阅读说明：本技术 导出或者使用针对外部系统的焊接定序器数据的系统和方法 (System and method for exporting or using welding sequencer data for external systems ) 是由 J·A·丹尼尔 E·A·恩耶迪 J·E·赫恩 于 2014-03-13 设计创作，主要内容包括：本文所描述的发明一般地涉及用于在使用焊接序列创建一个或更多个焊接期间实时地收集一个或更多个焊接参数的系统和方法。一个或更多个焊接参数可以与特定的焊接序列相关联。而且,基于收集的一个或更多个焊接参数,模型化的焊接参数可以被生成来提高质量、效率等。收集部件收集实时焊接参数数据,质量管理者部件从所述实时焊接参数数据创建模型化的焊接参数。模型化的焊接参数可以针对焊接序列被采用,以在后续的焊接期间监测或追踪焊接参数。(The invention described herein relates generally to systems and methods for collecting one or more welding parameters in real time during creation of one or more welds using a welding sequence. One or more welding parameters may be associated with a particular welding sequence. Also, based on the collected one or more welding parameters, modeled welding parameters may be generated to improve quality, efficiency, and the like. A collection component collects real-time welding parameter data from which a quality manager component creates modeled welding parameters. The modeled welding parameters may be employed for a welding sequence to monitor or track the welding parameters during subsequent welds.)

1. A welder system, the welder system comprising:

a processor; and

a non-transitory computer-readable medium storing instructions for execution by the processor, the instructions comprising:

a quality manager component configured to receive at least two measurements of a welding parameter associated with a weld, automatically create a welding parameter model based on a statistical analysis of the at least two measurements of the welding parameter, wherein the welding parameter model includes a target value for the welding parameter, and automatically employ the welding parameter model to monitor the welding parameter during a welding sequence, the welding parameter model being associated with the welding sequence;

a welding job sequencer component configured to perform at least a first weld and a second weld with the welding sequence for a welding work cell, wherein the welding sequence defines at least:

a first weld schedule having a first weld parameter;

a second welding schedule having a second welding parameter, wherein the second welding parameter is different from the first welding parameter; and

quality assurance collection of the first welding parameters;

wherein the collected first welding parameters are compared to the welding parameter model; and is

The welder system is configured to employ the welding sequence for the welding work cell to perform welding to assemble a workpiece by automatically adjusting settings on welding equipment within the welding work cell.

2. The welder system of claim 1, wherein the welding parameter model is based on an average measurement of the welding parameter.

3. The welder system of claim 1, wherein the welding parameter model is a defined range of values based on the measured values of the welding parameter.

4. The welder system of claim 1, wherein the welding parameter model comprises a threshold tolerance based on the measured values of the welding parameter.

5. The welder system of claim 1, further comprising a collection component configured to collect the welding parameters in real time.

6. The welder system of claim 5, wherein the collection component associates the weld parameter model with at least one of the first weld or the second weld.

7. The welder system of claim 5, wherein the collection component is further configured to collect the welding parameters during at least one of a training session, a virtual welding session, a welding simulation, and a model welding session.

8. The welder system of claim 1, wherein the quality manager component is further configured to collect the welding parameters in real time.

9. The welder system of claim 8, further comprising a guidance component configured to collect a portion of media captured during creation of the welding parameter during at least one of the first weld or the second weld.

10. The welder system of claim 9, wherein the guidance component displays a portion of the medium on an operator's equipment as at least one of a video, a portion of audio, a 3-dimensional (3D) image, a hologram, or an image.

11. The welder system of claim 1, wherein the welding parameter model is based on a standard deviation of the at least two measurements of the welding parameter.

12. The welder system of claim 1, wherein the welding parameter model is different from the at least two measurements of the welding parameter.

13. The welder system of claim 1, wherein the measurements of the welding parameter are collected in a first welding environment and the welding parameter model based on the measurements collected in the first welding environment is used for a second welding environment different from the first welding environment.

14. The welder system of claim 1, wherein the welding parameters comprise at least one of parameters for a weld, a weld schedule parameter, a welding tool position, an operator movement, a welding equipment position or location, an operator body part position or location, a welding equipment configuration, a welder setting, a weld creation time, a fixture position, or a welding tool speed.

15. The welder system of claim 1, wherein the welding sequence further comprises an alarm notification based on the comparison.

16. The welder system of claim 1, wherein the welding sequence is automatically created or edited to include timing of the quality assurance collection based on the comparison.

17. The welder system of claim 1, wherein the welding job sequencer component automatically implements a repeat function in the welding sequence based on the comparison, wherein the repeat function instructs an operator to repeat at least one of the first weld or the second weld.

18. The welder system of claim 1, wherein the welding job sequencer component automatically implements a repair function in the welding sequence based on the comparison, wherein the repair function instructs an operator to repair at least one of the first weld or the second weld.

19. The welder system of claim 1, wherein the welding job sequencer component automatically implements a log job function in the welding sequence based on the comparison, wherein the log job function instructs an operator to log information about at least one of the first weld or the second weld before the welding sequence continues.

20. A welder system, the welder system comprising:

means for executing computer readable instructions; and

means for storing the computer-readable instructions, the instructions comprising:

automatically creating a welding parameter model based on a statistical analysis of at least two measurements of a welding parameter, wherein the welding parameter model comprises a target value for the welding parameter;

automatically employing the welding parameter model to monitor the welding parameter during a welding sequence, the welding parameter model being associated with the welding sequence;

performing at least a first weld and a second weld with the welding sequence for a welding work cell, wherein the welding sequence defines at least:

a first weld schedule having a first weld parameter;

a second welding schedule having a second welding parameter, wherein the second welding parameter is different from the first welding parameter; and

quality assurance collection of the first welding parameters;

wherein the collected first welding parameters are evaluated based on the welding parameter model;

means for employing the welding sequence for the welding work cell to perform at least the first and second welds by automatically adjusting settings on welding equipment within the welding work cell.

Technical Field

Apparatuses, systems, and methods consistent with the present invention relate to a welding work cell (work cell).

Background

In the related art, a work unit is used to generate a weld (weld) or a welded part. 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 (schedule) and execution of welding operations is mostly automated with little operator intervention. Thus, these units generally have relatively low labor costs and relatively high productivity. However, their repeated operation cannot be easily adapted to changing welding conditions and/or sequences (sequences).

In contrast, semi-automatic work cells (i.e., work cells involving welding operations by at least some operators) generally provide less 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 robotic work cells. For example, a semi-automatic welding work cell may be more easily adapted to varying welding conditions and/or sequences.

Unfortunately, in related art semi-automatic work cells, when welding more complex components, multiple different weld schedules are typically required for different types of welds on different component 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, the manual adjustment is eliminated by storing a specific schedule in the work cell. Even in such systems, however, the operator still needs to pause the welding operation and press a button to select a new weld schedule before he can continue welding.

None of these practices for setting (set) different weld schedules is particularly efficient. Thus, in practice, the number of weld schedules used in a semi-automatic work cell is typically reduced in order to eliminate the need for continuous adjustment of 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 strict quality control specifications are adhered to, it is sometimes necessary to perform welds in a specific sequence, verify that each weld was performed under a given set of conditions, and monitor the output of the equipment during the welding operation. In a robot work cell, these requirements are easily met. However, in semi-automatic work cells, these requirements are susceptible to human error, as the operator must attend to all of these aspects in addition to performing the welding operation on his own.

An illustrative example of the above-described problem is shown in the related art semi-automatic welding method, which is presented graphically in fig. 1. In this method, each of the various scheduling, sequencing, inspection (inspection) and welding operations is organized and performed by the operator (i.e., welder) himself. Specifically, the operator begins the welding operation at operation 10. Subsequently, at operation 20, the operator sets (set up) the welding equipment according to schedule a. Next, the operator performs weld #1, weld #2, and weld #3 using weld schedule a in 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 weld #4 using weld schedule B. The operator then checks (check) 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 assembly at operation 60 and completes the welding operation at operation 70.

Clearly, the method shown in fig. 1 relies on the operator correctly following the sequencing and verification intended for performing the weld to accurately change between weld schedules (e.g., at operation 30) and perform the weld themselves. Errors in any of these responsibilities may result in rework (if the error is found during the inspection of operation 60) or in the defective part being supplied to the end user. In addition, the exemplary semi-automatic welding method constrains productivity because the operator must spend time configuring and reconfiguring the welding schedule.

The above-described problems are in the quest for improvements in related art systems.

Disclosure of Invention

In accordance with an embodiment of the present invention, a welding system is provided that includes a welding job sequencer component configured to identify a welding sequence for a welding work cell, wherein the welding sequence defines at least parameters and a welding schedule for a first welding procedure to create a first weld on a workpiece and defines at least parameters and a welding schedule for a second welding procedure to create a second weld on the workpiece. The welding job sequencer component is further configured to utilize the welding sequence in the welding work cell to automatically configure the welding equipment to perform the first welding process and the second welding process on the workpiece without intervention from an operator. In an embodiment, the welder system further includes a collection component configured to collect real-time welding parameters for at least one of the first weld or the second weld, wherein the collection component corresponds the real-time welding parameters to the identified welding sequence and the at least one of the first weld or the second weld. Preferred embodiments can be derived from the dependent claims.

According to an embodiment of the invention, a method of welding in a welding work cell with a welding sequence is provided, the method comprising at least the steps of: identifying a welding sequence for use by an operator in a welding work cell, wherein the welding sequence defines a first welding procedure including first parameters to create a first weld on a workpiece and a second welding procedure including second parameters to create a second weld on the workpiece; automatically altering welding equipment within the welding work cell with the welding sequence without intervention from an operator, creating at least one of a first weld or a second weld; collecting welding parameters in real-time during creation of at least one of the first weld or the second weld; associating a welding parameter with a welding sequence and at least one of the first weld or the second weld; generating a welding parameter model based on the one or more welding parameters collected in real time; and implementing a welding parameter model for a welding sequence performed at a time subsequent to creation of at least one of the first weld or the second weld. Preferred embodiments can be derived from the dependent claims.

According to an embodiment of the present invention, a welding system is provided, comprising at least the following: a welding sequence device for identifying a welding sequence for use by an operator in a welding work cell, wherein the welding sequence defines a first welding procedure including a first parameter to create a first weld on a workpiece and a second welding procedure including a second parameter to create a second weld on the workpiece; means for automatically altering welding equipment within a welding work cell with a welding sequence without intervention from an operator, creating at least one of a first weld or a second weld; means for collecting welding parameters in real-time during creation of at least one of the first weld or the second weld; means for associating a welding parameter with a welding sequence and at least one of the first weld or the second weld; means for generating a welding parameter model based on the one or more welding parameters collected in real-time; and means for implementing a weld parameter model for a weld sequence performed after creation of at least one of the first weld or the second weld.

One aspect of the present invention provides a welder system, comprising: a welding job sequencer component configured to identify a welding sequence for a welding work cell, wherein the welding sequence defines at least parameters and a welding schedule for a first welding procedure to create a first weld on a workpiece and defines at least parameters and a welding schedule for a second welding procedure to create a second weld on the workpiece; the welding job sequencer component is further configured to utilize the welding sequence in the welding work cell to automatically configure welding equipment to perform the first and second welding processes on the workpiece without intervention from the operator; a collection component configured to collect real-time welding parameters for at least one of the first weld or the second weld, wherein the collection component corresponds the real-time welding parameters to the identified welding sequence and at least one of the first weld or the second weld.

In some embodiments, the welder system further includes a weld scoring component configured to evaluate at least one of the first weld or the second weld performed on the workpiece by the operator based on at least one of an image of the first weld or the second weld or a user inspection.

In some embodiments, the collection component associates a portion of the assessment with an identified welding sequence and at least one of the first weld or the second weld.

In some embodiments, the welder system further comprises: a checkpoint component configured to monitor creation of the operator and at least one of the first weld or the second weld in real-time using the welding sequence; and the collecting component associates a portion of the monitoring with the identified welding sequence and at least one of the first weld or the second weld, and preferably further comprises: the welding job sequencer component is further configured to communicate instructions to the operator of the welding work cell to assemble the workpiece with the first welding procedure and the second welding procedure having two separate welding schedules; and wherein the instructions comprise at least one of a portion of the monitoring or a portion of the evaluating.

In some embodiments, the welder system further includes a quality manager component configured to evaluate the real-time welding parameters for at least one of the first weld or the second weld created with the welding sequence and identify a welding parameter model.

In some embodiments, the welding parameter model is based on a mean measurement of the real-time welding parameter, or wherein the welding parameter model is based on a defined range of values of the real-time welding parameter, or wherein the welding parameter model includes a threshold tolerance based on the real-time welding parameter.

In some embodiments, the collection component associates the weld parameter model with the identified weld sequence and at least one of the first weld or the second weld.

In some embodiments, the quality manager component is further configured to receive the real-time welding parameters for use as the welding parameter model.

In some embodiments, the welder system further comprises a guidance component configured to collect a portion of media captured during creation of the welding parameter during at least one of the first weld or the second weld, and preferably wherein the guidance component displays the portion of media as at least one of a video, a portion of audio, a 3-dimensional (3D) image, a hologram, or an image on the operator's equipment.

In some embodiments, the welder system further includes a notification component configured to generate an alert to an operator based on at least one of: the welding sequence, the performance of the first weld or the second weld, or the comparison of the real-time welding parameters to a welding parameter model calculated based on historical welding parameter data for the welding sequence, and preferably wherein the notification component is further configured to communicate the alert to the operator based on the urgency of the alert or a condition within the welding work cell.

One aspect of the present invention provides a method of welding in a welding work cell, the method comprising: identifying a welding sequence for use by an operator in a welding work cell, wherein the welding sequence defines a first welding procedure including first parameters to create a first weld on a workpiece and a second welding procedure including second parameters to create a second weld on the workpiece; automatically alter welding equipment within the welding work cell with the welding sequence without intervention from the operator, creating at least one of the first weld or the second weld; collecting welding parameters in real-time during creation of at least one of the first weld or the second weld; associating the welding parameter with the welding sequence and at least one of the first weld or the second weld; generating a welding parameter model based on the one or more welding parameters collected in real time; and implementing the weld parameter model for the weld sequence performed at a time after creation of at least one of the first weld or the second weld.

In some embodiments, the method further comprises displaying a portion of the medium showing execution of the weld parameter model.

In some embodiments, the portion of the medium is at least one of a video, an image, a picture, a holographic image, a holographic video, a 3-dimensional (3D) image, or a 3D video.

In some embodiments, the method further comprises: monitoring the welding work cell to identify conditions related to noise level, activity of the operator, or location of the operator; and communicating an alert to the operator based on the condition, wherein the alert is based on at least one of: the welding sequence, creation of additional welds, or real-time comparison of created additional welds to the weld parameter model.

One aspect of the present invention provides a welder system, comprising: a welding sequence device for identifying a welding sequence for use by an operator in a welding work cell, wherein the welding sequence defines a first welding procedure including first parameters to create a first weld on a workpiece and a second welding procedure including second parameters to create a second weld on the workpiece; means for automatically altering welding equipment within the welding work cell with the welding sequence without intervention from the operator, creating at least one of the first weld or the second weld; means for collecting welding parameters in real-time during creation of at least one of the first weld or the second weld; means for associating the welding parameter with the welding sequence and at least one of the first weld or the second weld; means for generating a welding parameter model based on the one or more welding parameters collected in real-time; and means for implementing the weld parameter model for the weld sequence performed after creation of at least one of the first weld or the second weld.

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

Drawings

The invention may take physical form in certain parts and arrangement of parts, a preferred embodiment of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein:

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

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

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

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

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

FIG. 6 is a block diagram illustrating a welding system including a plurality of welding work cells, wherein the welding work cells are managed by a cloud-based welding job sequencer component;

FIG. 7 is a block diagram illustrating a system that aggregates data associated with welding operations performed with a welding sequence;

FIG. 8 is a block diagram illustrating a system for communicating a portion of a medium to an operator to facilitate creating a weld using a welding process;

FIG. 9 is a block diagram illustrating a system for communicating an alert to an operator performing one or more welds using a welding sequence;

FIG. 10 is a block diagram illustrating a system for delivering an alarm to an operator creating a weld using a welding sequence based on conditions within a welding work cell;

FIG. 11 is a flow diagram of identifying a welding parameter model for a welding sequence based on one or more welding parameters collected in real time for the welding sequence used to create at least one weld; and

fig. 12 is a flow diagram for creating a welding parameter model for a welding sequence based on one or more parameters collected from previous welding operations using the welding sequence.

Detailed Description

Embodiments of the present invention relate to methods and systems relating to collecting one or more welding parameters in real time during the creation of one or more welds using a welding sequence. One or more welding parameters may be associated with a particular welding sequence. Also, based on the collected one or more welding parameters, modeled welding parameters may be generated to improve quality, efficiency, and the like. A collection component collects real-time welding parameter data from which a quality manager component creates modeled welding parameters. The modeled welding parameters may be employed for a welding sequence to monitor or track the welding parameters during subsequent welds.

According to an aspect of the present invention, a semi-automatic welding work cell is provided that includes a welding job sequencer that automatically selects a welding schedule for use by an operator in the semi-automatic welding work cell.

According to another aspect of the present invention, a method of welding in a semi-automatic work cell is provided that includes 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, a welding production line is provided, comprising at least one semi-automatic welding work cell, wherein the semi-automatic work cell comprises a welding job sequencer that automatically selects a welding schedule for use by an operator therein.

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

The term "component" as used herein may be defined as a portion of hardware, a portion of software, or a combination thereof. The portion of 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 the applicant at the time of filing this patent application. The examples and figures are merely illustrative and not meant to limit the invention, which is measured by the scope and spirit of the claims. Referring now to the drawings wherein the showings are for the purpose of illustrating exemplary embodiments of the invention only and not for the purpose of limiting the same, reference is made to FIG. 2. In the exemplary embodiment of the present invention illustrated in fig. 2, a welding job sequencer (sequencer) is provided. The welding job sequencer improves upon related art semi-automatic work cells 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 automatic changes in the semi-automatic work cell and by providing the operator with a large array of commands and instructions.

More specifically, in an exemplary embodiment, the welding job sequencer automatically selects and implements functions of the welding work cell. An example of such functionality includes a particular weld schedule to be used with the semi-automatic work cell. In other words, the welding job sequencer may select a welding schedule for a particular weld and automatically modify the settings of the semi-automatic work cell according to the selected welding schedule for the operator (i.e., without the operator's specific intervention).

Additionally, in an exemplary embodiment, the welding job sequencer may automatically indicate a sequence of operations that the operator should follow to make (create) the final welded assembly. In conjunction with the automatic selection of the weld schedule, 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 weld 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 chances of errors in the welding operation are greatly reduced, and productivity and quality are improved.

An exemplary embodiment is shown schematically 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 directs the operator to perform welds #1, #2, and # 3. Subsequently, the operator performs welds #1, #2, and #3 using weld schedule a (operations 122, 124, and 126). Next, the welding job sequencer sets the welding equipment to use welding schedule B (operation 130) and directs the operator to perform weld # 4. The operator then performs weld #4 using weld schedule B (operation 132). After completion of welding schedule B, the welding job sequencer sets the welding equipment to use welding schedule C (operation 150) and directs the operator to perform welds #5 and #6 and verify the parts. Subsequently, the operator performs weld #5 and weld #6 using weld schedule C (operations 152 and 154), and verifies the completed part to confirm that it is correct (operation 160). The inspection may include size verification, visual defect verification, or any other type of inspection that may be required. Further, operation 160 may include a requirement that the operator affirmatively indicate that the inspection is complete, for example by pressing an "OK" button, before possibly progressing to the next operation. Finally, the welding job sequencer indicates the welding operation to its end (operation 170) and resets for the next operation.

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

The welding job sequencer may select and implement new functions, such as the selection and implementation of the welding schedules A, B and C shown in FIG. 2, based on various variables or inputs. For example, the welding job sequencer simply selects a new welding schedule based on monitoring the elapsed time (elapsed time) since the welding operation started or since the welding was paused (e.g., the time after weld #3 in fig. 2 above). Alternatively, the welding job sequencer may monitor the actions of the operator, compare the actions to the identified welding sequence, and select a new welding schedule as appropriate. 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 (e.g., weld schedules) for use by an operator.

The parameters of the selected welding schedule may include variables such as, but not limited to, welding process, wire type, wire size, WFS, volt value (volt), trim (trim), which wire feeder (feeder) to use, or which feed head (feed head) to use.

While the above description focuses on weld 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 a plurality of wire feeders on a single power source according to a welding schedule. This functionality provides more variability in the welding jobs that can be performed by the operator in the semi-automatic work cell, as different wire feeders can provide large variability, such as wire size and type.

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

Another example of such a function would be a repeat function. This energy would instruct the operator to repeat a particular weld or weld sequence. Examples of the use of this function include when the quality check shows an anomaly or when multiple instances of the same weld (instance) are required.

Another example of such a function would be a warning 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 indicating to the operator that he is free to start welding, or indicating that the operator should inspect some portion of the welded component for quality purposes.

Another example of such a function would be the enter job information function. This function would require the welder to enter information, such as a part serial number, a personal ID number, or other special conditions, before the job sequencer can proceed. This information may also be read from the parts or inventory (inventories) by Radio Frequency Identification (RFID), bar code scanning, etc. The welding job sequencer may then use the entered information for the welding operation. An example of the use of this function may be as a predicate (predicate) to the overall welding operation to indicate which schedules and/or sequences should be selected by the welding job sequencer.

Yet another embodiment of such a function would be a job reporting function. This function will create a report on the welding job, which may include information such as: number of welds performed, total arc timing and individual arc timing, sequence breaks, errors, faults, wire usage, arc data, and the like. An example of the use of this function may be a report to the manufacturing quality department regarding 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 that the welding job can continue and may monitor these parameters as follows: wire supply, gas supply, time remaining in the shift (compared to the time required to end the job), and the like. The function may then determine whether the parameters indicate sufficient time and/or material for the welding operation to continue. This functionality will avoid down-time due to material exhaustion and will avoid in-process job (work-in-process) assembly being delayed, which can lead to quality problems due to thermal and scheduling factors.

Further, as mentioned above, the welding job sequencer may 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 a welding job sequencer is the perform welding operation function. This function is designed to detect the actual welding performed by the operator and report the welding so that the welding job sequencer can determine whether to proceed with further operations. For example, the function may operate to begin when the operator pulls down the trigger to begin the welding operation and end when the operator releases the trigger after the welding is complete, or after a predetermined period of time after it begins. This function may terminate when the trigger is released, or it may be configured to automatically turn off after a period of time, a certain amount of wire, or a certain amount of energy is delivered. This function may be used to determine when to select a new function, e.g., a new weld schedule as discussed above.

Furthermore, the various semi-automatic and/or robotic work cells may be integrated together in a single network, and the sequencing of welding steps of a single work cell may be fully integrated into a complete production schedule, where it may itself be modified as needed to follow changes in the production schedule. The sequencing and/or scheduling information may also be stored in a database, stored as archival information by date, and accessed to provide various production reports.

In an embodiment, a semi-automatic welding work cell for welding a component defined by a plurality of welds may be provided, the plurality of welds defined by at least two weld schedules may include welding equipment for use by a welding operator to perform the plurality of welds and complete an assembly with the welding equipment having a 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, a welding job sequencer may detect when an operator is performing 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 performing a welding operation, and the welding job sequencer selects a welding schedule based on an amount of welding wire supplied for the welding operation. In an embodiment, the welding job sequencer may detect when an operator is performing a welding operation, and the welding job sequencer selects a welding schedule based on an amount of energy supplied for the welding operation. In an embodiment, the welding schedule includes information related to at least one of a welding process, a wire type, a wire size, WFS, volt values, a trim, a wire feeder to use, or a 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 in order to schedule a workflow for creating a welding assembly and to indicate to a welding operator a sequence of work operations for completing an assembly. In an embodiment, the welding job sequencer may automatically alter the welding equipment according to a sequence of workflows and welding operations without intervention by the welding operator.

In an embodiment, the second welding schedule is defined according to an 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 performing the first welding schedule, and the second welding schedule is defined according to an amount of welding wire supplied for the first welding schedule. In an embodiment, at least one function detects when an operator is performing the first welding schedule, and the second welding schedule is defined according to an amount of energy supplied for the first welding schedule. In an embodiment, the at least one first welding setting parameter and the at least one second welding setting parameter comprise at least one of a welding process, a type of wire, a size of wire, WFS, volt value, dressing, a wire feeder to be used, or a feed head to be used. In an embodiment, the at least one first welding setting parameter and the at least one second welding setting parameter comprise 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 of the welding assembly, wherein the quality measurable includes information relating to at least an arc used to form a weld created by an operator. In an embodiment, at least one function indicates information to an operator in the 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 a welding instruction. In an embodiment, the at least one function generates a job report including at least one of a number of welds performed, a total arc time, individual arc times, sequence interruptions, errors, faults, wire usage, arc data. In an embodiment, the at least one function includes a system check of the unit, the system check including at least 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 an operator in the semi-automatic welding work cell. In an embodiment, 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 a quality measurable of a weld created by an operator, wherein the quality measurable includes information related to at least an 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 a part ID number, an operator ID number, or a welding instruction. In an embodiment, the welding job sequencer may generate a job report including at least one of a number of welds performed, a total arc time, individual arc times, sequence interruptions, errors, faults, wire usage, arc data. In an embodiment, the welding job sequencer may perform system checks that include 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 that includes 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, a method may include detecting when an operator is performing a welding operation, wherein automatically selecting is performed based on the detecting. In an embodiment, a method may include detecting when an operator is performing a welding operation, wherein automatically selecting is performed according to an amount of wire supplied for the welding operation. In an embodiment, a method may include detecting when an operator is performing 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 a welding process, a type of wire, a size of wire, WFS, volt values, a trim, a wire feeder to use, or a feed head to use.

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

In an embodiment, a welding production 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 a welding schedule for use by an operator in the semi-automatic work cell. In an embodiment, a welding production line includes a monitoring system in communication with a 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 production line is provided that includes automatically selecting a welding schedule for use by an operator in a semi-automatic welding work cell. In an embodiment, a 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 that includes a welding job sequencer that automatically selects a welding schedule for use by an operator in the semi-automatic welding work cell. The automatic selection may be by means of elapsed time, detection of the welding operation, detection of the amount of welding 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 having a welding apparatus and a welding job sequencer to complete an assembly defined by a plurality of welds may be provided, wherein the plurality of welds may be defined by at least two weld schedules. Embodiments may include at least the following steps: implementing a welding equipment function with a welding job sequencer to define a first welding schedule having at least one first welding setting parameter and at least one first welding command and a second welding schedule having at least one second welding setting parameter and at least one second welding command from at least two welding schedules, at least one of the second welding setting parameter and the second welding command being different from the first welding setting parameter and the first welding command; indicating to a welding operator a sequence of welding operations for completing an assembly based on the first and second welding schedules; and automatically altering the welding equipment according to 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, a method may include detecting when an operator is performing a welding operation, wherein defining the second schedule is based on the detecting. In an embodiment, defining the first and second welding schedules may include defining an amount of welding wire to supply for a welding operation. In an embodiment, defining the second welding schedule is according to an amount of energy supplied for a welding operation for the first welding schedule. In an embodiment, defining at least one of the first and second welding schedules may include selecting at least one of a welding process, a wire type, a wire size, WFS, volt values, a trim, a wire feeder to use, or a feed head to use. In an embodiment, 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, a method may include monitoring a quality measurable of a weld created by an operator, wherein the quality measurable includes information related to at least an arc used to form the weld created by the operator. In an embodiment, a method may include indicating information to an operator in a semi-automatic welding work cell. In an embodiment, a method may include receiving job information including at least a part ID number, an operator ID number, or a welding instruction. In an embodiment, a method may include generating a job report including at least one of a number of welds performed, a total arc time, individual arc times, sequence interruptions, errors, faults, wire usage, arc data; a system check is performed that includes at least detection of the wire supply, the gas supply, and the time.

In an embodiment, a welding production line is provided that includes at least one semi-automatic welding work cell for welding an assembly defined by a plurality of welds defined by at least two weld schedules, the semi-automatic welding work cell including welding equipment for use by a welding operator to perform the plurality of welds and complete the assembly, the welding equipment having a plurality of functions. In an embodiment, a welding production line may include a welding job sequencer that selects and implements at least one of a plurality of functions to define at least first and second welding schedules in a sequence of welding operations from at least two welding schedules used by the welding operator to complete a welding assembly. In an embodiment, a production line may include the first welding schedule including at least one first welding setting parameter and at least one first welding instruction for the welding operator and the second welding schedule including at least one second welding setting parameter and at least one second welding instruction for the welding operator, at least one of the first welding setting parameter and the first welding instruction being different from the second welding setting parameter and the second welding instruction, the welding job sequencer automatically altering 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 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 production line in at least one semi-automatic welding work cell for use by a welding operator to complete an assembly defined by a plurality of welds defined by at least two welding schedules, the semi-automatic welding work cell comprising welding equipment and a welding job sequencer. The method may comprise at least the steps of: defining, with a welding job sequencer, at least first and second welding schedules in a sequence of welding operations from at least two welding schedules, the first welding schedule having at least one first welding setting parameter and at least one first welding instruction, and the second welding schedule defining at least one second welding setting parameter and at least one second welding instruction, wherein at least one of the second welding setting parameter and the second welding instruction is different from the first welding setting parameter and the first welding instruction; determining, by the welding operator, completion of the first welding schedule; automatically changing welding equipment according to the second welding schedule without intervention by the welding operator; and monitoring the welding operation. In an embodiment, a method may include automatically altering 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 for use by an operator is provided. Embodiments may include a welding device having a plurality of functions for performing welding by an operator and a welding job sequencer that selects from the plurality of functions to set up and schedule the welding device for the operator. Embodiments may include a number of functions, including: a weld schedule function defined by a sequence of welding operations; a notification function that instructs an operator to perform a welding schedule; and a quality check function that monitors at least one welding operation in the sequence of welding operations.

In an embodiment, the quality check function performs a quality check for a weld 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 the 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 pauses the sequence of welding operations, and the notification function alerts an operator of the anomaly.

Fig. 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 a workpiece. 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 discussed above as a welding job sequencer, 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 the welding sequence to assist the operator in performing two or more welds. As discussed above, the welding job sequencer component 302 may be utilized with a 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 creation of one or more welds.

Welding system 300 further includes a checkpoint component 306, the 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 (e.g., voltage, current, etc.), welding schedule parameters (e.g., welding process, wire type, wire size, WFS, volt value, trim, wire feeder to use, feed head to use, etc.), welding on the workpiece (when the weld is created), operator movement, position of the welding tool, position or setting of the welding equipment, position or setting of the operator, sensor data (e.g., video camera, image capture device, thermal imaging device, thermal sensing camera, temperature sensor, etc.), and so forth. Checkpoint component 306 includes an alarm system (not shown) that can deliver an alarm or notification to indicate the status of the real-time monitoring. In an embodiment, checkpoint component 306 can utilize thresholds, ranges, limits, etc. for real-time monitoring to accurately identify anomalies of welding system 300. Additionally, the checkpoint component 306 can communicate an alert or notification to the welding work cell 304 or operator to at least one of: stopping the welding process, continuing the welding process, pausing the welding process, terminating the welding process, or requesting approval (apurval) of the welding process. In an embodiment, checkpoint component 306 can store monitored data (e.g., video, images, results, sensor data, etc.) in at least one of a server, a data store, a cloud, combinations thereof, and the like.

A weld scoring component 308 may be included with the welding system 300 and configured to evaluate welds created by an operator within the welding work cell 304 when such welds are completed. The weld score component 308 provides a rating or score for a completed weld to facilitate implementing quality control of the workpiece and/or assembly of the workpiece. For example, the weld scoring component 308 can alert a weld inspection upon completion, provide data collection of a job (e.g., assembly of a workpiece, welding on a workpiece, etc.), and the like. In an embodiment, an in-person quality check may be performed upon a partial assembly completion (e.g., completion of a weld, completion of two or more welds, completion of an assembly, etc.). In another embodiment, weld scoring component 308 can utilize sensors to collect data (e.g., video cameras, image capture devices, thermal imaging devices, heat sensing cameras, temperature sensors, etc.) to determine approval of a job. For example, quality checks may be performed remotely via video or image data collected at the completion of a job.

It is to be appreciated that the welding job sequencer component 302 can be a stand-alone component (as depicted), can be incorporated into the welding work cell 304, can be incorporated into the checkpoint component 306, can be incorporated into the welding scoring component 308, or a suitable combination thereof. Additionally, as discussed below, the welding job sequencer component 302 may be a distributed system, a software as a service (SaaS), a cloud-based system, or a combination thereof. Further, it is to be appreciated and understood that the checkpoint component 306 can be a stand-alone component (as depicted), can be incorporated into the welding work cell 304, can be incorporated into the welding job sequencer component 302, can be incorporated into the welding scoring component 308, or a suitable combination thereof. Additionally, the checkpoint component 306 can be a distributed system, a software as a service (SaaS), a cloud-based system, or a combination thereof. Moreover, it is to be appreciated and understood that the welding scoring component 308 can be a stand-alone component (as depicted), can be incorporated into the welding work cell 304, can be incorporated into the welding job sequencer component 302, can be incorporated into the checkpoint component 306, or a suitable combination thereof. Additionally, the weld scoring component 308 can be a distributed system, a software as a service (SaaS), a 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, wherein the welding work cell and/or the welding system 400 may produce a weld or welded component. The welding system 400 includes a welder power supply 410 and a display 415, the display 415 being operatively connected to the welder power supply 410. Alternatively, the display 415 can be an integral component of the welder power supply 410. For example, the display 415 can be incorporated into the welder power supply 410, can be a separate component (as depicted), or a combination thereof. The welding system 100 further includes a weld cable 120, a welding tool 430, a workpiece connector 450, a spool of welding wire 460, a wire feeder 470, a welding wire 480, and a workpiece 440. According to an embodiment of the present invention, wire 480 is fed from spool 460 into welding tool 430 via wire feeder 470. In accordance with another embodiment of the present invention, welding system 400 does not include spool 460 of welding wire, wire feeder 470, or welding wire 480, but instead, includes a welding tool that includes a consumable electrode, such as is used, for example, in hand welding. According to various embodiments of the invention, the welding tool 430 may include at least one of a welding torch, a welding gun, and a welding consumable.

The welding circuit path 405 extends from the welder power supply 410 to the welding tool 430 through the weld cable 420, through the workpiece 440 and/or to the workpiece connector 450, and back to the welder power supply 110 through the 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, the weld cable 420 includes a coaxial cable assembly. According to another embodiment, the weld cable 420 includes a first cable length extending from the welder power supply 410 to the welding tool 430 and a second cable length extending from the workpiece connector 450 to the welder power supply 410.

The welding system 400 includes a 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 the 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 a welding sequence that is utilized to configure the welding system 400 (or components thereof) without operator intervention to perform 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 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 a first weld, a second weld sequence may be used for a second weld, and a third weld sequence may be used for a third weld. Moreover, in such embodiments, the assembly of the entire workpiece including three (3) welds may be referenced as a weld sequence. In an embodiment, a welding sequence including a particular configuration or step may further be included within a distinct welding sequence (e.g., an embedded welding sequence). The embedded welding sequence may be a welding sequence that includes a welding sequence as part of a process. Moreover, the welding sequence may include at least one of a parameter, a welding schedule, a portion of a welding schedule, instructions step-by-step, a portion of media (e.g., images, video, text, etc.), individual directions, and so forth. Generally, a welding sequence may be created and employed to guide an operator through a welding process (es) for a particular workpiece without requiring the operator to manually set up welding equipment to perform such welding processes. The subject invention relates to creating a welding sequence and/or modifying a welding sequence.

One or more welder power sources (e.g., welder power source 410) aggregate respective data for respective welding processes that the welder power source provides power to implement. Such collected data relates to each welder power source and is referred to herein as "welding data". The welding data may include welding parameters and/or information for a particular welding process to which the welder power supply supplies power. For example, the welding data may be an output (e.g., waveform, signal, voltage, current, etc.), welding time, power consumption, welding parameters for a welding process, welder power output for a welding process, and so forth. In an embodiment, the welding data may be utilized with the welding job sequencer component 302. For example, the weld data may be set by a weld sequence. In another embodiment, the weld data may be used as a feedback or feed forward loop to verify the 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). In order to provide additional context for various aspects of the subject invention, the following discussion is intended to provide a brief, general description of a suitable computing environment in which the various aspects of the subject invention can be implemented. While the invention has been described above in the general context of computer-executable instructions that may run on one or more computers, those skilled in the art will recognize that the invention also can be implemented in combination with other program modules and/or as a combination of hardware and/or software. Generally, program modules include routines, programs, components, data structures, etc. that perform particular tasks or implement particular abstract data types.

Moreover, those skilled in the art will appreciate that the inventive methods may be practiced with other computer system configurations, including single-processor or multiprocessor computer systems, minicomputers, mainframe computers, and personal computers, hand-held computing devices, microprocessor-based or programmable consumer electronics, and the like, each of which may be operatively coupled to one or more associated devices. The illustrated aspects of the invention may also be practiced in distributed computing environments where certain tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices. For 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 the exemplary environment to implement various aspects of the invention including a computer including a processing unit, a system memory, and a system bus. A system bus couples system components including, but not limited to, the system memory to the processing unit. The processing unit can be any of various commercially available processors. Dual microprocessors and other multi-processor architectures may also be employed as the processing unit.

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 of a variety of commercially available bus architectures. The system memory may include Read Only Memory (ROM) and Random Access Memory (RAM). A basic input/output system (BIOS), which includes basic routines that facilitate passing information between elements within the welding job sequencer 302, such as during a start-up phase, is stored in ROM.

The welding job sequencer 302 may also include a hard disk drive that reads from or writes to a removable disk, a magnetic disk drive that reads from or writes to a removable disk, and an optical disk drive that reads from or writes to a CO-ROM disk or other optical media, for example. The 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 comprise computer storage media and communication media. Computer storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, Digital Versatile Disks (DVD) or other magnetic storage devices, or other media that may be used to store the desired information and that may be 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 such as a carrier wave or other transport mechanism and includes any information delivery media. The term "modulated data signal" means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic (acoustic), Radio Frequency (RF), Near Field Communication (NFC), Radio Frequency Identification (RFID), infrared, and/or other wireless media. Combinations of any of the above should also be included within the scope of computer readable media.

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

In addition, a user may enter commands and information into the computer through a keyboard and pointing device (e.g., a mouse). Other input devices may include a microphone, an IR remote control, a trackball, pen input devices, a joystick, a game pad, a digitizer pad, a satellite dish, a scanner, and the like. These and other input devices are often connected to the processing unit through a serial port interface that is coupled to the system bus, but may be connected by other interfaces, such as a parallel port, game port, universal serial bus ("USB"), IR interface, and/or various wireless technologies. A monitor (e.g., display 415) or other type of display device is also connected to the system bus via an interface, such as a video adapter. Visual output may also be accomplished by remote display network protocols (e.g., remote desktop protocols, VNC, and X-Window systems, etc.). In addition to visual output, computers typically include other peripheral output devices such as speakers, printers, and so forth.

A display (in addition to display 415 or in combination with display 415) may be used with the welding job sequencer 302 to present data received electronically from the processing unit. For example, the display may be a monitor of an LCD, plasma, CRT, etc., that electronically presents data. Alternatively or additionally, the display may present the received data in a hard copy format (e.g., printer, fax machine, 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, the welding job sequencer 302 and/or system 400 may be utilized with a mobile device (e.g., a cellular phone, a smart phone, a tablet computer, a portable gaming device, a portable internet browsing device, a Wi-Fi device, a Portable Digital Assistant (PDA), etc.).

The computer may operate in a networked environment using logical and/or physical connections to one or more remote computers, such as a remote computer(s). The remote computer(s) can be a workstation, a server computer, a router, a personal computer, an entertainment appliance-based microprocessor, a peer device or a general network node, and typically includes many or all of the elements described relative to the computer. The logical connections depicted include a Local Area Network (LAN) and a Wide Area Network (WAN). Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets and the Internet.

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

Alternatively or additionally, local or cloud (e.g., local, cloud, remote, etc.) computing platforms may be utilized for data aggregation, processing, and delivery. For this purpose, the cloud computing platform may include multiple processors, memories, and servers at particular 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 way, as data processing is generally conducted at the cloud, processing requirements at the local level are mitigated, thereby mitigating user network resources. Software-as-a-service applications allow users to log into a website-based service, e.g., via a website browser, that clusters (host) all programs residing in the cloud.

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

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

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 at one or more welding work cells. The welding sequences are stored in respective local data stores (e.g., data stores 550, 555, and 560). Further, it is to be appreciated and understood that each welding work cell may include local data storage (as depicted), collective and shared remote data storage, collective and shared local data storage, cloud data storage hosted by computing platform 510, or a combination thereof. The "data store" 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 comprise, without being limited to, these and other suitable types of memory. Further, the data storage device may be a server, a database, a hard drive, a flash drive, an external hard drive, a portable hard drive, a cloud-based storage device, a solid state drive, and the like.

For example, the welding job sequencer component 302 can manage each welding job sequencer component 535, 540, 545 in each welding work cell 515, 520, 530. In another embodiment, communications may be transmitted from the welding job sequencer 302 to each welding work cell (e.g., each welding job sequencer component). In another embodiment, communications from each welding work cell (e.g., 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 communicated to a disparate welding work cell directly or via the computing platform 510.

Fig. 6 illustrates a welding system 600 that includes a plurality of welding work cells, wherein the welding job sequencer component 302 hosts a computing platform 510 to configure welding equipment within one or more welding systems, welding environments, and/or welding work cells utilizing one or more welding sequences. The welding system 600 includes a local or cloud-based welding job sequencer component 302 that hosts a computing platform 510. The welding job sequencer component 302 may utilize a welding sequence with a number of welding work cells. For example, the welding system 600 may have a number of welding work units, such as, but not limited to, a first welding work unit 620, a second welding work unit 630, through an nth welding work unit, where N is a positive integer. It is to be appreciated that the location of the welding job sequencer component 302 is associated with each of the first welding work cell 620, the second welding work cell 630, and/or the nth welding work cell 640.

In an embodiment, the welding job sequencer 302 delivers one or more welding sequences to a target welding work cell, wherein the target welding work cell is a welding work cell that utilizes the delivered welding sequence. Still, in another embodiment, the welding job sequencer 302 utilizes a memory 650 that hosts the computing platform 510, wherein one or more welding sequences are stored. Further, the stored welding sequence may be related to or targeted for one or more welding work cells regardless of the storage location (e.g., local, cloud, remote, etc.).

Fig. 7 illustrates a system 700 that aggregates data associated with a welding operation performed with a welding sequence. As discussed above, the welding sequence is used by the welding job sequencer component 302 to perform two or more welds within the welding work cell 304 using two or more respective welding parameters (e.g., welding schedule, parameters, configuration, settings, etc.). In particular, one or more welding sequences are employed to automatically configure welding equipment, without operator intervention, to perform a first welding operation with a first welding schedule and a second welding operation with a second welding schedule. It is to be appreciated that the welding sequence may include additional steps or processes (as discussed below) implemented within the welding work cell 304. Welding job sequencer component 302 is configured to implement one or more welding sequences to perform welding operations, where the welding sequence(s) may be stored on welding sequence data store 706. The welding sequence(s) are identified or selected from the welding sequence data store 706 and loaded or used.

It is to be appreciated that the welding sequence(s) can be executed from the welding sequence data store 706, downloaded and executed locally (e.g., locally referenced to where the welding is performed with the welding sequence), or a combination thereof. As discussed above, the data storage (here, welding sequence data storage 706) may be, for example, volatile memory or non-volatile memory, or may include both volatile and non-volatile memory. The data storage of system 700 (here, weld sequence data storage 706) is intended to include, without being limited to, these and other suitable types of memory. Further, the data storage device may be a server, a database, a hard drive, a flash drive, an external hard drive, a portable hard drive, a cloud-based storage device, a solid state drive, and the like. It is to be appreciated that the received or registered input data (discussed below) can be stored: dedicated data storage for such data, weld sequence data storage, remote data storage, cloud-based environments, combinations thereof, and the like.

The system 700 further includes a collection component 702, the collection component 702 configured to collect real-time data from a welding operation using a welding sequence. Generally, the collection component 702 collects, receives, and/or aggregates welding parameters from welds performed using a portion of a welding sequence. For example, welding parameters are aggregated, received, or collected in real-time for a welding sequence used to perform one or more welds. By way of example and not limitation, the welding parameter may be at least one of: parameters for welding (e.g., voltage, current, etc.), welding schedule parameters (e.g., welding process, wire type, wire size, Wire Feed Speed (WFS), volt value, trim, wire feeder to use, feed head to use, etc.), movement of an operator, positioning of a welding tool, positioning or location of welding equipment, positioning or location of an operator, position or location of a body part of an operator, sensor data (e.g., video camera, image capture device, thermal imaging device, thermal sensing camera, temperature sensor, etc.), physical welding appearance (e.g., welding size, welding shape, welding dimension(s), etc.), welding equipment configuration (e.g., power supply setting, waveform, wire feed speed, etc.), welder settings (e.g., workpiece type, wire type, etc.), welding schedule parameters (e.g., welding process, wire type, wire size, Wire Feed Speed (WFS), volt value, trim, wire feeder to use, feed head to use, Material type, weld to be performed, etc.), time to create the weld, fixture location, cost to create the weld (e.g., costs including power, electrodes, gas, personnel expenses, etc.), speed of the welding tool, etc. By way of example and not limitation, the fixture secures the workpiece against movement during the first weld or the second weld. For example, the securing device may be a clamp, a temporary weld (e.g., spot weld), or the like. Further, it is to be appreciated and understood that any welding parameter can be selected with sound engineering judgment without departing from the intended scope of coverage of embodiments of the subject invention.

The real-time welding parameters are stored and associated with a welding sequence that is utilized by the collection component 702 while creating the weld. In other words, the welding sequence(s) may be tracked and monitored for each welding sequence used to evaluate the data and configure the welding equipment, the operator's welding technique, and so forth. The aggregated welding parameters may be associated with a corresponding welding sequence (e.g., where the correspondence refers to a welding sequence used while collecting the welding parameters) via metadata, metadata tags, data storage techniques, data storage management, naming conventions, and so forth. It is to be appreciated that any suitable technique may be employed to ensure that the welding sequence matches or corresponds to the welding parameter(s) collected in real-time.

The system 700 further includes a quality manager component 704, the quality manager component 704 configured to collect quality assurance data and create modeled welding parameters (e.g., also referred to as welding parameter models). In an embodiment, the quality manager component 704 collects quality assurance data during weld execution for a particular weld sequence. Tracking the quality assurance data for each weld sequence allows for the evaluation of each weld during each portion of the weld sequence, where such tracking allows for improved results, quality, etc. In an embodiment, quality manager component 704 is further configured to interact or communicate with a welding scoring component (discussed in fig. 3) and/or a checkpoint component (discussed in fig. 3). For example, quality assurance data can be collected by quality manager component 704 at a periodic time frequency, at a particular point or step during a welding sequence, at the beginning and/or end of a welding sequence, and so forth. In an embodiment, snapshots may be collected in time, with quality assurance data being collected and viewed in real time. If the quality assurance data does not meet the defined criteria, the welding sequence may be stopped, ended, restarted, eliminated, etc.

The quality manager component 704 utilizes the real-time welding parameter(s) for each welding sequence and generates modeled welding parameters based on the real-time welding parameter(s). The modeled welding parameters are applied to a corresponding welding sequence to maintain the quality of a welding operation performed with the welding sequence. In an embodiment, the modeled welding parameters may be based on the welding parameter(s) collected in real-time for each welding sequence. In another embodiment, the modeled welding parameters may be based on welding parameters collected in real-time during a welding training session, a virtual welding session, a welding simulation, or a specific welding session to create modeled welding parameters. For example, welding parameters a may be monitored in real time and collected for each instance of the welding sequence W being used. This data collected for welding parameter a may be evaluated to create modeled welding parameter a' after a duration of time or after two or more welds. The modeled welding parameters a' may be used for welding operations employing the welding sequence W in order to maintain consistency and/or quality. In another embodiment, more than one welding parameter may be collected in real time to create one or more welding parameter models. For example, data for welding parameters a and B may be used with welding sequence W, from which modeled welding parameters AB' may be generated for use with welding sequence W. It is to be appreciated that any suitable number of welding parameters may be used to create the welding parameter model and the discussion above is provided with respect to the embodiments.

The terms "modeled welding parameter" and/or "welding parameter model" as used herein may be defined as a real-time measurement or read target value for a welding parameter, where the target value is two or more real-time measurements (e.g., welding parameter real-time measurements) for a particular welding sequence and created weld. It is to be appreciated that the "modeled welding parameters" and/or the "welding parameter model" may be user defined, may be identified using a statistical analysis of two or more real-time welding parameters, may be identified via a user performing a weld using a welding sequence to detect real-time welding parameters, or a combination thereof. By way of example and not limitation, the statistical analysis may be an average of two or more real-time welding parameters, a range based on two or more real-time welding parameters, a threshold tolerance based on one or more real-time welding parameters, a weighted average, a median, a standard deviation, and/or the like of two or more real-time welding parameters. Further, it is to be appreciated and understood that the modeled welding parameters and/or welding parameter models can be employed in any formula that uses two or more real-time welding parameters, which can be selected with sound engineering judgment without departing from the intended scope of coverage of embodiments of the subject invention.

It is to be appreciated that real-time collection of welding parameters for a welding sequence can be utilized in one or more environments independent of the source or collection of welding parameters (e.g., independent of where the welding sequence is used and where data collection occurs). For example, an operator may perform two or more welds in welding environment a using welding sequence W and further create a welding parameter model in welding environment B using welding parameters collected from the two or more welds using welding sequence W. In another embodiment, real-time data for welding parameters may be collected across welding environment a and welding environment B (while using welding sequence W) to create a welding parameter model for welding sequence W for use in welding environment a, welding environment B, and/or welding environment C.

In an embodiment, the welding sequence may include quality assurance collection (e.g., also referred to as collecting quality assurance data). A welding sequence may be created, edited, or altered to include quality assurance collections for at least one of a welding work cell, welding equipment, or one or more welds. By way of example and not limitation, the quality assurance collection may be a data capture of at least one of: welding equipment (e.g., settings, physical location, amount of consumables, etc.), an operator (e.g., physical location of an individual, location of an arm, location of a hand, etc.), or welding (e.g., dimensions, location of a weld, etc.). It is to be appreciated that the data collection can be video, audio, images, settings, welding equipment settings, physical location of the operator, movement from the operator, and the like. For example, quality assurance collection may be included with a welding sequence as a step in the welding sequence, where the collection is based on a particular frequency, duration, or point in the welding process (e.g., middle of weld, end of weld, etc.). Thus, the welding environment, the welding system, and/or the welding work cell may have quality assurance data collected in real time. In an embodiment, the quality assurance collection may be a step in a welding sequence at a particular point in the welding process. In particular embodiments, the welding sequence may be evaluated over time to identify a particular weld site or region (containing errors). In such embodiments, quality assurance collection may be configured to aggregate data at a point in time before a particular point to avoid errors.

In an embodiment, the welding sequence may include a supply of consumables. A welding sequence may be created or edited to include replenishment of consumables for at least one of a welding work cell, welding equipment, and the like. For example, a replenishment of consumables may be included with the welding sequence after a period of time, wherein the period of time is estimated based on a duration of time that the welding equipment is used (e.g., estimating usage of consumables). Thus, the welding environment, the welding system, and/or the welding work cell may be evaluated 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. A welding sequence may be created or edited to include a verification request or a repair request based on factors such as, but not limited to, time, duration, etc. A welding work cell may have a maintenance period for a particular time, and if a welding sequence is created for such a welding work cell, repair or maintenance may be included with the created welding sequence. Thus, the welding environment, the welding system, and/or the welding work cell may be evaluated in real time or from collected real-time data, and the data identified to determine a check or repair.

In another embodiment, the welding sequence may include a pre-shift procedure performed prior to the welding operation. For example, a shift may be part of the operator's or employee's schedule, where the shift is the duration that the operator is working. As an example, the shift may be from seven (7) o' clock to 3 pm. Based on the aggregated historical welding data or real-time welding data, an estimate of welding time may be calculated to facilitate determining maintenance to be performed on the welding equipment. In an embodiment, at least one of gas flow, contact tip condition, contact tip replacement, nozzle verification, nozzle replacement, and the like may be included within the welding sequence based on the estimate of the welding time.

Additionally, it is to be appreciated and understood that the collection component 702 can be a stand-alone component (as depicted), can be incorporated into the welding job sequencer component 302, into welding equipment (not shown), into the quality manager component 704, into the welding work cell 304, or a combination thereof. Additionally, the welding job sequencer component 302 can be a stand-alone component (as depicted), can be incorporated into the collection component 702, incorporated into the welding equipment (not shown), incorporated into the quality manager component 704, incorporated into the welding work cell 304, or a combination thereof. Further, the welding sequence data store 706 can be a local data store, a remote data store, a cloud-based data store, a computing platform, and/or any other network or computing environment configuration discussed above with respect to the welding job sequencer component.

Fig. 8 illustrates a system 800 that communicates a portion of a medium to an operator to facilitate creating a weld using a welding process. The system 800 further includes a guidance component 802, the guidance component 802 configured to provide data to the welding work cell 304 to facilitate creation of a weld using a welding sequence, wherein the data is related to a portion of a medium (e.g., audio, video, images, etc.). In embodiments, a portion of the medium may be a weld (e.g., physical appearance), a welding torch (e.g., orientation, position, etc.), a workpiece (e.g., fixture position, etc.), a body part of an operator (e.g., hand position, body position, etc.), or a combination thereof. In an embodiment, the guidance component 802 receives a portion of a medium corresponding to a welding sequence or a portion of a welding sequence (e.g., a step, a segment, etc.) and provides a portion of such medium to an operator performing welding using the welding sequence or the portion of the welding sequence. In another embodiment, the directing component collects a portion of the media via the quality manager component 704. For example, a portion of the medium may be stored for a weld performed (with a welding sequence) having one or more welding parameters identified for the modeled welding parameters. In another embodiment, a portion of the predefined medium may be assigned to each portion of the welding sequence. Generally, a portion of the medium is presented to an operator, wherein the portion of the medium is based at least in part on the modeled welding parameters, the welding parameter model, the user-defined portion of the medium, the simulated welding operation, the virtual welding operation, and the like.

The guide member 802 is further configured to convey a portion of the medium corresponding to the welding sequence used. By way of example, and not limitation, portions of the medium may be delivered via a device (e.g., a smartphone, a speaker, a display, a handheld device, a portable gaming device, a tablet computer, a notebook computer, a monitor, a television, and so forth). Also, portions of the media may be displayed to or using the operator's equipment. By way of example and not limitation, the operator's equipment may be a helmet, a visor, a pair of glasses, a glove, an apron, a jacket, a welded sleeve, an operator's identification badge, an earpiece, a pair of headphones, an ear plug, a headband, a watch, a piece of jewelry (e.g., an earring, a necklace, a bracelet, etc.), and the like.

In an embodiment, the guide component 802 can display a hologram (e.g., holographic image, 3D video, holographic video, etc.) onto at least one of the user's equipment, a workpiece, or a surface on which the workpiece is located. The hologram may be a "ghost" showing the appearance of a weld utilizing a welding sequence to convey or show to an operator positioning (e.g., operator physical position, fixture position, torch angle/position, workpiece position, etc.), actions (e.g., torch action to create a weld, etc.), rates (e.g., speed at which a weld is formed, etc.), weld dimensions (e.g., weld size, appearance of a weld, etc.), and so forth.

In another embodiment, the guidance component 802 can display to the operator a location as to where to weld for a welding sequence, where the location is displayed via an indicator (e.g., light, target, graphic, image, etc.). For example, goggles worn by the operator may have an indicator displayed thereon such that from the operator's perspective, the indicator is positioned where the weld for the welding sequence should be performed.

Fig. 9 illustrates a system 900 that communicates an alert to an operator performing one or more welds using a welding sequence. The system 900 includes a notification component 902, the notification component 902 communicating an alert to the welding work cell 304. In particular, the notification component 902 can communicate an alert to at least one of the artifact 904, the operator 906, and/or the equipment 908. It is to be appreciated that the alert can be communicated to convey information/notifications related to at least one of: a welding sequence being used, a quality assurance condition (e.g., real-time monitoring compared to modeled welding parameter(s), not within a range or tolerance level, an action or movement to perform the welding is inappropriate, etc.), a work environment condition (e.g., lunch break, time of day, end of shift, Public Address (PA) announcement, evacuation announcement, fire alarm, emergency alarm, start of shift, end of break, end of lunch break, etc.), welding equipment (e.g., a welding torch in an inappropriate location, etc.), welding consumables (e.g., a replenishment alert, amount/level of consumables, stick-out too short, stick-out too long, etc.), safety concerns (e.g., approaching a welding torch, approaching welding equipment, etc.), or a combination thereof.

For example, the notification component 902 may display a red light on the workpiece 904 to alert the operator 906 to stop performing welding based on the detected problem (e.g., see the above embodiments). In another embodiment, the audio signal may be used to communicate to the operator 906: the weld for a particular workpiece is complete or has passed a quality check. In another embodiment, the green light may illuminate equipment 908 that requires replenishment of consumables. For example, the alarm may provide guidance to the operator regarding how to replace the consumable for the sequence. In another embodiment, a vibratory or tactile feedback alert may be communicated to the operator 906.

In another embodiment, background music may be played for the operator 906 that is interrupted based on an alarm or other communication. In particular embodiments, the background music may be modified (e.g., increasing tempo, decreasing tempo, changing type of music, changing genre of music, changing artist, etc.) to correspond to the alert communicated to operator 906. For example, if the operator performs welding with a welding sequence at a faster speed, the tempo of the background music may be changed (e.g., increased to communicate that the speed is too fast, slowed to communicate that the operator should slow down, set a different artist for too fast detection, etc.).

Fig. 10 illustrates a system 1000 that delivers an alarm to an operator who creates a weld using a welding sequence based on conditions within a welding work cell. The system 1000 includes a notification component 902, the notification component 902 further including an administrator component 1002, the administrator component 1002 configured to evaluate a condition in the welding work cell 304. The manager component 1002 selects one or more alerts 1004 to communicate to the welding work cell 304 based on the detected conditions in the welding work cell 304. For example, if the sound level within the welding work cell 304 is high, a visual alert or a tactile alert may be communicated. In another embodiment, an audible alert and/or a tactile alert may be delivered if the operator 906 is positioned away from the display or not in the field of view of the display. In another embodiment, if the operator 908 is remote from the welding work cell 304 (beyond the range of the audible and/or visual alarm), the tactile alarm may be communicated via a wireless device or a portable device (e.g., worn by the operator 906, incorporated into the operator's equipment, etc.). For example, tactile feedback (e.g., motion, vibration, movement, etc.) to the operator can be conveyed to the operator by notification component 902.

In another embodiment, the urgency of the alert may determine which alert to deliver (e.g., audible, visual, tactile, and/or combinations thereof). For example, the evacuation alert may be communicated with an audible alert, a visual alert, and a tactile alert. Less urgent alarms may be delivered with a tactile alarm because such an alarm does not distract or distract other operators except the receiving operator. It is to be appreciated that manager component 1002 can include predefined settings for alarms, conditions, and the like. Also, the administrator component 1002 can collect real-time data and automatically adjust based on operator preferences.

In view of the exemplary devices and elements described above, methodologies that may be implemented in accordance with the disclosed subject matter will be better appreciated with reference to the flowcharts and/or methodologies of fig. 11 and 12. The methods and/or flow diagrams are shown and described as a series of blocks, and the claimed subject matter is not limited by the order of the blocks, as some blocks may occur in different orders and/or concurrently with other blocks from what is depicted and described herein. In an embodiment, 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 an embodiment, the first input and the second input may be received substantially simultaneously. Moreover, not all illustrated blocks may be required to implement the methodologies and/or flow diagrams described hereinafter.

Continuing, the following occurs as illustrated in the decision tree flow diagram 1100 of fig. 11, which decision tree flow diagram 1100 is a flow diagram 1100 that identifies a welding parameter model for a welding sequence based on one or more welding parameters collected in real time for the welding sequence used to create at least one weld. The method 1100 receives data (e.g., welding parameters) during a welding operation using a welding sequence to generate (e.g., at a later point in time) a welding parameter model (e.g., also referred to as modeled welding parameters) for use with the welding sequence, where the welding parameter model is based on the collected data. A welding sequence for use by an operator in a welding work cell is identified, wherein the welding sequence defines a first welding procedure including first parameters to create a first weld on a workpiece and a second welding procedure including second parameters to create a second weld on the workpiece (reference block 1102). The welding sequence is utilized to automatically alter welding equipment within the welding work cell without intervention from an operator, creating at least one of a first weld or a second weld (refer to block 1104). Welding parameters are collected in real time during creation of at least one of the first weld or the second weld (reference block 1106). The welding parameters are associated with a welding sequence and at least one of the first weld or the second weld (reference block 1108). A welding parameter model is generated based on one or more welding parameters collected in real time (reference block 1110). The welding parameter model is implemented for a welding sequence performed at a time subsequent to creation of at least one of the first weld or the second weld (reference block 1112).

The following occurs as illustrated in the flow diagram 1200 of fig. 12. Flowchart 1200 relates to creating a welding parameter model for a welding sequence based on one or more parameters collected from previous welding operations using the welding sequence. A welding sequence is utilized to automatically alter welding equipment within a welding work cell without intervention from an operator, create at least one of a first weld or a second weld, wherein the welding sequence defines at least parameters and a welding schedule for a first welding procedure to create a first weld on a workpiece, and defines at least parameters and a welding schedule for a second welding procedure to create a second weld on the workpiece (reference block 1202). Welding parameters are collected in real-time during creation of at least one of a first weld or a second weld with a welding sequence (reference block 1204). A welding parameter model is generated based on one or more welding parameters collected in real time for a welding sequence (reference block 1206). The welding parameter model is utilized for a new welding operation using a welding sequence (reference block 1208).

In embodiments, the method may comprise at least the steps of: displaying a portion of a medium showing an execution of a welding parameter model, wherein the portion of the medium is at least one of a video, an image, a picture, a holographic image, a holographic video, a 3-dimensional (3D) image, or a 3D video. In embodiments, the method may comprise at least the steps of: monitoring the welding work cell to identify conditions related to noise level, operator activity, or operator location; and communicating an alert to an operator based on the condition, wherein the alert is based on at least one of: a welding sequence, creation of additional welds, or real-time comparison of created additional welds to a model of welding parameters.

By way of example and not limitation, welding equipment (e.g., a controller for a welder power supply, a wire feeder, a welder power supply, etc.) may include one or more steps related to a particular welding process for a particular workpiece, where the steps may include a respective setting or configuration for at least one welding equipment. For example, the first workpiece may include steps A, B, C and D based on 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 the welding sequence is employed, a controller that implements steps of the welding process via the welder power supply and/or the welding equipment may be managed and/or instructed. For example, the welding sequence may indicate at least one of: which step to perform, a redo (redo) step, a skip step, a pause of a series of steps, etc. Additionally, the controller (e.g., or other suitable component) may control one or more welder power sources, parameters, welding schedules, other parameters associated with one or more welding processes, where each welding process may have a corresponding welding sequence(s).

In an embodiment, a system may include a weld scoring component configured to evaluate at least one of a first weld or a second weld performed by an operator on a workpiece based on at least one of an image of the first weld or the second weld or a user inspection. In an embodiment, a collection component associates a portion of the assessment with an identified welding sequence and at least one of the first weld or the second weld. In an embodiment, a system may include a checkpoint component configured to monitor creation of an operator and at least one of a first weld or a second weld in real time using a welding sequence, and a collection component to associate a portion of the monitoring with the identified welding sequence and at least one of the first weld or the second weld.

In an embodiment, the system may include a welding job sequencer component further configured to communicate instructions to an operator of the welding work cell to assemble a workpiece with a first welding procedure and a second welding procedure having two separate welding schedules, wherein the instructions include at least one of a portion of the monitoring or a portion of the evaluating.

In an embodiment, a system may include a quality manager component configured to evaluate real-time welding parameters for at least one of a first weld or a second weld created with a welding sequence and identify a welding parameter model. In an embodiment, the welding parameter model is based on mean measurements of real-time welding parameters. In an embodiment, the welding parameter model is a defined range of values based on the real-time welding parameters. In an embodiment, the welding parameter model includes a threshold tolerance based on the real-time welding parameters. In an embodiment, the collection component associates the weld parameter model with the identified weld sequence and at least one of the first weld or the second weld. In an embodiment, the quality manager component is further configured to receive real-time welding parameters for use as a welding parameter model.

In an embodiment, a system may include a guidance component configured to collect a portion of media captured during creation of a weld parameter during at least one of a first weld or a second weld. In an embodiment, the guidance component displays a portion of the medium as at least one of a video, a portion of audio, a 3-dimensional (3D) image, a hologram, or an image on the operator's equipment.

In an embodiment, a system may include a notification component configured to generate an alert to an operator based on at least one of: a welding sequence, performance of a first weld or a second weld, or a comparison of real-time welding parameters to a welding parameter model calculated based on historical welding parameter data for the welding sequence. In an embodiment, the notification component is further configured to communicate the alert to an operator based on the urgency of the alert or a condition within the welding work cell.

The above examples are merely illustrative of several possible embodiments of various aspects of the present invention, wherein equivalent alterations and/or modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular and in regard to the various functions performed by the above described components (assemblies, devices/apparatus, systems and circuits, etc.), the terms (including a reference to a "means") used to describe such components are intended to correspond, unless otherwise indicated, to any component (e.g., hardware, software, or combination thereof) which performs the specified function of the described component (e.g., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the illustrated implementations of the invention. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Also, to the extent that the terms "including", "includes", "having", "has", "with", or variants thereof are used in either the detailed description and/or the claims, such terms are intended to be inclusive in a manner similar to the term "comprising".

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled 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 embodiments 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 language of the claims.

The best mode for carrying out the invention has been described for the purpose of illustrating the best mode known to the applicant at that time. The examples are illustrative only and not meant to limit the invention, as measured by the scope and value of the claims. The invention has been described with reference to preferred and alternative embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.

Reference numbers:

10 operation 440 workpiece

20 operation 450 workpiece connector

22 operation 460 spool of welding wire

24 operation 470 welding wire feeder

26 operation 480 welding wire

30 operation 500 System

32 operation 510 computing platform

40 operation 515 work cell

50 operation 520 work cell

52 operation 530 work unit

54 operation 535 welding job sequencer component

60 operation 540 welding job sequencer component

70 operation 545 welding job sequencer component

110 operation 550 data storage device

120 operation 555 data storage device

122 operation 560 data store

124 operation 600 welding system

126 operation 620 first welding work cell

130 operation 630 second welding work cell

132 operation 640 Nth welding work cell

150 operation 650 memory

152 operating 700 system

154 operation 702 Collection component

160 operation 704 manager component

170 operation 706 inventory

300 welding system 800 system

302 part 802 maintenance part

304 welding work unit 804 cost parts

306 checkpoint component 900 system

308 welding scoring component 902 guide component

400 welding system 904 marking components

405 welding a circuit path 906 workpiece

410 welder Power supply 908 operator's body part

415 location of display 910 mounting

420 weld cable 1000 system

430 welding tool 1002 welding environment

1004 welding sequence 1204 reference box

1100 method or diagram 1206 reference frame

Reference box 1102

1104 refer to Block A scheduling or procedure

1106 reference frame B scheduling or procedure

1108 refer to Block C scheduling or procedure

1110 reference frame D step

1200 method or flowchart E step

1202 reference frame F step