cells are used to create welds or welded components. There are at least two broad categories of work cells, including robotic work cells and semi-automatic work cells.

In robotic work cells, the scheduling and execution of welding operations are mostly automatic with little operator intervention. Therefore, these units generally have relatively low labor costs and relatively high productivity. However, their repetitive operation cannot be readily adapted to varying welding conditions and/or sequences.

In contrast, semi-automatic work cells (ie, work cells that involve welding operations by at least some operators) generally provide lower automation relative to robotic work cells, and accordingly have relatively higher labor costs and relatively lower productivity. However, there are many situations where the use of a semi-automatic welding work cell is actually advantageous over a robotic work cell. For example, semi-automatic welding work cells can be more easily adapted to changing welding conditions and/or sequences.

Unfortunately, in the related art semi-automatic work cell, when welding more complex assemblies, multiple different welding schedules are usually required for different types of welding on different assembly parts. In many systems, when a different welding schedule must be used, the operator is required to stop the welding operation 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 a specific schedule in the work cell. Still, even in such systems, the operator still needs to pause the welding operation and press a button to select a new welding schedule before he can resume welding.

None of these practices for setting different welding schedules is particularly efficient. Therefore, in practice, the number of welding schedules used in a semi-automatic work cell is often reduced in order to eliminate the need to continuously adjust the output of the semi-automatic equipment. Although the reduction in welding schedules makes the overall operation of the welder easier, the forced simplification of this approach may result in reduced productivity and lower overall quality.

Furthermore, when adhering to 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 operation. In a robotic work cell, these requirements are easily met. In a semi-automatic work cell, however, these requirements are susceptible to human error, as the operator must be mindful of all these aspects in addition to performing the welding operation himself.

An illustrative example of the above problem is shown in the related art semi-automatic welding method schematically presented in FIG. 1 . In this method, each of the various scheduling, sequencing, inspection, and welding operations is organized and performed by the operator (ie, the welder) himself. Specifically, the operator starts the welding operation at operation 10 . Subsequently, at operation 20, the operator sets up the welding equipment according to schedule A. Next, the operator performs Weld #1, Weld #2, and Weld #3 using Weld Schedule A at operations 23, 24, and 26. Subsequently, the operator stops the welding operation and sets up the welding equipment according to schedule B at operation 30 . Next, at operation 32, the operator performs welding #4 using welding schedule B. Subsequently, 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 Weld Schedule C at operations 52 and 54 . After the welding operation is complete, the operator visually inspects the welded components at operation 60 and completes the welding operation at operation 70 .

Clearly, the method shown in FIG. 1 relies on the operator to correctly follow the sequencing and verification predetermined for performing the weld, to accurately change between weld schedules (eg, at operation 30 ), and to perform the weld himself. Errors in any of these duties may result in rework (if errors are discovered during inspection at operation 60) or in defective parts being supplied to end users. Additionally, this exemplary semi-automatic welding method limits productivity because the operator must spend time configuring and reconfiguring the welding schedule.

The above problems are in urgent need of improvement in related technical systems.

SUMMARY OF THE INVENTION

According to an embodiment of the present invention, a welding system is provided, the welding system including a first component configured to receive parameters related to a welding schedule, wherein the parameters are derived from a previously performed welding process or a welding process being performed. At least one of the welding processes is collected. Within the embodiment, the welding system further includes a second component configured to create a welding sequence for the welding work cell, wherein the welding sequence defines at least parameters and a welding schedule for the first welding process to A first weld is created on the workpiece, and at least parameters and a weld schedule are defined for a second weld process to create a second weld on the workpiece. Within the embodiment, the welding system includes a welding job sequencer component configured to employ a welding sequence for a welding work cell.

According to an embodiment of the present invention, a method of creating a welding sequence is provided, the method comprising the steps of: receiving a first parameter associated with a first welding schedule; receiving a second parameter associated with a second welding schedule; A parameter and a second parameter create a welding sequence, wherein the welding sequence defines a first welding process including the first parameter to create a first weld on the workpiece, and defines a second welding process including the second parameter to create a second welding process on the workpiece welding; storing the created welding sequence remote from the welding work cell; and using the welding sequence to automatically change the welding equipment within the welding work cell without intervention from the operator, creating at least one of a first weld or a second weld.

According to an embodiment of the present invention, a welding system is provided, the welding system comprising: means for collecting parameters from a welding process in real time, wherein the parameters are related to a welding schedule; for creating a welding for a welding work cell an apparatus for a sequence, wherein the welding sequence defines at least parameters and a welding schedule for a first welding process to create a first weld on the workpiece, and defines at least parameters and a welding schedule for a second welding process to create a second weld on the workpiece; and means for performing one or more welds using a welding sequence for a welding work cell to assemble a workpiece by automatically adjusting settings on the welding equipment within the welding work cell.

These and other embodiments, objects and features of the present invention will be apparent when read in light of the accompanying drawings, the detailed description and the appended claims.

Brief Description of Drawings

The invention may take specific forms in particular parts and arrangement of parts, preferred embodiments of which are described in detail in the description and illustrated in the accompanying drawings, which form a part hereof and in which In the picture:

FIG. 1 illustrates a related art welding operation using a semi-automatic welding work cell;

Figure 2 illustrates a welding operation using a semi-automatic welding work cell in accordance with the present invention;

3 is a block diagram illustrating a welding system utilizing a welding job sequencer component to configure welding equipment to assemble workpieces for two or more welding operations;

4 is a block diagram illustrating a welding system utilizing a welding job sequencer component;

5 is a block diagram illustrating a distributed welding environment with multiple welding work cells connected to a welding job sequencer component via a local, remote, or cloud database;

6 is a block diagram illustrating a welding system including a plurality of welding work cells managed by a cloud-based welding job sequencer component;

7 is a block diagram illustrating a system for generating a welding sequence based on welding process data;

8 is a block diagram illustrating a system for creating a welding sequence from an operator performing welding with welding equipment on a workpiece;

9 is a block diagram illustrating a system for creating a welding sequence for use in a welding environment;

10 is a block diagram illustrating a system for performing two or more welds utilizing a welding sequence for automatic configuration of the welding system;

11 is a flowchart of creating a welding sequence for use within a welding work cell to automatically configure welding equipment; and

12 is a flowchart of creating a welding sequence based on one or more parameters of a welding process that is being performed or has been performed.

Detailed description of the invention

Embodiments of the present invention relate to methods and systems that involve creating a welding sequence for a welding environment, wherein the welding sequence is based on real-time data collected from performed or previously performed welding processes. Welding process information is collected and utilized to create a welding sequence to perform two or more welds, wherein at least one parameter is based on the collected welding process information (eg, a real world welding process). A welding sequence is utilized to automatically configure a welding operation and/or at least one welding equipment to perform two or more welds including different welding schedules (at least a portion of the welding schedules are different) ). Furthermore, the welding sequence may preclude operator intervention to configure or update welding equipment, which allows the operator to focus on the behavior of welding rather than welding equipment setup, configuration, and the like.

According to an aspect of the present 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.

According to another aspect of the present invention, there is provided a method of welding in a semi-automatic work cell comprising automatically selecting a welding schedule for use by an operator in the semi-automatic welding work cell.

According to another aspect of the present invention, there is provided a welding line comprising at least one semi-automatic welding work cell, wherein the semi-automatic work cell includes a welding job sequencer that automatically selects a welding schedule for which the operator uses.

According to another aspect of the present invention, there is provided a method of monitoring a welding line including automatically selecting a welding schedule for use by an operator in a semi-automatic welding work cell.

The term "component" as used herein may be defined as a portion of hardware, a portion of software, or a combination thereof. A portion of the hardware may include at least a processor and a portion of memory, where the memory includes instructions to be executed.

The best mode for carrying out the invention will now be described for the purpose of illustrating the best mode known to applicants at the time of filing this patent application. The examples and drawings are illustrative only and not meant to limit the invention, which is to be measured by the scope and spirit of the claims. Referring now to the drawings, which are shown for purposes of illustrating exemplary embodiments of the present invention only and not for the purpose of limiting exemplary embodiments of the present invention, reference is made to FIG. 2 . In the exemplary embodiment of the present invention illustrated in Figure 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 welding schedules available therein. The welding job sequencer achieves this improvement by implementing automated changes in semi-automatic work cells and by providing the operator with a large array of commands and instructions.

More specifically, in the exemplary embodiment, the welding job sequencer automatically selects and implements the functions of the welding work cell. Examples of such functionality include specific welding schedules to be used with semi-automatic work cells. In other words, the welding job sequencer can select a welding schedule for a particular weld, and automatically (ie, without operator intervention) modify the settings of the semi-automatic work cell according to the selected welding schedule.

Additionally, in an exemplary embodiment, the welding job sequencer may automatically indicate a sequence of operations that an operator should follow to create the final welded assembly. Along with the automatic selection of welding schedules, the indicated sequence allows the operator to follow the sequence to make the final welded part without having to spend time adjusting, selecting, or reviewing each individual welding schedule and/or sequence.

Thus, because the welding job sequencer sets up the welding equipment and organizes the workflow, and because the operator only performs the welding operation itself, the opportunity for errors in the welding operation is greatly reduced, while productivity and quality are improved.

An exemplary embodiment is given diagrammatically in FIG. 2 . In FIG. 2, at operation 110, the welding job sequencer begins operation and immediately sets the welding equipment to use welding schedule A (operation 120) and instructs the operator to perform welds #1, #2, and #3. Subsequently, the operator performs welding #1, #2 and #3 using welding schedule A (operations 122, 124 and 126). Next, the welding job sequencer sets the welding equipment to use welding schedule B (operation 130), and instructs the operator to perform welding #4. The operator then performs Weld #4 using Weld Schedule B (operation 132). After welding schedule B is completed, the welding job sequencer sets the welding equipment to use welding schedule C (operation 150), and instructs the operator to perform weld #5 and weld #6, and inspect the parts. The operator then performs Weld #5 and Weld #6 using Weld Schedule C (operations 152 and 154), 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 inspection that may be required. Further, operation 160 may include a requirement that the operator affirmatively indicate that the verification is complete before possibly proceeding to the next operation, such as by pressing an "OK" button. Finally, the welding job sequencer instructs the welding operation to its end point (operation 170) and resets for the next operation.

Thus, as noted above, the sequencing and scheduling of welding operations is done by the sequencer and frees the operator to focus on performing the welding according to the instructions.

The welding job sequencer can select and implement new functions based on various variables or inputs, such as the selection and implementation of welding schedules A, B, and C shown in FIG. 2 . For example, the welding job sequencer selects a new welding schedule simply based on monitoring the elapsed time since the welding operation started or since the welding was paused (eg, the time after weld #3 in Figure 2 above). Procedure. Alternatively, the welding job sequencer may monitor the operator's actions, compare the actions to the identified welding sequences, and appropriately select a new welding schedule. Still further, various combinations of these methods, or any other effective method, may be implemented, so long as the net effect is to provide automatic selection and implementation of functions (eg, weld scheduling) for use by the operator.

The parameters of the selected welding schedule may include, for example, welding process, wire type, wire size, WFS, volts, trim, which wire feeder to use, or which feed head to use ), but not limited to this.

Although the above description focuses on welding schedule selection as a function of automatic selection and implementation, the welding job sequencer is not limited to using only this function.

For example, another possible function that may be selected and implemented by the welding job sequencer is to select one of multiple wire feeds on a single power source according to the welding schedule. This feature provides more variability in the welding jobs that can be performed by the operator in a semi-automatic work cell, as different wire feeders can provide large variability, eg, wire size and type.

Another example of a function that is compatible with the welding job sequencer is a quality check function. This function performs a quality check of the weld (either during the weld or after the weld is complete) before allowing the job sequence to continue. This quality check can monitor various welding parameters and, if an abnormality is detected, can abort the welding operation and alert the operator. An example of a welding parameter measurable by this function may be arc data.

Another example of such a function would be a repeat function. This energy will guide the operator to repeat a particular weld or welding sequence. Examples of the use of this functionality include when a quality check shows anomalies or when multiple instances of the same weld are required.

Another example of such a function would be a reminder welder function that transmits information to the welder. This function will display information, give an audible signal, or communicate with the welder by some other means. Examples of the use of this function include an indication to the operator that he is free to start welding, or that the operator should inspect some parts of the welded part for quality purposes.

Another example of such a function would be an entry job information function. This feature will require the welder to enter information such as part serial numbers, personal ID numbers, or other special conditions before the job sequencer can continue. This information can also be read from a part or inventory by radio frequency identification (RFID), barcode scanning, or the like. The welding job sequencer can then use the entered information for the welding operation. An example of the use of this function may be as a predicate for the entire welding operation to instruct the welding job sequencer which schedules and/or sequences should be selected.

Yet another embodiment of such a function would be a job reporting function. This function will create a report on the welding job, which can include information such as: number of welds performed, total and individual arc timing, sequence interruptions, errors, faults, wire usage, arc timing data, etc. An example of the use of this function could be a report to the manufacturing quality department on the efficiency and quality of the welding process.

Yet another embodiment of such a function would be a system check function. This function will verify whether the welding job can continue and can monitor parameters such as wire supply, gas supply, time remaining in the shift (compared to the time required to end the job), etc. The function can then determine whether the parameters indicate that there is sufficient time and/or material for the welding job to continue. This functionality will avoid down-time due to material exhaustion, and will avoid work-in-process assembly being delayed which may cause quality issues due to thermal and scheduling factors.

Furthermore, as mentioned above, the welding job sequencer can select and implement new functions based on various variables or inputs. These variables and inputs are not particularly limited, and may even be another function. For example, another function compatible with the welding job sequencer is the execute welding operation function. This function is designed to detect the actual weld performed by the operator, and to report the weld so that the weld job sequencer can determine whether to progress to further operations. For example, the function may operate to begin when the operator pulls the trigger to begin the welding operation and end when the operator releases the trigger after welding is complete, or after a predetermined period of time after it begins. This function can be terminated when the trigger is released, or it can be configured to automatically turn off after a period of time, after a certain amount of wire or a certain amount of energy has been delivered. This function can be used to determine when to select a new function, eg, a new welding schedule as discussed above.

] Furthermore, various semi-automatic and/or robotic work cells can be integrated together in a single network, and the sequencing of the welding steps of a single work cell can be fully integrated into a complete production schedule, which itself can be Modify to follow changes in the production schedule. Sequencing and/or scheduling information can also be stored in a database, stored as profile information by date, and can be accessed to provide various production reports.

In an embodiment, a semi-automatic welding work cell may be provided for welding an assembly defined by a plurality of welds, the plurality of welds defined by at least two welding schedules may include welding equipment for use by a welding operation used by the operator to perform the plurality of welds and complete the assembly with the welding equipment having the plurality of functions. In an embodiment, the work cell may include a welding job sequencer that automatically selects a welding schedule for use by an operator in a semi-automatic welding work cell. In an embodiment, the welding job sequencer may select a welding schedule based on elapsed time. In an embodiment, the welding job sequencer may detect when an operator is conducting a welding operation and select a welding schedule based on the detection. In an embodiment, the welding job sequencer may detect when an operator is conducting a welding operation, and the welding job sequencer selects a welding schedule based on the amount of wire supplied for the welding operation. In an embodiment, the welding job sequencer can detect when an operator is conducting a welding operation, and the welding job sequencer selects a welding schedule based on the amount of energy supplied for the welding operation. In an embodiment, the welding schedule includes information related to at least one of welding process, wire type, wire size, WFS, volts, trim, wire feeder to use, or feed head to use.

In an embodiment, the welding work cell may include a welding job sequencer that selects and implements at least one of a plurality of functions to define at least a first welding schedule and a second welding schedule from at least two welding schedules Two welding schedules to schedule the workflow for creating welded assemblies and instruct the welding operator to sequence the work operations for completing the assembly. In an embodiment, the welding job sequencer can automatically change the welding equipment according to the workflow and the sequence of welding operations, without the intervention of the welding operator.

In an embodiment, the second welding schedule is defined according to the elapsed time of the first welding schedule. In an embodiment, at least one function detects completion of the first welding schedule by the operator and automatically changes from the first welding schedule to the second welding schedule. In an embodiment, at least one function detects when an operator is conducting the first welding schedule, and the second welding schedule is defined according to the amount of wire supplied for the first welding schedule. In an embodiment, at least one function detects when an operator is conducting the first welding schedule and the second welding schedule is defined according to the amount of energy supplied for the first welding schedule. In embodiments, the at least one first welding setup parameter and the at least one second welding setup parameter include welding process, wire type, wire size, WFS, volts, trim, wire feeder to use, or feeder to use Enter at least one of the headers. In an embodiment, the at least one first welding setup parameter and the at least one second welding setup parameter include a feeder for use by an operator in a semi-automatic welding work cell. In an embodiment, at least one function monitors a quality measurable value of the welding assembly, wherein the quality measurable value includes at least information related to the arc used to form the weld created by the operator. In an embodiment, at least one function indicates information to an operator in a semi-automatic welding work cell. In an embodiment, at least one function accepts job information, including at least a part ID number, an operator ID number, or welding instructions. In an embodiment, at least one function generates a job report including at least one of number of welds performed, total arc time, individual arc times, sequence interruptions, errors, faults, wire usage, arc data. In an embodiment, at least one function includes a system inspection of the unit, the system inspection including at least the detection of wire supply, gas supply and time.

In an embodiment, the welding job sequencer may select a welding sequence for use by an operator in a semi-automatic welding work cell. In an embodiment, the welding job sequencer may indicate the selected welding sequence to the operator in the semi-automatic welding work cell. In embodiments, the welding job sequencer may select a wire feeder for use by an operator in a semi-automatic welding work cell. In an embodiment, the welding job sequencer may monitor quality measurables of the weld created by the operator, wherein the quality measurables include at least information related to the arc used to form the weld created by the operator . In an embodiment, the welding job sequencer may indicate information to an operator in a semi-automatic welding work cell. In an embodiment, the welding job sequencer may accept job information including at least part ID numbers, operator ID numbers, or welding instructions. In an embodiment, the welding job sequencer may generate a job report including at least one of number of welds performed, total arc time, individual arc times, sequence interruptions, errors, faults, wire usage, arc data. In an embodiment, the welding job sequencer may perform a system check that includes at least detection of wire supply, gas supply, and time.

In an embodiment, a method of welding in a semi-automatic welding work cell may be provided, the method comprising automatically selecting a welding schedule for use by an operator in the semi-automatic welding work cell. In an embodiment, the automatic selection may be performed after an elapsed time. In an embodiment, the method may include detecting when an operator is conducting a welding operation, wherein the automatic selection is performed based on the detecting. In an embodiment, the method may include detecting when an operator is conducting a welding operation, wherein the automatic selection is performed based on the amount of wire supplied for the welding operation. In an embodiment, the method may include detecting when an operator is conducting a welding operation, wherein the automatic selection is performed according to an amount of energy supplied for the welding operation. In an embodiment, the welding schedule may include information related to at least one of welding process, wire type, wire size, WFS, volt value, trim, wire feeder to use, or feed head to use.

In embodiments, the method may include selecting a welding sequence for use by an operator in a semi-automatic welding work cell. In an embodiment, the method may include indicating the selected welding sequence to an operator in the semi-automatic welding work cell. In embodiments, the method may include selecting a wire feeder for use by an operator in a semi-automatic welding work cell. In an embodiment, the method may include monitoring a quality measurable value of the weld created by the operator, wherein the quality measurable value includes at least information related to the arc used to form the weld created by the operator. In an embodiment, the method may include instructing an operator in a semi-automatic welding work cell. In an embodiment, the method may include accepting job information, including at least a part ID number, an operator ID number, or welding instructions. In an embodiment, the method may include generating a job report including at least one of number of welds performed, total arc time, individual arc times, sequence interruptions, errors, faults, wire usage, arc data. In an embodiment, the method may include performing a system check that includes at least detection of wire supply, gas supply, and time.

In an embodiment, the welding line is provided with at least one semi-automatic welding work cell, wherein the semi-automatic work cell includes a welding job sequencer that automatically selects for use by an operator in the semi-automatic work cell Welding schedule. In an embodiment, the welding line includes a monitoring system in communication with the welding job sequencer to direct the welding job sequencer to automatically select a welding schedule for use by an operator in a semi-automatic work cell.

In an embodiment, a method of monitoring a welding line is provided, the method comprising automatically selecting a welding schedule for use by an operator in a semi-automatic welding work cell. In an embodiment, the method may include directing a welding job sequencer to automatically select a welding schedule for use by an operator in a semi-automatic welding work cell.

In an embodiment, a semi-automatic welding work cell is provided, the semi-automatic welding work cell including a welding job sequencer that automatically selects a welding sequence for use by an operator in the semi-automatic welding work cell Procedure. Automatic selection may be by means of elapsed time, detection of the welding operation, detection of the amount of wire supplied for the welding operation, or detection of the amount of energy supplied for the welding operation.

In an embodiment, a method of welding in a semi-automatic work cell may be provided, the semi-automatic work cell having welding equipment and a welding job sequencer to complete an assembly defined by a plurality of welds, wherein the plurality of welds may be formed by at least two Welding schedule is limited. Embodiments may include at least the step of implementing a welding equipment function with a welding job sequencer to define a first welding schedule and a second welding schedule from at least two welding schedules, the first welding schedule having at least a first weld setup parameter and at least one first weld instruction, the second weld schedule having at least one second weld setup parameter and at least one second weld instruction, the second weld setup parameter and the second weld at least one of the instructions is different from the first welding setup parameter and the first welding instruction; indicating to a welding operator a sequence of welding operations for completing an assembly based on the first and second welding schedules; and according to The welding equipment is automatically changed based on the sequence of welding operations for completing the assembly based on the first and second welding schedules.

In an embodiment, a method may include defining the second welding schedule to be executed after an elapsed time defined by the first welding schedule. In an embodiment, the method may include detecting when an operator is conducting a welding operation, wherein defining the second schedule is based on the detecting. In embodiments, defining the first and second welding schedules may include defining the amount of welding wire supplied for the welding operation. In an embodiment, defining the second welding schedule is based on an amount of energy supplied for a welding operation for the first welding schedule. In embodiments, defining at least one of the first and second welding schedules may include selecting and welding process, wire type, wire size, WFS, volt value, trim, wire feeder to use, or wire feeder to use feed at least one of the heads. In embodiments, defining at least one of the first and second welding schedules may include selecting a wire feeder for use by an operator in a semi-automatic welding work cell. In an embodiment, the method may include monitoring a quality measurable value of the weld created by the operator, wherein the quality measurable value includes at least information related to the arc used to form the weld created by the operator. In an embodiment, the method may include instructing an operator in a semi-automatic welding work cell. In an embodiment, the method may include accepting job information, including at least a part ID number, an operator ID number, or welding instructions. In an embodiment, the method may include generating a job report including at least one of number of welds performed, total arc time, individual arc times, sequence interruptions, errors, faults, wire usage, arc data; performing a system check, the The system check includes at least the inspection of wire supply, gas supply and timing.

In an embodiment, a welding line is provided, the welding line including at least one semi-automatic welding work cell for welding an assembly defined by a plurality of welds defined by at least two welding schedules, the semi-automatic welding work cell comprising Welding equipment for use by a welding operator to perform multiple welds and complete an assembly, the welding equipment has multiple functions. In an embodiment, the welding line may include a welding job sequencer that selects and implements at least one of a plurality of functions to define at least a first and a sequence of welding operations from at least two welding schedules A second welding schedule, the at least two welding schedules are used by the welding operator to complete a welding assembly. In an embodiment, a production line may include the first weld schedule and the second weld schedule, the first weld schedule including at least one first weld setup parameter and at least one first weld schedule for the weld operator Welding instructions, the second welding schedule includes at least one second welding setup parameter and at least one second welding instruction for the welding operator, at least one of the first welding setup parameter and the first welding instruction Unlike the second welding setup parameters and the second welding instructions, the welding job sequencer automatically changes the welding equipment according to the sequence of operations, without intervention by the welding operator. In an embodiment, the production line may include a monitoring system in communication with the welding job sequencer to monitor the completion of at least one welding instruction for each of the first and second welding schedules.

In an embodiment, a method for monitoring a welding 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 consisting of at least two welding rows Program-defining, semi-automatic welding work cells include welding equipment and a welding job sequencer. The method may include at least the step of defining at least first and second welding schedules in a sequence of welding operations from at least two welding schedules with a welding job sequencer, the first welding schedule having at least one first welding setting parameters and at least one first weld instruction, and the second weld schedule defines at least one second weld setup parameter and at least one second weld instruction, wherein the second weld setup parameter and one of the second weld instructions at least one different from the first welding setup parameter and the first welding instruction; determining completion of the first welding schedule by the welding operator; automatically changing welding equipment according to the second welding schedule, Intervention of the welding operator is not required; and the welding operation is monitored. In an embodiment, a method may include automatically changing welding equipment according to the second welding schedule based on the completion of the first welding schedule.

In an embodiment, a semi-automatic welding work cell is provided for use by an operator. Embodiments may include a welding device having multiple functions for performing welding by an operator, and a welding job sequencer selected from multiple functions to set up and schedule welding for the operator equipment. Embodiments may include multiple functions including: a welding scheduling function defined by a sequence of welding operations; a notification function instructing an operator to execute a welding schedule; and a quality checking function monitoring at least one welding operation in the sequence of welding operations.

In an embodiment, the quality check function performs quality checks on welds completed by at least one welding operation. In an embodiment, the quality check function monitors at least one welding operation during the at least one welding operation. In an embodiment, the quality check function monitors at least one welding operation after the at least one welding operation is completed. In an embodiment, the welding schedule function defines a plurality of welding schedules, each welding schedule having a first welding operation and at least a second welding operation. In an embodiment, the quality check function monitors at least one welding operation before allowing the sequence of welding operations to continue. In an embodiment, the quality check function detects an anomaly, the sequencer suspends the sequence of welding operations, and the notification function alerts the operator to the anomaly.

3 is a schematic block diagram of an exemplary embodiment of a welding system 300 that utilizes a welding job sequencer component 302 to configure welding equipment for two or more welding operations to assemble workpieces. The welding job sequencer component 302 is configured to implement a welding sequence (including settings, configurations, and/or parameters) to perform two or more welding processes on a workpiece. In particular, the welding job sequencer component 302, as the welding job sequencer as discussed above, automatically configures welding equipment to create two or more welds that include two or more welding schedules. Also, the welding job sequencer component 302 utilizes welding sequences to assist an operator in performing two or more welds. As discussed above, the welding job sequencer component 302 may be utilized with the semi-automatic welding work cell 304 . However, it is to be appreciated and understood that the welding job sequencer component 302 may be implemented in a suitable welding environment or system that includes at least welding equipment and an operator to facilitate the creation of one or more a welding.

The welding system 300 further includes a checkpoint component 306 configured to monitor the welding process and/or the welding operator in real time. For example, the welding process is monitored in real time to detect at least one of: welding parameters (eg, voltage, current, etc.), welding schedule parameters (eg, welding process, wire type, wire size, WFS, volts, trim , the wire feeder to use, the feed head to use, etc.), the weld on the workpiece (when the weld is created), the movement of the operator, the position of the welding tool, the position or setting of the welding equipment, the operator location or settings, sensor data (eg, video cameras, image capture devices, thermal imaging devices, thermal sensing cameras, temperature sensors, etc.), etc. Checkpoint component 306 includes an alert system (not shown) that can deliver alerts or notifications to indicate the status of real-time monitoring. In embodiments, checkpoint component 306 may utilize thresholds, ranges, limits, etc. for real-time monitoring to accurately identify anomalies in welding system 300 . Additionally, the checkpoint component 306 may communicate an alert or notification to the welding work cell 304 or an operator to at least one of stop the welding process, continue the welding process, pause the welding process, terminate the welding process, or request approval of the welding process (approval). In an embodiment, the checkpoint component 306 may store monitored data (eg, video, images, results, sensor data, etc.) in at least one of a server, a data storage device, the cloud, a combination thereof, and the like.

Weld scoring component 308 may be included with welding system 300 and configured to evaluate welds created by an operator within welding work cell 304 when such welding is completed. The weld scoring component 308 provides a rating or rating for completed welds to facilitate quality control of workpieces and/or assemblies of workpieces. For example, the weld scoring component 308 may alert weld inspections upon completion, provide data collection for jobs (eg, assembly of workpieces, welding on workpieces, etc.), and the like. In embodiments, in-person quality inspection may be performed upon completion of a portion of an assembly (eg, completion of a weld, completion of two or more welds, completion of an assembly, etc.). In another embodiment, the weld scoring component 308 may utilize sensors to collect data (eg, video cameras, image capture devices, thermal imaging devices, thermal sensing cameras, temperature sensors, etc.) to determine approval of a job. For example, quality inspections may be performed remotely via video or image data collected when the job is completed.

It is to be appreciated that the welding job sequencer component 302 may be a separate component (as depicted), may be incorporated into the welding job cell 304, may be incorporated into the checkpoint component 306, may be incorporated into the weld scoring component 308, or a suitable combination thereof. Additionally, as discussed below, the welding job sequencer component 302 may be a distributed system, software as a service (SaaS), cloud-based system, or a combination thereof. Further, it is to be appreciated and understood that the checkpoint component 306 may be a separate component (as depicted), may be incorporated into the welding work cell 304, may be incorporated into the welding job sequencer component 302 , may be incorporated into the weld scoring component 308, or a suitable combination thereof. Additionally, checkpoint component 306 may be a distributed system, software as a service (SaaS), cloud-based system, or a combination thereof. Moreover, it is to be appreciated and understood that the weld scoring component 308 may be a separate component (as depicted), may be incorporated into the welding work cell 304, may be incorporated into the welding job sequencer component 302, May be incorporated into the checkpoint component 306, or a suitable combination thereof. Additionally, the welding scoring component 308 may be a distributed system, software as a service (SaaS), cloud-based system, or a combination thereof.

FIG. 4 illustrates a schematic block diagram of an exemplary embodiment of a welding system 400 including a welding circuit path 405 . It is to be appreciated that the welding system 400 is also referred to as a welding work cell, where the welding work cell and/or the welding system 400 may produce welds or welded components. The welding system 400 includes a welder power supply 410 and a display 415 operably connected to the welder power supply 410 . Alternatively, display 415 may be an integral part of welder power supply 410 . For example, display 415 may be incorporated into welder power supply 410, may be a separate component (as depicted), or a combination thereof. Welding system 100 further includes welding cable 120 , welding tool 430 , workpiece connector 450 , spool 460 of welding wire, wire feeder 470 , welding wire 480 , and workpiece 440 . According to embodiments of the present invention, welding wire 480 is fed into welding tool 430 from spool 460 via wire feeder 470 . According to another embodiment of the present invention, the welding system 400 does not include a spool 460 of welding wire, a wire feeder 470, or a welding wire 480, but instead includes a welding tool that includes a consumable electrode, such as is used with In, for example, hand soldering. According to various embodiments of the present invention, the welding tool 430 may include at least one of a welding torch, a welding gun, and welding consumables.

Weld circuit path 405 extends from welder power source 410 to weld tool 430 through weld cable 420 , through workpiece 440 and/or to workpiece connector 450 , and back to welder power source 110 through weld cable 420 . During operation, when a voltage is applied to the welding circuit path 405 , current flows through the welding circuit path 405 . According to an exemplary embodiment, welding cable 420 includes a coaxial cable assembly. According to another embodiment, welding cable 420 includes a first cable length extending from welder power source 410 to welding tool 430 and a second cable length extending from workpiece connector 450 to welder power source 410 .

The welding system 400 includes the welding job sequencer component 302 (as described above). The welding job sequencer component 302 is configured to interact with a portion of the welding system 400 . For example, the welding job sequencer component 302 may interact with at least a power source 410, a portion of the welding circuit path 405, a spool of welding wire 460, a wire feeder 470, or a combination thereof. The welding job sequencer component 302 automatically adjusts one or more components of the welding system 400 based on the welding sequence utilized to configure the welding system 400 (or its components) without operator intervention to Two or more welding processes are performed, the two or more welding processes having respective settings or configurations for each welding process.

In an embodiment, the welding job sequencer component 302 employs a welding sequence to automatically configure welding equipment. It is to be appreciated that the welding system 400 or welding work cell may employ multiple welding sequences for the assembly of one or more workpieces. For example, the workpiece may include three (3) welds to complete the assembly, where a first weld sequence may be used for the first weld, a second weld sequence may be used for the second weld, and a third weld sequence may be used for the third weld used. Also, in such an embodiment, an assembly of the entire workpiece comprising three (3) welds can be referenced as a welding sequence. In embodiments, welding sequences including specific configurations or steps may be further included within distinct welding sequences (eg, embedded welding sequences). An embedded welding sequence may be a welding sequence that includes a welding sequence as part of a process. Furthermore, the welding sequence may include at least one of parameters, a welding schedule, a portion of a welding schedule, step-by-step instructions, a portion of media (eg, images, video, text, etc.), individual instructions, and the like. Generally, a welding sequence can be created and employed to guide an operator through the welding process(s) for a particular workpiece without requiring the operator to manually set up welding equipment to perform such welding process. Inventions of the present subject matter relate to creating welding sequences and/or altering welding sequences.

One or more welder power supplies (eg, welder power supply 410 ) aggregate respective data for respective welding processes that provide power to perform the respective welding processes. Such collected data pertains to each welder power source and is referred to herein as "welding data". Welding data may include welding parameters and/or information specific to the welding process for which the welder power supply is powered. For example, welding data may be outputs (eg, waveforms, signals, voltages, currents, etc.), welding time, power consumption, welding parameters for the welding process, welder power output for the welding process, and the like. In embodiments, welding data may be utilized with the welding job sequencer component 302 . For example, welding data can be set by a welding sequence. In another embodiment, weld data may be used as a feedback or feedforward loop to verify settings.

In one embodiment, the welding job sequencer component 302 is a computer operable to perform the disclosed methods and processes, including the methods 1100 and 1200 described herein. To provide additional context for the various aspects of the invention, the following discussion is intended to provide a concise, general description of a suitable computing environment in which various aspects of the invention may be implemented. Although the invention has been described above in the general context of computer-executable instructions that can be executed on one or more computers, those skilled in the art will appreciate that the invention may also be incorporated into other programs modules and/or implemented 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.

Moreover, those skilled in the art will appreciate that the inventive methods may be implemented with other computer system configurations, including single- or multi-processor computer systems, microcomputers, mainframe and personal computers, hand-held computing devices, microprocessor-based or programmable consumer electronics, etc., each of which may be operably coupled to one or more associated devices. The illustrated aspects of the invention can 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 example, a remote database, a local database, a cloud computing platform, a cloud database, or a combination thereof may be utilized with the welding job sequencer 302 .

The welding job sequencer 302 may utilize an exemplary environment to implement various aspects of the invention including a computer including a processing unit, a system memory, and a system bus. The system bus couples system components, including but not limited to system memory, to the processing unit. The processing unit may be any of a variety of commercially available processors. Dual microprocessors and other multiprocessor architectures can also be employed as processing units.

The system bus can be any of several types of bus structures, including a memory bus or memory controller, a peripheral bus, and a local bus using any kind of commercially available bus architecture. System memory may include read only memory (ROM) and random access memory (RAM). A basic input/output system (BIOS) is stored in ROM, the basic input/output system (BIOS) includes basic routines that facilitate the transfer of information between components within the welding job sequencer 302, such as in the startup phase.

Welding job sequencer 302 may also include a hard disk drive, such as a magnetic disk drive for reading from or writing to a removable magnetic disk, a magnetic disk drive, and an optical disk drive, such as for reading CO-ROM disks or from other Optical media reads or writes to other optical media. Welding job sequencer 302 may include at least some form of computer-readable media. Computer readable media can be any available media that can be accessed by a computer. By way of example and not limitation, computer-readable media may include computer storage media and communication media. Computer storage media includes volatile and nonvolatile, removable and non-removable, implemented in any method or technology for storage of information (eg, computer readable instructions, data structures, program modules or other data) medium. Computer storage media include, but are not limited to, RAM, ROM, EEPROM, flash memory or other storage technology, CD-ROM, digital versatile disk (DVD), or other magnetic storage devices, or may be used to store desired information and may be accessed by Other media accessed by the welding job sequencer 302 .

Communication media typically embodies computer readable instructions, data structures, program modules, or other data in a modulated data signal (eg, carrier waves or other transport mechanism) and includes any information delivery media. The term "modulated data signal" means a signal having 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 include wired media such as a wired network or direct wired connection, and wireless media such as acoustic, radio frequency (RF), near field communication (NFC), radio frequency identification (RFID), Infrared media and/or other wireless media. Combinations of any of the above should also be included within the scope of computer-readable media.

A number of program modules may be stored in the drives and RAM, including the operating system, one or more application programs, other program modules, and program data. The operating system at welding job sequencer 302 may be any of a number of commercially available operating systems.

In addition, a user can enter commands and information into the computer through a keyboard and pointing device (eg, a mouse). Other input devices may include microphones, IR remote controls, trackballs, pen input devices, joysticks, game pads, digitizing pads, satellite dishes, scanners, and the like. These or other input devices are typically connected to the processing unit by a serial port interface coupled to the system bus, but may be connected by other interfaces such as parallel ports, game ports, universal serial bus ("USB"), IR interfaces and/or or various wireless technologies. A monitor (eg, display 415) or other type of display device may also be connected to the system bus via an interface (eg, a video adapter). Visual output can also be accomplished by remote display network protocols such as Remote Desktop Protocol, VNC and X-Window System, etc. In addition to visual output, computers typically include other peripheral output devices such as speakers and printers.

A display (in addition to or in combination with display 415) may be used with welding job sequencer 302 to present data electronically received from the processing unit. For example, the display may be an LCD, plasma, CRT, etc. monitor that electronically presents data. Alternatively or additionally, the display may present the received data in a hard copy format (eg, printer, fax, plotter, etc.). The display may present data in any color and may receive data from the welding job sequencer 302 via any wireless or hardwired protocol and/or standard. In another embodiment, welding job sequencer 302 and/or system 400 may communicate with mobile devices (eg, cell phones, smart phones, tablet computers, portable gaming devices, portable Internet browsing devices, Wi-Fi devices, portable digital Assistant (PDA), etc.) are utilized together.

Computers may operate in a network environment using logical and/or physical connections to one or more remote computers, such as the remote computer(s). The remote computer(s) may be workstations, server computers, routers, personal computers, entertainment-based microprocessors, peers, or common network nodes, and typically include the components described relative to the computer. many or all of them. The logical connections described include local area networks (LANs) and wide area networks (WANs). Such networked environments are commonplace in offices, enterprise-wide computer networks, intranets, and the Internet.

When used in a LAN networked environment, the computer is connected to the local network by a network interface or adapter. When used in a WAN networking environment, a computer typically includes a modem, or is connected to a communications server on a LAN, or has other means for establishing communications over the WAN (eg, the Internet). In a network environment, program modules, or portions thereof, described in relation to a computer may be stored in remote memory storage devices. It will be appreciated that the network connections described herein are exemplary and other means of establishing a communication link between the computers may be used.

Alternatively or in addition, a local or cloud (eg, local, cloud, remote, etc.) computing platform may be utilized for data aggregation, processing, and delivery. For this purpose, a cloud computing platform may include multiple processors, memories, and servers at specific remote locations. Under the Software-as-a-Service (SaaS) paradigm, a single application is employed by multiple users to access data residing in the cloud. In this manner, when data processing is typically performed in the cloud, processing requirements at the local level are mitigated, thereby relieving user network resources. A software-as-a-service application allows a user (eg, via a web browser) to log into a web-based service that hosts all programs residing in the cloud.

Turning to Figure 5, a system 500 illustrates a welding environment with multiple welding work cells via a local, remote or cloud database. The system 500 includes a plurality of welding work units, such as a first welding work unit 515, a second welding work unit 520 to an Nth welding work unit 530, where N is a positive integer. In an embodiment, each welding work unit includes welding job sequencer components 535, 540 and 545 that are used for each welding work unit and or alternatively Weld schedule(s) are implemented for the enterprise-wide welding operation(s) and/or the enterprise-wide welding work cell(s). The welding sequence(s) from each welding job sequencer component 535, 540, and 545 are received from a local or cloud database (eg, local database, cloud database, remote database, etc.) computing platform 510.

In an embodiment, each welding work cell further includes a local data storage device. For example, the first welding work unit 515 includes a welding job sequencer component 535 and a data storage device 550, the second welding work unit 520 includes a welding job sequencer component 540 and a data storage device 555, and the Nth welding work unit 530 includes Welding job sequencer component 545 and data storage device 560. It is to be appreciated that the system 500 includes a welding job sequencer 302 hosted by a computing platform 510, wherein each welding work cell includes a distributed and respective welding job sequencer component. Again, it is to be understood that welding job sequencer 302 (and distributed welding job sequencer components 535 , 540 and 545 ) may be a separate component in each welding work cell or a separate component in computing platform 510 components.

Each welding work cell may include a respective data storage device that stores a portion of at least one welding sequence. For example, the welding sequence associated with welding process A is employed in one or more welding work cells. The welding sequences are stored in respective local data storage devices (eg, data storage devices 550, 555, and 560). Again, it is to be appreciated and understood that each welding work cell may include a local data storage device (as depicted), a collective and shared remote data storage device, a collective and shared local data storage device, a data storage device generated by the computing platform 510 A cloud data storage device as a host or a combination thereof. "Data storage" or "memory" may be, for example, volatile memory or non-volatile memory, or may include both volatile and non-volatile memory. The data storage devices of the subject systems and methods are intended to include, but are not limited to, these and other suitable types of memory. Additionally, the data storage device may be a server, database, hard drive, flash drive, external hard drive, portable hard drive, cloud-based storage, or the like.

For example, the welding job sequencer component 302 may manage each welding job sequencer component 535 , 540 , 545 in each welding work cell 515 , 520 , 530 . In another embodiment, communications may be transmitted from the welding job sequencer 302 to each welding work unit (eg, each welding job sequencer component). In another embodiment, communications from each welding work unit (eg, each welding job sequencer component) may be received from the welding job sequencer 302 . For example, a welding sequence may be used with the first welding work cell 515 and passed to a distinct welding work cell, either directly or via the computing platform 510 .

FIG. 6 illustrates a welding system 600 including a plurality of welding work cells, wherein the welding work sequencer component 302 is hosted by the computing platform 510 to utilize one or more welding sequences in one or more welding systems, Welding equipment is configured within the welding environment and/or welding work cell. The welding system 600 includes a local or cloud-based welding job sequencer component 302 hosted on a computing platform 510 . The welding job sequencer component 302 can utilize welding sequences with many welding work cells. For example, welding system 600 may include a number of welding work cells, such as, but not limited to, first welding work cell 620, second welding work cell 630, through Nth welding work cell, where N is a positive integer. It will be appreciated that the location of the welding job sequencer component 302 is associated with each of the first welding work unit 620 , the second welding work unit 630 and/or the Nth welding work unit 640 .

In an embodiment, the welding job sequencer 302 passes one or more welding sequences to a target welding work cell, where the target welding work cell is a welding work cell that utilizes the passed welding sequence. Still further, in another embodiment, welding job sequencer 302 utilizes memory 650 hosted on computing platform 510 in which one or more welding sequences are stored. Also, the stored welding sequence may be related to or specific to one or more welding work cells, regardless of the storage location (eg, local, cloud, remote, etc.).

FIG. 7 illustrates a system 700 that generates a welding sequence based on welding process data. The system 700 includes a collection component 702 configured to receive a portion of the welding process data to create a welding sequence 706 . Collection component 702 receives, collects, aggregates, and/or identifies a portion of the welding process data that generation component 704 utilizes to create welding sequence 706 . As discussed above, the welding sequence 706 is used by the welding job sequencer component (see FIGS. 3-6 ) to utilize two or more respective welding parameters (eg, welding schedules, parameters, configurations, settings) etc.) perform two or more welds. In particular, welding sequence 706 is 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.

A portion of the welding process data is related to at least one of a welding process or process performed, or a welding process or process that has been performed. For example, a portion of the welding process data is data based on real-world welding operations (eg, real-time welds being performed and data collected from said real-time welds being performed, data previously collected from welds performed, etc.) . By way of example and not limitation, the welding process data may be at least one of: welding parameters, settings (eg, voltage, current, etc.), monitored readings (eg, measured current, measured voltage, etc.), Welding equipment configuration (eg, power settings, waveforms, wire feed speed, etc.), welder settings (eg, workpiece type, wire type, material type, weld to be performed, etc.), etc. Generally, welding process data may be any data collected or monitored from welding or welding equipment during the actual welding being performed or created.

Although system 700 is illustrated as a stand-alone system, it is to be appreciated that system 700 may be a stand-alone system (as depicted), may be incorporated into a welding job sequencer component (not shown), or be a their combination. Further, welding process data may be via the welding job sequencer and thus from a local data storage device, a remote data storage device, a cloud-based data storage device, a computing platform, and/or any other discussed above with respect to the welding job sequencer. A network or computing environment configuration is received. For example, welding environment A may collect welding process data or parameters, wherein such welding process data is communicated to welding environment B (eg, via the Internet, cloud, computing platform, etc.). Welding environment B may utilize the welding process data from environment A to create a welding sequence for welding environment B based on correlated or matched parameters for the welding process to be performed.

In embodiments, real-world welding data or real-world welding process data may be utilized by generating component 704 to create welding sequences 706 that are independent of the welding environment from which the welding process data originated. For example, welding process data may be collected from one or more operations, welding equipment, welding environments, welding work cells, and the like. Based on the collected welding process data, generation component 704 may be further configured to identify one or more parameters for use as welding sequence 706 . In embodiments, computer-based assessments may be utilized to determine which collected welding process data provides desired results. In another embodiment, an operator or user may evaluate the collected welding process data to select which welding process data provides the desired result. As discussed above, a cloud-based or computing platform may be employed to collect welding process data used to generate welding sequence(s) 706 .

In an embodiment, the welding sequence may include replenishment of consumables. A welding sequence may be created or edited to include replenishment of consumables for at least one of welding work cells, welding equipment, and the like. For example, a replenishment of consumables may be included with the welding sequence after a period of time that is estimated based on the duration that the welding equipment is used (eg, estimated use of consumables). Thus, the welding environment, welding system, and/or welding work cell can be assessed in real-time or from collected real-time data, and the data identified to determine replenishment of consumables. In another embodiment, the welding sequence may include inspection or repair. Weld sequences can be created or edited to include inspection requests or repair requests based on factors such as, but not limited to, time, duration, etc. Welding work cells may have maintenance periods for specific times, and if a welding sequence is created for such welding work cells, repair or maintenance may be included with the created welding sequence. Thus, the welding environment, welding system, and/or welding work cell can be assessed in real-time or from real-time data collected, and the data identified to determine inspection or repair.

Additionally, it is to be appreciated and understood that the collection component 702 may be a separate component (as depicted), incorporated into the generation component 704, incorporated into the welding job sequencer component (not shown) , or their combination. Additionally, the generation component 704 may be a separate component (as depicted), incorporated into the collection component 704, incorporated into the welding job sequencer component (not shown), or a combination thereof.

8 illustrates a system 800 that creates a welding sequence from an operator performing welding with welding equipment on a workpiece. The system 800 further includes a training component 802 configured to receive field feeds (eg, real-time capture) of the welding process and/or the creation of the weld. The training component 802 enables the operator 804 to input welding process data to create a welding sequence, wherein the input is that the operator physically performs the welding and/or the welding process by which the welding sequence is created. By way of example and not limitation, training component 802 allows operator 804 to perform welding (eg, create a weld with welding equipment 806 on workpiece 808 ) rather than providing welding process data. It is to be appreciated that system 800 and/or training component 802 can create a welding sequence based on at least one of welding process data, welding physically performed (via training component 802), or a combination thereof.

The training for the welding sequence may be based on the operator or machine performing the welding or welding process. Monitoring of the operator or machine performing the welding or welding process may be recorded using, for example, video cameras, video cameras, data collectors (eg, collection settings, voltages, currents, materials used, welding equipment settings, etc.), and the like. For example, embodiments may include snapshots of settings for welding equipment 806 as a basis for the creation of welding sequences. With the established settings of welding equipment 806, a welding sequence can be utilized to automatically configure one or more welding equipment 806 to perform two or more welds without user intervention.

The training component 802 is further configured to record data related to the welding process from which the welding sequence is to be created or derived from. For example, welding characteristics related to the welding operation performed (eg, voltage, current, wire feed speed, settings for welding equipment, etc.) may be collected. Additionally or alternatively, data related to the behavior of performing the welding process may also be captured. As will be discussed in more detail below, data related to the behavior of performing the welding process may include media (eg, video, images, audio, etc.) of the operator and/or machine performing the welding process.

In an embodiment, a user may perform a physical weld and approve or reject whether the performed physical weld (and its associated weld process data) is to be used by the generation component 704 to create a weld sequence. If approved, data collected from real-time physical welding via training component 802 is used to create a welding sequence. If rejected, the collected data is not used to create the welding sequence. In another embodiment, the average of the data collected during training can be taken. For example, training component 802 may monitor, track, and/or collect real-time data during physical training of weld creation for a specific number of welds. During such training, the average of the data collected or tracked can be used to create a setup or configuration for use with the created welding sequence. Thus, monitoring or tracking the physical creation of more than one weld or welding process may provide more accurate data for use in generating welding sequences.

In another embodiment, the welding and/or welding process may be stored in a data storage device (discussed in more detail below). Using data storage devices for welding and/or welding processes, characteristics (eg, type of weld, material, workpiece, type of welding equipment, wire feed speed, wire gauge, time, pace, etc.) can be identified, and individual characteristics can be One or more welding sequences are created from the features. In other words, individual weld data (welding process data for a single weld) can be collected for a particular welding sequence (either created or used), from which the best tracked individual weld data can be Weld sequences replace existing data (eg, based on performance analysis, etc.).

FIG. 9 illustrates a system 900 that creates a welding sequence for use in a welding environment. System 900 includes a media component 902 configured to include media for a welding sequence. It is to be appreciated that the media may be, but are not limited to, photographs, images, graphics, text, audio, video, computer-generated imagery, animation, dictation, sound recordings, and the like. For example, the media component 902 includes media that facilitates performing welding or welding operations from an operator's perspective. In an embodiment, the media component 902 includes a video of a weld created for a welding sequence (eg, via the training component above). Thus, when a welding sequence is used to create a weld, the video can guide the operator on how to perform the weld. In another embodiment, the media component 902 provides media related to at least one of the following: safety concerns for utilizing the welding sequence, areas of attention, problematic conditions, warnings, potential errors, ratings, time, date , Alignment of welding performed, etc. The media component 902 includes data with welding sequences that can be displayed, communicated, or output to an operator: in the welding work cell, where the welding sequence is used within the welding environment, and the like.

The system 900 further includes an identification component 904 configured to aggregate data for the description of the created welding sequence. The identification component 904 associates data with welding sequences during or after creation, where the data may detail such welding sequences. By way of example and not limitation, the data may be related to the following: date, time, user identification who created, user identification who changed, welding job, customer, workpiece information, welding information (eg, welding parameters, Welding equipment settings, etc.), environmental data (eg, the welding environment in which the welding sequence will be used, target welding equipment, etc.), job information (eg, work orders, customers, work orders, etc.), and the like. The identification component 904 can be customized to include data to set and employ welding sequences via retrieval and/or query based on criteria defined or included with the welding sequences. In an embodiment, job-based criteria may be employed in which data about the job is aggregated for and associated with the created welding sequence. Thus, after the creation of a welding sequence, queries using job-based data (discussed in more detail below) can be utilized to set up and find welding sequences. It is to be appreciated that various data may be collected at various points of creation and associated with the created welding sequence, and any suitable data may be collected at any suitable point during creation of the welding sequence.

For example, the identification component 904 may collect the employee identification of the creator of the welding sequence. By way of example and not limitation, employee identification may be associated with the creator of the welding sequence, the actor performing the welding process (eg, via the training component discussed above), the editor of the welding sequence, and the like. It is to be appreciated that the identification component 904 can associate one or more employee identifications with the welding sequence to provide tracking of each welding sequence creation, editing and/or modification of the welding sequence. This employee identification information may be used to provide query results for one or more creators (eg, employees, workers, users, etc.).

Furthermore, it is to be appreciated and understood that the identification component 904 may collect data for a portion of a welding sequence to enable portions or parts of the welding sequence to be identified or positioned. This, for example, allows the user to identify parts or portions of a welding sequence to reuse in the creation of another welding sequence.

The system 900 further includes a communication component 906 configured to transmit and/or receive at least a portion of the welding sequence. In an embodiment, the communication component 906 can transmit a portion of the welding sequence from the first location to the second location. For example, a welding sequence may be passed from a welding work cell to a dissimilar welding work cell, from a welding environment to a dissimilar welding environment, from an operator to a dissimilar operator, and so on. In an embodiment, the communication component 906 is further configured to print data related to the welding sequence, wherein the data is at least one of work orders, related media, customer information, welding parameters, welding equipment settings, details of the welding sequence, and the like .

FIG. 10 illustrates a system 1000 for performing two or more welds utilizing an automatically configured welding sequence for a welding system. The system 1000 includes a query component 1002 configured to receive a query and provide results based on the query. The query component 1002 can query one or more of the data stores discussed above. In particular, the query component 1002 can query the data stored in the welding sequence data storage 1004 . The welding sequence storage 1004 stores at least one of a welding sequence, a portion of a welding sequence, and/or data associated with the welding sequence (eg, metadata, metadata tags, etc.). Based on the received query, the query component 1002 can generate results from at least the welding sequence store 1004 . Query component 1002 and weld sequence data store 1004 (eg, by allowing portions of weld sequences to be reused) facilitate creation of weld sequences, management of weld sequences, and setup of weld sequences (eg, update, synchronization, consistency, etc.). As discussed above, the query component 1002 can utilize data collected via the identification component (see Figure 9).

In an embodiment, the query component 1002 is further configured to match welding sequences based on the collected query or data. For example, a query requesting a welding sequence related to a particular parameter can be received by the query component 1002, wherein welding sequences matching or including the particular parameter are returned. In more particular embodiments, the welding process can be monitored in real-time to collect real-time parameters (eg, welding process data), and the query component 1002 can identify welding sequences that match or include a portion of the welding process data. Using the matched welding sequence, the welding equipment and/or operator(s) may be guided through the previously monitored welding process. For example, an experienced operator can be monitored, and subsequently (after a welding process is created or matched) an inexperienced operator and/or equipment can be guided and/or configured.

The system 1000 further includes an update component 1006 configured to alter a previously created welding sequence. The update component 1006 modifies an existing welding sequence with new (eg, non-existing data) or edited (eg, previously existing data) information. It is to be appreciated that the update component 1006 can create a new welding sequence that includes the changed data and archive the previous welding sequence. In another embodiment, the update component 1006 may replace the previous welding sequence with a new welding sequence with changed data. Also, it is to be appreciated that the update component 1006 may be utilized in conjunction with the query component 1002, the weld sequence store 1004 and/or the identification component (see Figure 9).

For example, a user can utilize the query component 1002 to identify previously created welding sequences to update the welding sequences with the updated medium. Once identified in the welding sequence data store 1004 via the query component 1002 using the identifying component, the user or operator may utilize the welding sequence addition or alternative medium to provide up-to-date instructions.

In embodiments, when the created welding process is complete, a data model and/or software model may be employed to manage the factors of the welding process used for the welding process. The software model and/or the data model evaluates the welding process performed in the corresponding welding sequence, wherein factors can be adjusted. For example, the cycle time and/or evolution for the welding process may be adjusted based on at least one of a software model and/or a data model.

In view of the exemplary apparatus and elements described above, methods that may be implemented in accordance with the disclosed subject matter will be better understood with reference to the flowcharts and/or methods of FIGS. 11 and 12 . The methods and/or flow diagrams are shown and described in a series of blocks, the claimed subject matter is not limited to the order of the blocks, as some blocks may appear in a different order and/or differ from others from those depicted and described herein boxes appear together. In an embodiment, the first input may be received before the second input (as described below). In another embodiment, the second input may be received before the first input. In embodiments, the first input and the second input may be received substantially simultaneously. Furthermore, not all of the illustrated blocks may be required to implement the methods and/or flowcharts described below.

Continuing, the following occurs as illustrated in the decision tree flowchart 1100 of FIG. 11 , which is the creation of a welding sequence employed to automatically configure welding equipment within a welding work cell Flowchart 1100 of . The method 1100 evaluates one or more parameters related to a welding process that is being performed or has been performed. A first parameter is received, wherein the first parameter is related to a first welding schedule (reference block 1102). A second parameter is received, wherein the second parameter is related to the second welding schedule (reference block 1104). It is to be appreciated that the first parameter and/or the second parameter may be based on at least one of a previously performed welding process or an ongoing (eg, real-time) welding process. A welding sequence is created based on a first parameter and a second parameter, wherein the welding sequence defines a first welding process and a second welding process, the first welding process including the first parameter to create a first weld on the workpiece, the second welding process The welding process includes second parameters to create a second weld on the workpiece (reference block 1106). The created welding sequence is stored away from the welding work cell (reference block 1108). For example, welding sequences are stored on a different network than the network that handles part of the welding work cell. In another embodiment, the welding sequence may be stored locally with respect to the welding work cell (eg, the welding sequence is stored on the same network as the welding work cell). The welding sequence is utilized to automatically change the welding equipment within the welding work cell without intervention from the operator, creating at least one of a first weld or a second weld (reference block 1110).

The following occurs as illustrated in flowchart 1200 of FIG. 12 . Flowchart 1200 involves creating a welding sequence based on one or more parameters of a welding process that is being performed or has been performed. Parameters are collected in real-time from the welding process, where the parameters are related to the welding schedule (reference block 1202). A welding sequence is created for the welding work cell, wherein the welding sequence defines at least parameters and a welding schedule for a first welding process to create a first weld on the workpiece, and defines at least parameters and a welding schedule for a second welding process to create a welding schedule on the workpiece Create a second weld on (reference block 1204). A welding sequence for a welding work cell is employed to perform one or more welds to assemble a workpiece by automatically adjusting settings on welding equipment within the welding work cell (reference block 1206).

By way of example and not limitation, welding equipment (eg, a controller for a welder power supply, a wire feeder, a welder power supply, etc.) may include one or more welding processes associated with a particular welding process for a particular workpiece. A plurality of steps, wherein the steps may include respective settings or configurations for at least one welding equipment. For example, the first workpiece may include steps A, B, C, and D based on the desired welding parameters, the welding process used, and/or the workpiece. In another embodiment, the second workpiece may include steps B, C, A, E and F. As a welding sequence is employed, a controller that implements the steps of the welding process via the welder power supply and/or welding equipment may be managed and/or directed. For example, a welding sequence may indicate at least one of: which step to perform, redo a step, skip a step, pause a series of steps, and the like. Additionally, a controller (eg, or other suitable component) may control one or more welder power sources, parameters, welding schedules, and other associated with one or more welding processes, where each welding process may have The corresponding welding sequence(s).

In an embodiment, the method may include altering the created welding sequence to update at least a portion of the first welding schedule or the second welding schedule. The method may further include tracking the welding process in real time; collecting one or more parameters of the welding process in real time; and employing the collected one or more parameters as at least one of the first parameter or the second parameter. In an embodiment, the step of creating the welding process further comprises: evaluating at least one of the first parameter or the second parameter in comparison to a previously created welding sequence; identifying the first parameter and the second parameter using a portion of the at least one previously created welding sequence correlation between the second parameter; and creating a welding sequence using a portion of a previously created welding sequence. In an embodiment, the method may include attaching the welding sequence with a medium, the medium being at least one of a video or an image, to assist in performing at least one of the first weld or the second weld.

In embodiments, the system may include a weld scoring component configured to evaluate the first weld or the second weld performed on the workpiece based on at least one of an image of the first weld or the second weld or a user inspection at least one of the two welds. In embodiments, the system may include a checkpoint component configured to monitor the creation of at least one of the first weld or the second weld in real time. In an embodiment, the welding job sequencer component further instructs an operator of the welding work cell to assemble the workpiece using a first welding process and a second welding process having two separate welding schedules.

In an embodiment, the system may include a third component configured to receive real-time data from an operator associated with the creation of a weld, and to use the received real-time data to create a welding sequence. In an embodiment, the welder system may include a data storage device that stores at least one of a parameter, a work schedule, or a welding sequence; and a fourth component configured to be based on the received query A query result is generated, wherein the query result is a welding sequence derived from a previously performed welding process from the data storage device that satisfies the received query. In embodiments, the system may include a fifth component configured to attach a portion of the medium to the welding sequence, wherein the medium specifies instructions for performing the welding sequence on the workpiece.

In an embodiment, the system may include a sixth component configured to collect identifying information for the welding sequence. In an embodiment, the identifying information is metadata related to at least one of the following: user who created the welding sequence, welding type, customer name, material of workpiece, date, time, location, serial number, price, wire speed, The originating welding process or wire type that is the source of the welding sequence. In an embodiment, the welding sequence includes replenishment of consumables based on real-time data collected from the welding work cell to estimate the duration for which the replenishment is to be performed. In an embodiment, the welding sequence includes at least one of repair or maintenance of the welding equipment based on real-time data collected from the welding work cell to estimate a duration for which the repair or maintenance is to be performed.

In an embodiment, the steps are at least one of: inspection, maintenance for welding equipment, refilling of consumables used in the welder system, preventive maintenance for welding equipment, media capture for assembly of workpieces. In embodiments, the system may include a seventh component configured to deliver a portion of the welding sequence. In an embodiment, the seventh component is further configured to generate work orders for the welding sequence based on the welding schedule. In a further embodiment, a welding machine system is provided, the welding system comprising means for collecting parameters from a welding process in real time, wherein the parameters are related to a welding schedule; for creating a weld for a welding work cell An apparatus for a sequence, wherein a welding sequence defines at least parameters and a welding schedule for a first welding process to create a first weld on a workpiece, and defines at least parameters and a welding schedule for a second welding process to create a second weld on the workpiece welding; and means for performing one or more welds using a welding sequence for a welding work cell to assemble a workpiece by automatically adjusting settings on the welding equipment within the welding work cell.

The above examples are merely illustrative of several possible embodiments of various aspects of the invention, with equivalent alterations and/or modifications that will occur to those skilled in the art upon reading and understanding the specification and drawings. In particular, with respect to the various functions performed by the above-described components (components, devices/devices, systems and circuits, etc.), terms used to describe such components (including references to "means") are intended and performed Any component (eg, hardware, software, or combination thereof) of the specified function of the described component (eg, a functionally equivalent component) corresponds to any component (eg, hardware, software, or a combination thereof), unless otherwise indicated, even if not structurally equivalent to performing the invention illustrated The disclosed structure of the functionality in the implementation. Furthermore, although particular features of the invention may have been disclosed with respect to only one of several implementations, such features may be combined with one of the other implementations as desired and advantageous for any given or particular application or more other features in combination. Also, to some extent, the terms "including", "includes", "having", "has", "with" or variations thereof are described in detail in As used in the description and/or claims of , such terms are intended to be inclusive in a manner similar to the term "comprising."

This written description uses embodiments to disclose the invention, including the best mode, and also to enable any person 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 do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

The best mode for carrying out the invention has been described for the purpose of illustrating the best mode known at the time to the applicants. The embodiments are illustrative only, and are not meant to limit the invention, as measured by the scope and value of the claims. The present invention has been described with reference to preferred and alternative embodiments. Obviously, once this specification has been read and understood, modifications and alterations will occur to others. The intention is to include all such modifications and variations as fall within the scope of the appended claims or their equivalents.

Reference number:

10 Operating the 430 Welding Tool

20 operations 440 workpieces

22 Operating the 450 Workpiece Connector

24 operations 460 reels

26 Operating the 470 Wire Feeder

30 Operation 480 Wire

32 Operating the 500 System

40 Operation 510 Computing Platform

50 Operation 515 First welding cell

52 Operation 520 Second welding cell

54 Operation 530 Nth Welding Cell

60 Operation 535 Weld Job Sequencer Components

70 Operation 540 Weld Job Sequencer Components

100 Welding Systems 545 Welding Job Sequencer Components

110 Operation/Welder Power 550 Data Storage Device

120 Operation/Welding Cable 555 Data Storage Device

122 Operating the 560 Data Storage Device

124 Operating the 600 Welding System

126 Operation 620 First welding cell

130 Operation 630 Second welding cell

132 Operation 640 Nth Welding Work Cell

150 Operation 650 Memory

152 Operating the 700 System

154 Operation 702 Collecting parts

160 Operation 704 Parts

170 Operations 706 Welding Sequences

300 Welding System 800 System

302 Welding Job Sequencer Parts 802 Training Parts

304 Welding cell 804 Operator

306 Inspection point components 806 Welding equipment

308 Weld Scored Parts 808 Workpieces

400 Welding System 900 System

405 Solder circuit paths 902 Media parts

410 Welder power supply 904 Identifying parts

415 Displays 906 Communication parts

420 Welding Cable 1000 System

1002 Query Component 1200 Method/Flowchart

1004 Welding sequence data storage device 1202 Reference frame

1006 Update parts 1204 Reference frame

1100 Method/Tree Flowchart 1206 Reference Box

1102 Reference frame

1104 Reference frame A welding schedule

1106 Reference frame B welding schedule

1108 Reference Frame C Welding Schedule

1110 Reference frame N positive integer

Claims (19)

1. A welding machine system, comprising: A welding job sequencer component configured to employ a welding sequence for a welding work cell to perform at least a first weld and a second weld, wherein the welding sequence defines at least: a first weld schedule having at least one first weld setup parameter and at least one first weld instruction; and A second weld schedule having at least one second weld setup parameter and at least one second weld instruction, wherein at least one of the second weld setup parameter and the second weld instruction is different from the first weld setup parameter and the first weld instruction; and generating a component configured to automatically select and implement the first weld setup parameter or the second weld setup parameter to the welding sequence based on welding process data from performing at least one of the welds middle. 2. The welder system of claim 1, wherein the welding job sequencer component further defines notifications to an operator of the welding work cell. 3. The welder system of claim 1, further comprising a collection component configured to receive real-time welding process data associated with the creation of at least one of the welds, and to utilize the received real-time welding process data Welding process data to create the welding sequence. 4. The welder system of claim 3, wherein the welding sequence is automatically created based on collected real-time welding process data. 5. The welder system of claim 1, wherein the generation component is further configured to automatically evaluate the weld setup parameters to determine whether the setup parameters provide a desired result for the weld schedule. 6. The welder system of claim 1, wherein automatically implementing the weld setup parameters into the weld sequence includes a user verifying that the weld setup parameters provide a desired result for the weld schedule. 7. The welder system of claim 1, wherein the welding setup parameters are collected in a first welding environment and wherein the welding sequence is employed in a second welding environment, the second welding environment being different from the first welding environment. 8. The welder system of claim 1, wherein the at least one weld setup parameter includes a plurality of weld setup parameters. 9. The welder system of claim 1, wherein the welding sequence further defines a non-welding function associated with at least one of the welds; and wherein the generating component is further configured to automatically implement a system check function into the welding sequence based on the welding process data. 10. The welder system of claim 9, wherein the non-welding function automatically defined by the generating component includes a quality check of at least one of the first weld and the second weld, the quality checks monitor parameters associated with at least one of the welds; and wherein the generating component is further configured to automatically define a measurable value of the parameter associated with at least one of the welds, the measurable value indicative of a normal weld during the quality inspection, and wherein the The measurable values are automatically defined based on the welding process data representative of at least one of the welds in a non-real world environment. 11. The welder system of claim 10, wherein the measurable value of the parameter associated with at least one of the welds comprises a threshold value, the measurable value indicating a the normal welding. 12. The welder system of claim 10, wherein the measurable values of the parameters associated with at least one of the welds comprise a range of values indicative of the quality of The normal welding during inspection. 13. The welder system of claim 10, further comprising a weld scoring component configured to be based on at least one of the image of the first weld, the image of the second weld, and user verification one to evaluate the parameters associated with at least one of the welds. 14. The welder system of claim 10, further comprising a checkpoint component configured to monitor the parameter associated with at least one of the welds in real time. 15. The welder system of claim 10, further comprising an alarm notification when the measurable value indicates abnormal welding. 16. The welder system of claim 9, wherein the non-welding functions automatically defined by the generating component include system checks that monitor parameters associated with at least one of the welds to determining whether the welding sequence can continue; and wherein the generating component is further configured to automatically define a measurable value of the parameter associated with at least one of the welds, the measurable value indicating a welding sequence stop point, and wherein the measurable value is based on The welding process data representative of at least one of the welds in a non-real world environment is automatically defined. 17. The welder system of claim 16, wherein the parameter includes a welding time and wherein the welding sequence stop point initiates replenishment of consumables. 18. The welder system of claim 16, wherein the parameter includes a welding time and wherein the welding sequence stop point initiates at least one of inspection and repair. 19. A welding machine system, comprising: Apparatus for automatically creating a welding sequence for a welding work cell to perform at least a first weld and a second weld, wherein the welding sequence defines at least: a first weld schedule having at least one first weld setup parameter and at least one first weld instruction; and A second weld schedule having at least one second weld setup parameter and at least one second weld instruction, wherein at least one of the second weld setup parameter and the second weld instruction is different from the first welding setting parameter and the first welding instruction; means for automatically selecting and implementing the first weld setup parameter or the second weld setup parameter into the welding sequence based on welding process data from performing at least one of the welds; and Means for performing at least the first weld and the second weld using the welding sequence for the welding work cell by automatically adjusting settings on welding equipment within the welding work cell.