JP2001071140A - Manual welding support device, manual welding support method, manual welding training device, and manual welding training method - Google Patents

Abstract

(57) [Summary] [Problem] To maintain stable welding quality and improve work efficiency in welding monitoring regardless of the skill and skill of a welder during manual welding work. A hand welding support device includes: a welding operation measurement device for measuring data on a welding environment including an object to be welded when a manual welding operation is performed and a behavior of a welder PS during the welding operation; Environmental measurement device 102
An arithmetic processing device 104 that extracts a feature amount of a welding state during welding from the measurement data, a welding state determination device 105 that determines the quality of a manual welding state based on the extracted feature amount, A welding state presentation device 107 is provided for presenting information on the transition of the welding state including the determination result here to the welder PS who is performing welding in a recognizable manner.
Further, the apparatus includes a welding process recording device 103 that records and holds the above-described measurement data, determination results, and characteristic amounts, and a welding process display device 106 that displays at least the determination results.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a manual welding support apparatus and a manual welding support method for assisting a welder engaged in manual welding work, and a manual welding training apparatus and manual welding training used for training a welder. About the method.

[0002]

2. Description of the Related Art Conventionally, in the field of welding, an apparatus for performing a simulated practical training of a welder is known (for example,
See JP-A-4-97383. This conventional example is shown in FIG.
It is shown in FIG. The simulation training apparatus shown in FIG. 11 includes a construction condition setting unit 201 for setting an item to be trained from among items such as a material and a construction know-how in a predetermined welding construction condition, and a training operation. Pen 202 for simulating a welding arc to be generated between the welder and the workpiece to be welded, and a simulation for evaluating the welding arc simulated by the light pen 202 from the workpiece side. Light receiving board 203 for receiving an optical signal carrying information on a pseudo welding result
And a simulated welding result obtained by the light receiving board 203 and the contents set by the execution condition setting device 201, and a comparator 204 for judging a training result and the like based on the comparison result. And a display 205 for displaying or indicating the training result by the user 204.
01 to 205 enables the welding worker to perform a simulated practical training of welding work.

[0003]

SUMMARY OF THE INVENTION However, the above-described simulation practical training apparatus of the prior art is intended to provide a skill so that a welder can stably generate and maintain a welding arc. Therefore, the only information that the trainee can perceive at the simulated welding point during the simulated welding process is the shape of the welding arc simulated with the light pen, ensuring stable penetration depth and securing fusion to the groove wall. However, there is a problem that the welding technique, which is determined based on the shape of the molten portion, must be learned while actually performing welding.

[0004] On the other hand, it has been pointed out that the welding operation by a human can flexibly cope with the shape of the welded portion as compared with the automatic welding operation, but is significantly inferior in terms of stability of welding quality and work efficiency. ing.

For example, in the automatic welding process, an apparatus for monitoring an automatic welding process online by monitoring some typical features in the welding process has been developed and put into practical use. Various methods have been proposed, and research into technology development and patenting of the methods have been attempted. In contrast, techniques for monitoring and assisting manual welding operations performed by human welders do not use such automatic welding monitoring device technology, and the welding quality is limited to the skills and skill of the welder. It was very dependent on the degree.

That is, in the conventional manual welding environment, there is no application example in which the welding state is monitored online or the work of a welder is supported by providing information or the like. In the case of application to the above case, there is no known problem of what to measure in the manual welding condition, and there is no known device for measuring without obstructing the welding environment, and it has conventionally been considered difficult.

The present invention has been made in view of such a conventional problem, and maintains welding quality stably without depending on the skill and skill of a welder during manual welding work in welding monitoring. The aim is to increase efficiency.

Further, the present invention facilitates and efficiently learns a welding technique in which a fusion depth such as stabilization of a penetration depth and securing of fusion to a groove wall is determined in a simulation training. Another purpose.

[0009]

In order to achieve the above-mentioned object, a hand-welding support device according to the present invention presents the welding progress to a welder in an easy-to-understand manner while monitoring a state quantity relating to a hand-welding execution state. And a welding environment measuring means having a measuring device for monitoring a welding state including a welding target and a welding operation measuring means having a device for measuring the behavior of a welder during welding. Data measuring means, arithmetic processing (feature amount extraction) means for extracting features relating to the welding condition in progress from a signal defining the welding state obtained by the data measuring means, and welding condition from the output of the arithmetic processing means And welding state presenting means for presenting a transition of the welding state to a welder during welding work. Further, in addition to this configuration, a welding process recording means for recording and holding the data, arithmetic processing results, and determination results obtained by the data measurement means, and a welding process display means for displaying the determination results by the welding state determination means. It is desirable to have one.

[0010] It is preferable that the data measuring means includes a plurality of measuring devices for simultaneously and concurrently measuring multidimensional data constituted by a plurality of different process quantities as the data. According to the plurality of measuring devices, the welding state can be described in more detail.

The feature amount extracting means comprises a plurality of arithmetic processing units for simultaneously processing a plurality of different feature amounts from the multi-dimensional data measured by the plurality of measuring devices in parallel and extracting a multi-dimensionally. It is preferable that

[0012] The welding state determination means includes a data reference means for referring to data obtained during an appropriate welding operation performed in the past, and whether the welding state is good or bad based on the data referred to by the data reference means. It is preferable to provide a determination unit.

[0013] The welding state presenting means may apply a judgment result of the welding state determined by the welding state judging means to a sensory sensation, such as a hearing, a tactile sensation, or a force sensation, other than a visual sense of the welder. It is preferable to provide a sensory transmission unit that directly presents as a message, and the sensory transmission unit includes a unit that alerts the welder and prompts the welder to change the welding operation.

[0014] It is preferable that the welding state presenting means is provided with means for presenting information on an operation path of an action to be taken by the welder in a manner superimposed on the view of the welder.

The welding state presenting means includes a data comparing means for comparing data obtained at the time of proper welding work performed in the past with data relating to the current welding operation, and a data comparing means based on the comparison result by the data comparing means. Preferably, means for determining whether the welding state is good or not is provided.

It is preferable that the welding state presenting means is provided with means for selectively and preferentially presenting a specific process amount during the welding operation in the field of view of the welder.

It is preferable that the feature quantity extracting means includes means for estimating compensation data when the data measured by the data measuring means is not appropriate due to disturbance such as welding noise mixing. . The estimation of the compensation data is desirably based on, for example, another measured amount or a physical model.

In order to achieve the above object, a method for performing manual welding according to the present invention provides a method for monitoring the progress of manual welding while monitoring the state of manual welding when a welder performs manual welding on an object to be welded. A method for assisting the manual welding by recognizing the situation to the welder, wherein the manual welding includes a welding environment including a welding target and a welder during the welding operation when the manual welding is performed. The data on the behavior is measured, and the characteristic amount of the welding state during the welding operation is extracted from the measured data, and the quality of the manual welding state is determined based on the extracted characteristic amount. And a step of presenting information relating to the transition of the welding state including the above to the welder during the welding work in a recognizable manner.

In order to achieve the above object, a manual welding training apparatus according to the present invention trains a welder engaged in manual welding, and includes a device for measuring the behavior of the welder during the welding training. Measuring means having a welding training environment measuring means provided with a training operation measuring means and a measuring device for measuring the state of the welding training environment, and a signal which defines the state of the welding training obtained by the data measuring means. Arithmetic processing (characteristic amount extraction) means for extracting characteristics relating to the simulated welding conditions; simulated welding state determining means for determining whether the simulated welding state is good or not based on the output of the arithmetic processing means;
Simulated welding process recording means for recording and holding data, arithmetic processing results, and judgment results obtained by the measuring means, simulated welding process display means for displaying the behavior of the welder in training and the simulated welding state, and simulated welding process A simulated welding environment image generating means for generating an image of a welded portion obtained by the method, and a simulated welding state presenting means for presenting a transition of the welding state to a welder during welding training.

In addition to this configuration, a simulated welding process recording means for recording and holding data obtained by the measuring means, arithmetic processing results, and judgment results, and displays the behavior of the welder in training and the simulated welding state. It is desirable to have a simulated welding process display means.

With this configuration, the information obtained from the welding operator training operation measuring means and the welding training environment measuring means is calculated using the arithmetic processing means and the simulated welding information determining means, and the calculation result is used as the simulated welding process. In addition to recording using the recording means, the behavior of the welder in the training and the simulated welding state are displayed by the simulated welding process display means, and the simulated welding environment image generating means is generated for the welder during the welding training. The visual information of the simulated welded part and the auditory, tactile, and force information derived from the results of the arithmetic processing means and the like are presented using the simulated welding state perception presentation means. As a result, it is possible to provide an environment in which the welder feels that welding is actually being performed,
More advanced welding training becomes possible.

It is preferable that the data measuring means includes a plurality of measuring devices for measuring multidimensional data constituted by a plurality of different process amounts as the data simultaneously in parallel. According to the plurality of measuring devices, the simulated welding state can be described in detail.

The feature amount extracting means includes a plurality of arithmetic processing units for simultaneously processing a plurality of different feature amounts from the multi-dimensional data measured by the plurality of measuring devices in parallel and extracting a plurality of features. It is preferable that

It is preferable that the feature amount extracting means includes means for estimating compensation data when the data measured by the data measuring means is not appropriate due to disturbance such as welding noise mixing. . The estimation of the compensation data is desirably based on, for example, another measured amount or a physical model.

The simulated welding condition determination means includes a data reference means for referring to data obtained during an appropriate welding operation performed in the past, and the simulated welding condition based on the data referred to by the data reference means. It is preferable to include means for judging pass / fail.

The simulated welding state presenting means determines whether or not the simulated welding state is good or bad, which is determined by the simulated welding state determining means, based on a perception except for the welder's vision, for example, auditory,
Perceptual transmission means for directly presenting as tactile sensation, force sensation, etc. as a sensory stimulus shall be provided, and this perceptual transmission means shall include means for alerting the welder and prompting the welder to change the welding operation. Is preferred.

[0027] It is preferable that the simulated welding state presentation means includes means for presenting guidance information on an operation path of an action to be taken by the welder in a manner superimposed on the view of the welder.

The simulated welding state presenting means includes data comparing means for comparing data obtained during the past proper welding work with data relating to the current simulated welding operation, and a comparison result by the data comparing means. Means for judging the quality of the welding operation in the training of the welder based on the above.

It is preferable that the simulated welding state presentation means includes means for reproducing data relating to the behavior of the welder obtained in the past welding training.

In order to achieve the above object, a manual welding training method according to the present invention trains a welder engaged in manual welding work, and includes a step of measuring the behavior of the welder during the welding training, A step of measuring the state of the environment, an arithmetic processing step for extracting features relating to simulated welding conditions in progress from signals defining the state of welding training obtained by these measuring steps, and an output of the arithmetic processing step And a step of presenting the transition of the welding state to a welder during welding training.

Further, in addition to this configuration, a step of recording and holding data, arithmetic processing results, and judgment results obtained in these steps, a step of displaying a welder's actions and a simulated welding state in training, Generating an image of a weld obtained in the welding process.

[0032]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram showing an embodiment of an apparatus and a method according to the present invention;

(First Embodiment) First, an embodiment of a hand welding support apparatus and a hand welding support method according to the present invention will be described with reference to FIGS.

In FIG. 1, the manual welding support device generates an arc between a welding torch held by a welder and a groove formed by two base materials to be welded, for example, when performing manual welding. A weld pool is formed in the groove by the heat, and a belt-like bead is generated in the moving direction by continuously moving the formation point of the weld pool, thereby welding the two base materials. It supports construction.

As shown in FIG. 1, such a manual welding support device is a welder operation measuring device (hereinafter referred to as "operation measuring device") for measuring information on the welding operation state of a welder PS when welding is performed. Abbreviated) 101 and a welding environment measuring device (hereinafter referred to as "environment measuring device") 102, which are connected to the latter stage (output side) of both measuring devices 101 and 102, and hold, manage, signal process, and judge the welding state. And the like, ie, a welding process recording device (hereinafter, “recording device”) 103, an arithmetic processing device 104, and a welding condition determining device (hereinafter, “determining device”) 105, and processing results of these devices 103 to 105. Process display device (hereinafter referred to as “display device”) 10 for presenting the information to the welder PS 10
6 and a welding state perception presentation device (hereinafter, “perception presentation device”) 107.

As shown in FIG. 2, the motion measuring device 101 includes a protective glove 110 and a protective mask 1 worn by a welder PS.
08, a motion measuring sensor 121 (CCD camera 121a and position / direction sensor 121b, etc.), and the position (field of view) and motion of the welder PS based on the measurement signal from the motion measuring sensor 121. A welder operation characteristic amount extraction unit 122 for extracting characteristic amounts relating to the operation.

With this configuration, the operation measuring device 101
The three-dimensional position coordinate values (X, Y, Z) and the Euler angles (Pitch, Yaw, Roll) of the welder PS in the three-dimensional space during the welding operation are calculated by the motion measurement sensor 121.
Information about the continuous operation of the welder PS is measured in real time during the progress of the welding process by acquiring a time-series signal of the temporal change of the degree of freedom. It extracts feature quantities related to the movement of the chief PS, such as hand movement and face direction, and sends these signals to the recording device 103 and the arithmetic processing device 104.

The environment measuring device 102 is constituted by a system capable of measuring the physical state of the welding process environment and the progress of the process in real time.
2. An environment measurement sensor 12 that measures a plurality of various state quantities related to a molten pool 115 and a torch 114 at an arc occurrence location.
3 (current / voltmeter 123a, torch position / direction sensor 123b, CCD camera 123c, infrared camera 12
3d, acoustic microphone (ultrasonic microphone having sensitivity up to the ultrasonic band) 123e, position sensor 123 for base material
f, and accelerometer 123g) and this sensor 12
And a welding environment feature extraction unit 124 for extracting feature amounts relating to the welding environment based on the various measurement signals from the third.

In such a sensor 123, for example, the state of arc generation, the shape of the molten pool, the shape of the bead, and the shape of the tip of the torch are monitored by the CCD camera 123c, and the temperature of the base material 112 is increased by the infrared temperature sensor 123d. Evaluated, torch position / direction sensor 123f
, The angle of the welding torch 114 is measured, and the sound pressure and the state change of the sound generated during the welding operation are accurately and quickly captured by the acoustic microphone 123e. In addition, the sound pressure is supplied by a flow sensor to prevent oxidation of the welded portion. The flow rate of the cover gas is measured, and the welding torch 114 is measured by a voltage / ammeter.
The arc voltage and the current value are measured in order to evaluate the heat input amount. Then, the measurement / measured value from each of the sensors 123 is sent to the welding environment feature extraction unit 124, where the feature amount of the welding environment is extracted, and the extracted feature amount is stored in the welding process recording device 103 and the arithmetic processing. Sent to the device 104.

The recording device 103 records data collection / analysis processing / display / presentation information of the present device relating to welding work.
The information is made playable after welding, and is held in a database (not shown) for use as basic data for performing information processing and feature extraction related to manual welding offline. This system not only shows the total measurement amount recorded during operation and the processing result in the later stage,
A large amount of welding work process data recorded in the past is retained and managed, and it is possible to search and retrieve retained data online and offline as necessary, as described later.

The arithmetic processing unit 104 includes two measuring devices 1
Based on the measured quantities related to welding obtained in steps 01 and 102, physical characteristics of the welding state such as a frequency spectrum are calculated. For example, not only a calculation process such as a frequency spectrum distribution analysis process of a sound generated at the time of welding collected by the microphone 123e, but also a positional relationship between the welding equipment and the welder based on the position of the welding torch 103 or the position of the molten pool 115. Are processed based on image processing and position sensor information.

In the arithmetic processing unit 105, there is a high possibility that data is lost due to noise in actual measurement. To compensate for this, data before and after the loss is complemented and used.
Missing data is estimated based on other measured quantities using a physical model of the welding state, and the missing data is estimated and non-measured quantities are calculated. For example, in the case of torch position information, the position sensor / azimuth sensor 123b and the like are usually installed as sensors that provide the information, but when these data are partially unavailable due to the influence of noise or the like. The information can be obtained by a process of extracting position information by image processing based on information of an image sensor such as the CCD camera 123c.

The result processed by the arithmetic processing device 104 is supplied to the recording device 103, the determination device 105, and the perception presentation device 107.

The judging device 105 performs arithmetic processing by the arithmetic processing device 104, welding conditions set in advance, and data obtained by similar welding operations performed in the past recorded and held in the recording device 103. Based on the above, it is determined whether or not the welding state has already been performed, whether or not the current arc state is good, and whether or not there is a possibility of departure from an appropriate state, and the determination result is displayed on the recording device 103. Apparatus 10
6 and send it to the sensory presentation device 107.

Here, for the welding performed in the past, nondestructive inspections and the like are usually performed after the welding, and the correspondence between the online data at the time of the welding and the occurrence of defective welds and the like is performed in detail. Therefore, by retaining these data in the recording device 103 and effectively using the data, it is possible to use the data for determining the conditions for the current welding operation. In this case, as a determination method, a sequential likelihood ratio test method or the like that can quickly detect a change in a measurand feature between a normal time and a trouble occurrence is employed.

The perceptual presentation device 107 has a central function of assisting the welder online during the welding operation. The perceptual presentation device 107 partially processes the output from the arithmetic processing device 104 and the judging device 105 and applies the information to the work operation. Present online to the welder inside. In this case, information presentation to the welder is performed in consideration of how to move as a human operation, and at what timing the welder should perform the next action. An example of the perception presentation device 107 is shown in FIGS.

FIG. 3 is a view for explaining an example of an apparatus for visualizing various kinds of information necessary for assisting welding work through the field of view of the welding protection mask 108 worn by the welder PS. In this apparatus, in addition to the actual visual field 141 in the visual field viewed through the protective mask 108, online measurement information 142 on the current welding process, an enlarged welded image 143, and the like can be displayed along with the visual field 141. I have. Among them, a plot image showing a time series signal from each sensor 123 is presented as a process trend in the online measurement information 142, and a welded portion enlarged image 143 includes
Information that guides the movement of the welder's hand such as the arc position 144 and the torch tip position 145 on the molten pool 147 is presented. In addition, information corresponding to the trajectory is superimposed and displayed on the actual visual field 141 as a guide for the torch operation,
As a result, the hand movement to be performed next can be easily grasped, and a better welding operation can be expected.

The perceptual presentation device 107 employs means (tactile presentation means, auditory presentation means, etc.) for directly presenting various perceptions such as human tactile sense and auditory sense in addition to the above-described visual presentation means. It is also possible. For example, there is a certain time delay between presenting textual information as visual information, actually recognizing it, interpreting it logically, and reflecting it on behavior. It can have a decisive effect on the construction status.

As a countermeasure, a method is employed in which a means for prompting the welder to quickly respond by directly stimulating non-visual sensations is employed, thereby processing the presentation information and presenting the information to the welder. I do. In this case, there is considerable freedom in the movement of the welder's hand, and the torch position and angle are not fixed as in the automatic welding machine, and the appropriate torch position is specified as a condition with a certain margin. This is considered to be one of the major factors that determine the quality of manual welding.

As means for directly stimulating the senses other than the visual sense, for example, the welder objectively senses the relative angle and position of the torch held by the welder PS with respect to the molten pool. It presents difficult information in an easy-to-understand manner as shown in the figure, monitors the tendency of welding conditions to be within an appropriate range, and when trying to deviate from that range, hold a torch based on the result of the trend monitoring It is preferable to adopt a force sense presentation device that imposes restrictions on the degree of freedom of hand movement and prevents the hand from moving beyond a certain angle. An example of this is shown in FIG.

The force sense presentation device 107a shown in FIG. 3 is incorporated in a protective glove 111 for a welder, and includes a plurality of pressurized sheets 134 attached to predetermined positions of respective fingers in the protective glove 111. 134 and a plurality of pressurized tubes 13 individually connected to each pressurized sheet 134
133, a pressurizing device 131 for supplying oil, air, or the like pressurized to each pressurized sheet 134 via each pressurized sheet 133, and a feeding condition by the pressurizing device 131 for welding. And a pressurizing control device 132 for controlling based on the output of the judging device 105.

With this configuration, this force sense presentation device 107
In a, when the torch position or angle becomes inappropriate due to the movement of the hand, the pressurizing control device 132 supplies the pressurizing device 131 to the pressurizing tube 133 based on the output of the welding condition determining device 105. Is controlled, and the pressurized sheet 134 corresponding to the direction in which the movement of the hand of the welder is desired to be restricted is expanded to generate a tactile stimulus.

The display device 106 displays information relating to the current construction state in an on-line state in accordance with the actual construction state based on the result of the decision made by the decision unit 105, and displays various information for performing a welding construction confirmation in an off-line state. Display. Here, a display example at the time of offline is shown in FIG.

On the display screen shown in FIG. 5, in addition to the welded part enlarged image reproduction screen 154 and the view image reproduction screen 155 from the protection mask, a bead image (weld part bead visible image) 151 formed by welding work , A time-series signal (sensor output time-series signal) 152 obtained by the welder operation measuring device 101 and the welding environment measuring device 102, and an image 153 indicating a signal processing result by the arithmetic processing device 104 are arranged in a time-series manner. It can be displayed.

According to the display device 106, a plurality of data items relating to the welding operation are displayed in association with each other, and other conditions and the like at the time of the operation where the significant change in the characteristic amount is recognized are displayed in the welded portion enlarged image. Since it is possible to reconfirm on the reproduction screen 154, the visual field image reproduction screen 155, and the like, the welder can more efficiently determine the construction state after the construction with the assistance of such detailed information presentation,
Further, it is possible to provide information that can be referred to as a welding execution history in a non-destructive inspection performed after the completion of the execution.

Therefore, according to this embodiment, the welding quality can be kept stable and the working efficiency can be improved without depending on the skill and skill of the welder during the manual welding work in the welding monitoring.

(Second Embodiment) Next, an embodiment of a manual welding training apparatus and a manual welding training method according to the present invention will be described with reference to FIGS.

In FIG. 6, a manual welding training apparatus includes a welding operator training operation measuring apparatus (hereinafter, “operation measuring apparatus”) 209, a welding training environment measuring apparatus (hereinafter, “environment measuring apparatus”) 212,
Arithmetic processing unit 213, simulated welding process recording device (hereinafter "recording device") 214, simulated welding state determination device (hereinafter "determination device") 215, simulated welding environment image generation device (hereinafter "image generation device") 216, a simulation welding process display device (hereinafter, “display device”) 217, and a simulation welding state perception presentation device (hereinafter, “perception presentation device”) 218.

The motion measuring device 209 includes, for example, a plurality of sensors (CC in the example of FIG. 7) attached to a protective glove 207 and a protective mask 208 provided by the welder 206 during welding training.
The position coordinate values (X, Y, Z) and the Euler angles (Pit) in space at predetermined positions of the D camera 222 and the protective glove 207
ch, Yaw, Roll), and a sensor 221) for measuring the position and orientation of the protection mask 208 at a predetermined position of the same degree of freedom at predetermined positions of the protective mask 208. These sensors are used for welding training. At this time, information related to the movement of the welder's hand and face is measured, and the measurement signal is supplied to the arithmetic processing device 213 and the recording device 214.

The environment measuring device 212 is a simulation welding torch 2
11 and sensors for measuring the physical state of the simulated welding environment during the welding training, for example, as shown in FIG. Position (position coordinate values (X, Y,
Z)) and a position sensor 22 for measuring a three-dimensional shape
3 and the shape measuring sensor 224 and the simulation welding torch 21
1 includes a position sensor 225 and a CCD sensor 226 for a simulated welding torch for measuring the position, angle, etc.
The signals measured by the sensors 224 to 226 are supplied to the arithmetic processing device 213 and the recording device 214.

The arithmetic processing unit 213 comprises two measuring units 2
The measured values from 09 and 212 are input, and the values representing the characteristics of the welding state are virtually calculated from the measured values.

The recording device 214 stores basic data such as all data collection, analysis processing, and presentation information relating to the simulation welding training, and the simulation welding state of a skilled person as a model to be input in advance. To the equipment.

The determination device 215 includes a virtual welding state feature amount calculated by the arithmetic processing device 213 and the recording device 2.
14 and input the information of the proper welding state recorded in advance, and based on the information, the quality of the execution state of the simulated welded part, the quality of the position of the simulated welding torch, and the deviation from the appropriate construction conditions are possible. Determine the presence or absence of sex.

The image generating device 216 includes the arithmetic processing device 21
3 and the respective measurement amounts measured by the two measuring devices 209 and 212 are input and obtained as visual information when welding is actually performed from the viewpoint of a welder. A virtual image that simulates the weld to be made is generated.

The display unit 217 simulates the virtual welding state feature quantity obtained by the arithmetic processing unit 213, the judgment result obtained by the judgment unit 215, and the welded portion generated by the image generation unit 216. By inputting a virtual image and information on an appropriate welding state previously input to the recording device 214, the simulation welding process can be compared with the appropriate welding state and displayed.

The perception presentation device 218 is
Of the virtual welding state obtained in step 3 and the determination device 21
5 and the virtual weld image generated by the image generation device 216, so that the welder can perceive the current simulated welding state in various ways such as visual, tactile, and auditory. And the operation content and timing that the welder should take in performing proper welding from the current situation.

Next, the overall operation of this embodiment will be described.

First, the simulated welding training of the welder PS is started. During the simulated welding process, two measuring devices 2 are used.
09 and 212 are performed. For this measurement,
The two position / direction sensors 2 in the motion measuring device 209
20, 221 and information relating to the continuous operation of the welder PS, such as the position, orientation, and movement of the hand, and the position and movement of the head, based on the measurement information from the CCD camera 222 indicate the temporal change. It is acquired in real time as a time-series signal, and is sent to the arithmetic processing unit 213 and the recording unit 214.

At the same time, the position sensor 223 and the shape measurement sensor 224 on the test body 210 side and the position sensor 225 and C
Specimen 2 based on measurement information from CD camera 226
10 and the position and shape of the simulated weld, simulated welding torch 2
Simulated welding portion and simulation welding torch 21 for position and angle of 11, etc.
One piece of information such as a continuous positional relationship is acquired in real time as a time-series signal indicating a change over time, and is sent to the arithmetic processing unit 213 and the recording device 214.

Next, in the arithmetic processing of the arithmetic processing unit 213, various virtual feature values of the welding state are calculated as follows.

First, a welding voltage value and a welding current value are derived from the shape of the simulated welding portion and the relative positional relationship of the simulated welding torch 211 based on the measured amounts from the two measuring devices 209 and 212. Thus, the heat input amount and the heat input direction to be applied to the simulated welded portion, which is one characteristic amount representing the characteristics of the welding state, are calculated.

The heat input amount and heat input direction thus calculated, the shape of the simulated welded portion, the moving speed of the simulated welding torch 211 obtained from the movement of the hand of the welder, and the feed amount of the filler metal. From this, the molten state or the welded state of the simulated welded portion, which is one characteristic amount representing the characteristic of the welding state, is calculated.

By comparing the welding voltage value and the welding current value calculated as described above with the conditions previously input to the simulation welding process recording device 214, the frequency characteristic of the audible sound generated from the simulation welding portion is calculated. Is done.

In the calculation of such a characteristic amount, if a part of the measured value from the two measuring devices 209 and 212 required for the calculation is lost due to the mixing of environmental noise or the like, the information of the measured value which is not missing is deleted. The information is complemented by using a value estimated based on a preset physical model or the like and a measured value before the unit time stored in the recording device 14.

The characteristic amounts of various virtual welding states calculated in this way are sent to the recording device 214, the determination device 215, the image generation device 216, and the perception presentation device 218.

First, in the determination device 215, various kinds of virtual welding state feature amounts calculated by the arithmetic processing unit 213 and information of the proper welding state feature amount recorded in the recording device 212 in advance. Are compared with each other, and the presence / absence of a welding defect at the present time and the recording device 2 of the simulated welding process are referred to.
12 is used to determine whether there is a possibility of departure from proper construction conditions, etc., from the amount of time-series change in the feature amount of the welding state, which is always recorded, and if so, the deviation is also calculated. Then, values such as the position / angle and the moving speed of the simulated welding torch 211 necessary for leading to the optimum welding state are calculated. The determination result and the calculation amount here are stored in the recording device 21.
4, sent to the display device 217 and the perceptual presentation device 218.

Further, the image generating device 216 creates a three-dimensional model of the simulated welded portion from the characteristic amounts of various virtual welding states from the arithmetic processing device 213. Then, the information on the position and movement of the head of the welder 6 obtained by the movement measuring device 209 and the information of the simulated welded portion obtained by the environment measuring device 212
A virtual image 241 simulating a weld obtained as visual information when welding is actually performed from the viewpoint of the welder 206 by using the computer graphics technology from the information of the dimensional positional relationship and the shape (FIG. 9)
And a virtual image 233 simulating a weld at a position where the viewpoint is fixed irrespective of the position and movement of the welder's head.
(See FIG. 8) are respectively generated. The two images 241 and 233 generated here are sent to the sensory presentation device 218 and the display device 217.

Next, on the display device 217, as shown in FIG. 8, an image 231 of the CCD camera 226 attached to the environment measuring device 212 and the test object 210 used for training are displayed.
Various training conditions 232 such as materials and welding methods, a virtual image 233 generated by the image generation device 216, which simulates a weld at a position where the viewpoint is fixed, and a recording device 214 are stored in advance. The recorded virtual image 234 of the welded part to be an example of a skilled person, the process trend 235 of various virtual welding state features calculated by the arithmetic processing unit 213, and the obtained by the determination unit 215. The determination result and the information 236 on the calculation amount are displayed, respectively, so that a third party such as an instructor who provides welding training guidance can grasp the current training situation.

At the same time, the perceptual presentation device 218
The feature amounts of various virtual welding states calculated by the arithmetic processing unit 213, the determination results and calculation amounts obtained by the determination unit 215, and the virtual parts simulating the welds generated by the image generation unit 216. Based on a typical image, present the current simulated welding status to the welder for various perceptions such as visual, tactile, and auditory senses, and also perform the actions that the welder should take to perform appropriate welding from the current situation Present the content and timing.

As shown in FIG. 9, a virtual image 24 simulating a weld obtained by the image generating device 216 is visually displayed.
1, a process trend 235 of various virtual welding state feature amounts calculated by the arithmetic processing unit 213,
In performing appropriate welding based on the calculated amount obtained by the determination device 215, an image obtained by combining the image with the line drawing 242 as a guide for the next hand movement performed by the welder 206 is used as the protection mask 209.
Is superimposed and displayed in the field of view 243 where the welder 206 can be seen through the
4 is presented.

As a presentation method other than visual, FIG.
As shown in FIG. 0, the next hand movement performed by the welder 206 in performing appropriate welding based on the calculated amount obtained by the determination device 215 as a force sense or a tactile sense is performed by the pressurizing control device 251 by the pressurizing device 252. It is also possible to employ a means for controlling the pressure supply to the pressurizing tube 253 from above and generating a tactile stimulus by expanding a plurality of pressurizing sheets 254 attached to the protective glove 207. In this case, for example, when it is desired to present the simulation welding torch so as to increase the moving speed, pressure is applied to the pressurizing sheet 254a other than the thumb to give the welder 206 a feeling that the hand is being pressed.

As means utilizing auditory sense, it is possible to employ, for example, a means for generating and presenting a synthesized sound from the frequency characteristics of the audible sound calculated by the arithmetic processing unit 213.

After the completion of the simulated welding, the recording device 21
4 is played back to the arithmetic processing unit 213, the determination unit 215, and the display unit 217, so that the contents performed in the simulation welding training can be reproduced. It is possible to understand the problem of the operation that has been performed.

Therefore, according to this embodiment, information simulating the condition of the welded portion close to the time of actual welding is presented to the welder during welding training, and the presenting means is provided to guide the welding to proper welding. Therefore, extremely effective welding training can be performed.

[0085]

As described above, according to the manual welding support apparatus and the manual welding support method according to the present invention, it is possible to provide detailed information on a welding process to a welder in a manual welding environment, which has not been conventionally performed. Can provide online support for performing welding tasks, stabilizing welding quality, de-skilling manual welding, and reducing the burden on welders.
In addition, with this support device and support method, the data of the hand welding process that has been collected is utilized offline, and the correspondence between the welding defect part obtained as a result of the non-destructive inspection of the welded part after construction and the state of the manual welding construction work is detailed. The analysis makes it possible to understand in detail the mechanism of occurrence of welding defects and their characteristics.

According to the manual welding training apparatus and manual welding training method of the present invention, information simulating the situation of the weld near the time of actual welding can be presented to the welder during welding training.
This allows not only training while immediately judging whether welding conditions are good or bad, but also allows the user to objectively compare his own welding operation with that of a skilled person after training. As a result, the welder can easily understand the quality of his or her own welding work, and can easily and efficiently learn welding techniques in simulated welding training.

[Brief description of the drawings]

FIG. 1 is a schematic block diagram showing an overall configuration of a manual welding support device according to a first embodiment.

FIG. 2 is a schematic diagram showing details of a welder operation measuring device and a welding environment measuring device.

FIG. 3 is a schematic diagram illustrating a visual presentation example of a welding state perception presentation device.

FIG. 4 is a schematic diagram illustrating a visual presentation example of the welding state perception presentation device.

FIG. 5 is a schematic diagram showing a screen display example of the welding process display device.

FIG. 6 is a schematic block diagram showing the overall configuration of a manual welding training device according to a second embodiment.

FIG. 7 is a schematic diagram showing details of a simulated welding training operation measuring device and a welding training environment measuring device.

FIG. 8 is a schematic diagram illustrating display contents of a simulation welding process display device.

FIG. 9 is a schematic diagram illustrating presentation contents related to vision of the simulation welding state perception presentation device.

FIG. 10 is a schematic diagram for explaining a presentation method relating to a force sense and a tactile sense of the simulated welding state perception presentation device.

FIG. 11 is a conceptual diagram showing the overall configuration of a device used in a simulation training in a conventional example.

[Explanation of symbols]

Reference Signs List 101 Welder operation measuring device (data measuring means) 102 Welding environment measuring device (data measuring means) 103 Welding process recording device (record holding means) 104 Arithmetic processing device (feature amount extracting means) 105 Welding state determining device (welding state determination) Means) 106 Welding process display device (display means) 107 Welding state perception presenting device (welding state presenting means) 108 Protective mask 110 Protective gloves 111 Groove 112 Welding base material 113 Bead 114 Torch 115 Weld pool 121 Motion measuring sensor unit 122 Welding Characteristic extraction unit 123 Environmental measurement sensor unit 124 Welding environment characteristic extraction unit 131 Pressurizing device 132 Pressurizing control device 133 Pressurizing tube 134 Pressurizing sheet 141 Field of view from protective mask 142 Sensor time-series signal 143 Welding portion enlargement Image 144 Arc position 145 Reach tip position 146 Bead 147 Weld pool 151 Welded bead visible image 152 Sensor output time-series signal 153 Signal processing result image 154 Applicable welded portion enlarged image reproduction screen 155 View image reproduction screen from protection mask 201 Construction condition setting device 202 Light pen 203 Light receiving board 204 Comparator 205 Result display 207 Protective gloves 208 Protective mask 209 Welder training motion measuring device (Data measuring means) 210 Specimen 211 Simulated welding torch 212 Welding training environment measuring device (Data measuring means) 213 Arithmetic processing unit (feature amount extraction unit) 214 Simulated welding process recording device (record holding unit) 215 Simulated welding state determination device (simulated welding state determination unit) 216 Simulated welding environment image generation device (image generation unit) 217 Simulated welding process display device (display means) 18 Simulated welding state perception presentation device (simulated welding state presentation means) 220, 221 Position / azimuth sensor 222, 226 CCD camera 223, 225 Position sensor 224 Shape measurement sensor 251 Pressurizing control device 252 Pressurizing device 253 Pressurizing tube 254 Pressurized sheet PS welder

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Kenichi Nomura Inventor 66-2 Horikawa-cho, Saiwai-ku, Kawasaki City, Kanagawa Prefecture (72) Katsumi Kubo 8-8 Shinsugita-cho, Isogo-ku, Yokohama-shi, Kanagawa Prefecture (72) Inventor Shozo Hirano 2-4, Suehirocho, Tsurumi-ku, Yokohama-shi, Kanagawa Prefecture Inside the Toshiba Keihin Works

Claims (22)

[Claims] When the hand welding is performed on a welding target by a welder, the progress of the manual welding is monitored so as to be recognizable to the welder while monitoring the state of the manual welding. An apparatus for supporting welding, wherein when the manual welding is performed, a data measuring unit that measures data on a welding environment including a welding target and behavior of a welder during the welding process, and the data measuring unit. Extraction means for extracting a characteristic amount of the welding state during the welding operation from the data measured by the method, and welding for judging pass / fail of the manual welding state based on the characteristic amount extracted by the characteristic amount extraction means. State determining means, and welding state presenting means for presenting information on the transition of the welding state including the determination result by the welding state determining means to a welder during the welding operation so as to be recognizable. Manual welding support apparatus characterized by comprising a. 2. The apparatus according to claim 1, wherein the data measured by said data measuring means, the judgment result by said welding state judging means, and the feature quantity extracted by said feature quantity extracting means are recorded and held. Record holding means;
And a display unit for displaying at least a result of the determination by the welding state determination unit. 3. The invention according to claim 1, wherein the data measurement means includes a plurality of measurement devices for simultaneously and concurrently measuring multidimensional data composed of a plurality of different process quantities as the data. Features a manual welding support device. 4. The invention according to claim 3, wherein the feature amount extracting means processes a plurality of different feature amounts simultaneously and in parallel from the multidimensional data measured by the plurality of measurement devices, and multifacetedly extracts the feature amounts. A hand welding support device comprising a plurality of arithmetic processing devices. 5. The invention as set forth in claim 1, wherein said welding state determination means is referred to by data reference means for referring to data obtained at the time of proper welding performed in the past, and said data reference means. Means for judging the quality of the welding state based on data. 6. The welding state presenting means according to claim 1, wherein said welding state presenting means senses a judgment result of the welding condition judged by said welding state judging means to a sense other than a visual sense of said welder. A hand-welding support device comprising: a perceptual transmission unit that directly presents as a stimulus; and wherein the perceptual transmission unit includes a unit that alerts the welder and prompts the welder to change a welding operation. 7. The invention according to claim 1, wherein the welding state presenting means includes means for presenting information on an operation path of an action to be taken by the welder in a manner superimposed on a field of view of the welder. A manual welding support device characterized by the following. 8. The invention according to claim 1, wherein the welding state presenting means includes a data comparing means for comparing data obtained at the time of proper welding performed in the past with data on a current welding operation, Means for judging the quality of the welding condition based on the result of comparison by the data comparing means. 9. The invention according to claim 1, wherein the welding state presenting means selectively and preferentially superimposes and presents a specific process amount during the welding operation on the field of view of the welder. A hand welding support device characterized by comprising: 10. The invention according to claim 1, wherein said characteristic amount extracting means includes means for estimating compensation data when the data measured by said data measuring means is not appropriate. Welding support device. 11. When hand welding is performed on an object to be welded by a welder, the progress of the manual welding is displayed to the welder in a recognizable manner while monitoring the state of the manual welding. A method for assisting welding, wherein when the manual welding is performed, measuring data on a welding environment including a welding target and behavior of a welder during the welding operation, and performing the welding from the measured data. The feature amount of the welding state during construction is extracted, and the quality of the manual welding state is determined based on the extracted feature amount, and information on the transition of the welding state including the determination result is included in the welding during the welding operation. A hand welding support method characterized by comprising each step of presenting to a technician recognizable. 12. An apparatus for training a welder engaged in a manual welding operation, wherein when the simulated welding training for the manual welding operation is performed, the apparatus relates to the behavior of the welder during the welding training and the state of the welding training environment. Data measurement means for measuring data; feature quantity extraction means for extracting feature quantities relating to simulated welding conditions during the welding training based on the data measured by the data measurement means; and Simulation welding state determination means for judging the quality of the simulation welding state based on the obtained characteristic amount; image generation means for generating an image of a welded portion based on the characteristic amount extracted by the characteristic amount extraction means; A simulation in which information on the transition of the simulated welding state including the result of the simulated welding state determination and the image generated by the image generating means is provided to the welder during the welding training. Manual welding exercise device being characterized in that a contact state presenting means. 13. The invention according to claim 12, wherein the data measured by said data measuring means, the judgment result by said welding state judging means, and the feature quantity extracted by said feature quantity extracting means are recorded and held. A manual welding training apparatus, further comprising: a record holding unit; and a display unit for displaying a behavior of a welder and a simulated welding state in training based on data held by the record holding unit. 14. The invention according to claim 12, wherein said data measurement means includes a plurality of measurement devices for simultaneously and concurrently measuring multidimensional data composed of a plurality of different process quantities as said data. Hand-welding training equipment. 15. The invention according to claim 12, wherein the feature amount extracting means processes a plurality of different feature amounts simultaneously and in parallel from the multidimensional data measured by the plurality of measurement devices, and multifacetedly extracts the feature amounts. A manual welding training device comprising a plurality of arithmetic processing units. 16. The invention according to claim 12, wherein said characteristic amount extracting means includes means for estimating and obtaining compensation data when the data measured by said data measuring means is not appropriate. Hand welding training equipment. 17. The invention according to claim 12, wherein said simulated welding state determination means includes a data reference means for referring to data obtained during an appropriate welding operation performed in the past;
Means for judging the quality of the simulated welding condition based on the data referred to by the data reference means. 18. The simulated welding condition presenting means according to claim 12, wherein the simulated welding condition presenting means determines whether or not the simulated welding condition is good or bad determined by the simulated welding condition determining means with respect to the perception of the welder except for the visual sense. A hand percussion transmitting means for directly presenting as a sensory stimulus, said perceptual transmitting means including means for alerting said welder and prompting a change in welding operation. 19. The invention according to claim 12, wherein the simulated welding state presenting means comprises means for presenting guidance information on an action path of an action to be taken by the welder in a manner superimposed on a view of the welder. Manual training equipment. 20. The simulated welding state presenting means according to claim 12, wherein the simulated welding state presenting means compares data obtained at the time of proper welding performed in the past with data relating to the current simulated welding operation. And a means for judging the quality of the welding operation in the welding training based on the result of comparison by the data comparing means. 21. The welding training apparatus according to claim 12, wherein said simulated welding state presenting means comprises means for reproducing data relating to the behavior of a welder obtained in past welding training. . 22. A method for training a welder engaged in a manual welding operation, the method comprising: when the simulation welding of the manual welding operation is performed, the method relates to the behavior of the welder during the welding training and the state of the welding training environment. The data is measured, and a feature amount related to the simulated welding condition during the welding training is extracted based on the measured data, and the quality of the simulated welding state is determined based on the extracted feature amount, Generating an image of the welded portion based on the characteristic amount, and presenting the generated image and information on the transition of the simulated welding state including the determination result to the welder during the welding training so as to be recognizable. Training method for manual welding.