FORM -2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
A PORTABLE SYSTEM FOR SIMULATING ARC WELDING
TATA CONSULTANCY SERVICES LTD.,
an Indian Company,
of Nirmal Building, 9th Floor,
Nariman Point, Mumbai - 400 021.
Maharashtra, India.
Inventor details:
V. Muralitharan
Srinivasan Raman
Basha Irfan
Palanimuthu Vignesh
Chiderae Rajasekhar
Srinivasan Swarna
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED

FIELD OF THE DISCLOSURE
The present disclosure generally relates to the field of training systems for arc welding technology.
DEFINITION
The expression 'welding torch1 used hereinafter in the specification refers to but is not limited to welding tools, welding guns and such hand tools intended to coalesce materials, typically metals or thermoplastics.
This definition is in addition to those expressed in the art.
BACKGROUND
Acquiring expertise in any skilled art including welding requires approximately 10,000 hours of intensive practice. However, cost of consumables and power impedes trainees getting such practice. Most training centers invariably churn out unemployable welders. Again, welders are often semi- literate or school dropouts who lack the confidence and motivation to succeed. Also, while welding skills can be acquired by practice, most welders lack an understanding of the theoretical (scientific and metallurgical) underpinnings of welding. Imparting theoretical knowledge to a semi-literate user and simultaneously training him in practical welding skills is a challenge that needs to be addressed.
Existing methods of welding training rely on recruiting trained faculty. The very nature of welding also makes it hard to train groups of students simultaneously. Cost of consumables and safety is also a concern in traditional setups. Welding simulators known in the art are very expensive and bulky. High

capital costs incurred and operational costs involved in purchasing welding consumables is a major hindrance in such setups. Lack of portability also is a major hindrance in providing such simulators in backward areas where there is a need to train students in such skills. Maintenance is also expensive and time consuming because of the choice of material and hardware involved. Simulators known in the art are not designed considering the economic conditions or psychology of the target users of such tools.
Accordingly there is a need for providing a portable, cost effective, safe and simple system for simulating arc welding that would also motivate and educate the target semi-literate and literate user alike in a competitive and collaborative exercise.
OBJECTS
Some of the objects of the present disclosure which at least one embodiment is adapted to provide, are described herein below:
It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
An object of the present disclosure is to provide a reliable system for simulating arc welding that can be utilized for imparting training in welding technology by faithfully replicating user experience of performing welding in the real world.
Another object of the present disclosure is to provide a portable system for simulating arc welding.

Still another object of the present disclosure is to provide a cost effective system for simulating arc welding.
Yet another object of the present disclosure is to provide a rugged system for simulating arc welding.
One more object of the present disclosure is to provide a simple and easy to operate system for simulating arc welding.
A further object of the present disclosure is to provide a safe system for simulating arc welding.
Still another object of the present disclosure is to provide a system for simulating arc welding that motivates the target semi-literate user and literate user alike.
An additional object of the present disclosure is to provide a system for simulating arc welding that includes an exhaustive database of theoretical content to educate the target semi-literate user along with practical training.
Still another object of the present disclosure is to provide a system for simulating arc welding that can interact with other such systems and can be monitored and maintained remotely.
Other objects and advantages of the present disclosure will be more apparent from the following description when read in conjunction with the accompanying figures, which are not intended to limit the scope of the present disclosure.

SUMMARY
In accordance with an aspect of the present disclosure, there is provided a portable system for simulating arc welding comprising:
• a simulated hand welding torch comprising a holder and a simulated consumable welding rod in the form of an elongate threaded rod;
• a reversible stepper motor fitted to the torch for displacing the threaded rod linearly along an axis operatively forward and backward;
• a simulated portable work space adapted to define:
o a simulated work piece defining a simulated job to be weld;
o two cameras fitted within the work space, the cameras adapted to capture sets of parameters corresponding to every movement of the welding rod, the parameters being associated with a simulated welding operation including the location of the tip relative to the simulated job;
• a computer adapted to receive the sets of parameters from the cameras for
processing, the computer comprising:
o a game engine adapted to render 3D visuals of a real welding
experience and sound via an audio feedback; o a first repository adapted to store the sets of parameters; o a comparator adapted to compare the captured set of parameters
with the stored set of parameters and generate a score for the user
of the system; and o a processor adapted to receive the captured set of parameters to
generate control signals to maintain the tip of the welding rod at a
predetermined distance from the work piece for effecting

simulation of the weld, said processor further adapted to generate corresponding graphical output for said game engine;
o a welding controller adapted to receive the control signals from the processor and control the stepper motor to drive the welding rod towards the work piece at the beginning of the simulated weld process and away from the work piece during the simulated weld process to simulate consumption of the welding rod; and
o a second repository of theoretical content for integrating with the 3D visuals; and • at least one display means and at least one speaker adapted to co-operate
with the game engine.
Optionally, in accordance with the present disclosure, the system as described herein above may further comprise an LED light source disposed towards the end of the welding rod proximal the work piece, the LED light source adapted to light up when the tip of the welding rod is at the predetermined distance from the work piece for effecting simulation of the weld.
The predetermined distance of the tip of the welding rod from the work piece may correspond to simulated arc length for effecting simulation of the weld.
The captured set of parameters may be selected from the group consisting of x, y, z co-ordinates of the tip of the welding rod, distance of the tip of the welding rod from the work piece, angle of the welding rod, speed of movement of the welding rod, number of threads of the welding rod displaced linearly and the length of the welding rod displaced linearly during the simulation of the weld.
The cameras may be concealed within the work space.

The control signals may be transmitted to the welding torch via either a wireless or a wired communication media.
The portable system as described herein above ,may further comprise a monitoring unit adapted to monitor predetermined health parameters of the portable system
Additionally, in accordance with another aspect of the present disclosure, there is provided an interactive system comprising a plurality of portable systems for simulating arc welding as described herein above, wherein the computer of each of the portable systems for simulating arc welding co-operates with each of the other portable systems for simulating arc welding.
Furthermore, the control signals for any of the portable systems for simulating arc welding corresponding to the stored set of parameters may be received from another portable system for simulating arc welding.
Again, each of the portable systems for simulating arc welding may comprise a monitoring unit adapted to monitor predetermined health parameters of the associated portable system and may be further adapted to co-operate with a central remote server adapted to display the health status of each of the portable systems corresponding to the monitored health parameters and further adapted to maintain the portable systems remotely.
In accordance with yet another aspect of the present disclosure, there is provided a method of simulating arc welding performed in a simulated work space defining a simulated work piece, the method comprising the steps of:

• providing a simulated hand welding torch comprising a holder and a simulated consumable welding rod in the form of an elongate threaded rod serving as a rack;
• engaging the welding rod with a stepper motor serving as a pinion;
i
• capturing sets of parameters corresponding to every movement of the welding rod, the parameters being associated with a simulated welding operation including the location of the tip relative to the simulated job;
• storing the sets of captured parameters;
• comparing the captured set of parameters with the stored set of parameters and generating a score for the user of the system;
• receiving the captured set of parameters and generating control signals to maintain the tip of the welding rod at a predetermined distance from the work piece for effecting simulation of the weld on a display;
• receiving the control signals and controlling the movement of the . welding rod in x, y and z plane such that the welding rod is driven towards the work piece at the beginning of the simulated weld process and away from the work piece during the simulated weld process to simulate consumption of the welding rod;
• • rendering 3D visual images corresponding to the movement of the
welding rod;
• integrating sound with the 3D visual images; and
• integrating theoretical content with the 3D visual images.
The step of capturing sets of parameters may include at least one step selected from the group consisting of motion recognition, image tracking and point tracking.

Additionally, the step of capturing sets of parameters may include the step of capturing at least one of x, y, z co-ordinates of the tip of said welding rod, distance of the tip of said welding rod from the work piece, angle of said welding rod, speed of movement of said welding rod, number of threads of the welding rod displaced linearly and the length of the welding rod displaced linearly during the simulation of the weld.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS:
A portable system for simulating arc welding of the present disclosure will now be explained in relation to the accompanying drawings, in which:
Figure 1 illustrates a schematic representation of a perspective view of a simulated portable work space in accordance with an aspect of the present disclosure;
Figure 2 illustrates an exploded view of the simulated work space of Figure 1;
Figure 3 illustrates a perspective view of a simulated hand welding torch in accordance with an embodiment of the present disclosure; and
Figure 4 illustrates a schematic representation of a perspective view of the system for simulating arc welding in accordance with the present disclosure.
DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The cost of consumables is high in traditional methods employed for providing training in welding technology. Conventional systems that impart welding

training by simulation, besides being expensive and not portable, do not provide motivation for the target semi-literate users.
Several attempts have been made to simulate arc welding for educative purposes. For instance, CN201220433892, US2013040270, WO2012016851, US2011091846, CN1866317 disclose such simulated systems using cameras to detect position of the electrode. Again disclosures in US2013040270, EP2327068, US2011091846, KR20090111556, CN1866317, WO2006 /034571 disclose simulated welding systems that incorporate display means for the simulated weld process. However these systems known in the art rely on expensive hardware sensing components to detect welding parameters besides location of the electrode, thus making the system expensive and bulky and beyond the reach of the target semi-literate user. Also, the psyche of the demotivated users who typically need such training has not been considered in any of these systems known in the art.
The system for simulating arc welding in accordance with the present disclosure will now be described with reference to the accompanying drawings which do not limit the scope and ambit of the disclosure, and the key components are referenced generally by numerals as indicated. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and

to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The system for simulating arc welding (100) firstly comprises a simulated work space (10) that is easy to assemble. Figure 1 illustrates a schematic representation of a perspective view of a simulated portable work space in accordance with an embodiment of the present disclosure and Figure 2 illustrates an exploded view of the simulated work space (10) of Figure 1. A simulated work piece (12) is defined within the work space (10) to serve as a simulated job for the weld. Two cameras (14) are fitted within the work space (12). In accordance with another embodiment the cameras may be fitted or concealed at predefined locations within the work space (12).
Secondly, the system (100) includes a simulated welding torch (20) that comprises a holder (not particularly referenced) and a simulated consumable welding rod (22) in the form of an elongate threaded rod. A reversible stepper motor (24) engages with the welding rod (22) in such a manner that the welding rod (22) in the form ofan elongate threaded rod serves as a rack and the stepper motor (24) serves as a pinion to form a linear actuator. Figure 3 illustrates a perspective view of the simulated hand welding torch (20) in accordance with an embodiment of the present disclosure.
The cameras (14) capture parameters related to the welding process including x, y, z co-ordinates of the tip of the welding rod, distance of the tip of the welding rod from the work piece, angle of the welding rod, speed of movement of the welding rod, number of threads of the welding rod displaced linearly and the length of the welding rod displaced linearly during the simulation of the weld.

Thirdly, the system (100) includes a computer (30). The computer (30) essentially comprises a first repository that stores sets of parameters, captured by the cameras (14), corresponding to every movement of the welding rod (22). A comparator then compares a captured set of parameters with a stored set of parameters and generates a score for the user. A processor receives the captured set of parameters and generates control signals. These control signals are received by a welding controller that controls the stepper motor (24) that in turn drives the welding rod (22) towards the work piece (12) at the beginning of the simulated weld process and away from the work piece (12) during the simulated weld process to simulate consumption of the welding rod (22). The control signals are transmitted to the welding torch via either a wireless or a wired communication media. During the simulated weld process, the tip of the welding rod (22) is required to be maintained at a predetermined distance from the work piece (12) for effective simulation of the weld. This predetermined distance corresponds to the simulated arc length for effecting simulation of the weld. The computer (30) also comprises a game engine to render 3D visuals of a real welding experience on a display and sound via an audio feedback using speakers. The processor besides generating the control signals also generates corresponding graphical output for the game engine.
The operative forward and backward movement of the welding rod may be achieved by operating a switch provided in the torch such that the forward movement commences upon activation of the switch and the distal end of the. welding rod moves towards the simulated job to begin the simulated weld process and activation of the switch once again would commence the retraction

of the welding rod making the end proximal to the simulated job move away from the simulated job to simulate consumption of the welding rod.
This simulation is achieved in an alternate embodiment by the computer (30) that generates control signals for controlling the operative forward and backward movement based on the captured parameters mentioned herein above.
Figure 4 illustrates a schematic representation of a perspective view of the system for simulating arc welding in accordance with the present disclosure.
In accordance with an embodiment, the system (100) includes at least one display means (not particularly referenced) and at least one speaker that cooperates with the computer (30). The display means provides a fun element via a competitive, game like exercise to motivate the user by means of interesting audio / video depiction of the welding process. To further add educative value to this experience, the computer (30) further comprises a second repository of theoretical content for integrating with the 3D visual images. The theoretical content from the second repository when integrated with the visual display adds educational value to practical training without the drudgery of traditional learning methods.
Optionally, an LED light source is disposed towards the end of the welding rod proximal the simulated job as an additional guide for controlling the movement of the rod. The LED light source typically lights up when the tip of the welding rod is at the predetermined distance from the work piece for effecting simulation of the weld.

The present disclosure also envisages an interactive system comprising a plurality of systems (100) for simulating arc welding as described herein above wherein each of the computers (30) of each of the systems (100) co-operate with each other. Such an interactive system helps motivate the target semi-literate user through immersive, social, collaborative and visually appealing content. The process of learning is personalized by comparing the logs stored in the first repository of a welding process of a user with that of the peers to further enhance the user's control of the welding process by providing corrected desired parameters. The interactive system keeps track of progress made / scores attained by peers and contextually recommends peers to extend help to a learner. Thus a learner can collaborate with peers to identify errors in order to make progress. Such collaboration is rewarded to further motivate the learner.
Again, each of the systems (100) constituting the interactive system includes a monitoring unit (not shown) to monitor predetermined health parameters of the associated system which is communicated to a central remote server (not shown) for display of the health status of each of the systems (100) corresponding to the monitored health parameters and for maintaining the systems, if required, remotely.
The user is thus provided an interesting alternative wherein the fear of conventional methods of learning theoretical concepts from books or from conventional pedagogical settings is eliminated. In accordance with an alternative embodiment, the theoretical concepts are provided via multi lingual content support depending on the user's comfort level.
Use of low cost cameras for detecting welding parameters, without the need for expensive sensing hardware components makes the entire system of the present

disclosure light-weight, portable and inexpensive, thus making the system affordable to training centers, technical colleges, workshops and even . individuals for aiding education and training welders on a relatively large scale.
Being a low cost system, users get more hours of welding practice thus enhancing the skill of the user for performing welding in the real world. Also the method of simulating arc welding as described herein above is simple to implement and does not add to the overheads for manufacture of the system and accordingly proves motivation enough for manufacturing such systems and enabling a larger population of trainees to be exposed to a skill that can be attained and converted into a high-tech trade.
TECHNICAL ADVANCEMENTS AND ECONOMICAL
SIGNIFICANCE
The technical advancements offered by the present disclosure include the realization of:
• a reliable system for simulating arc welding that can be utilized for imparting training in welding technology by faithfully replicating user experience of performing welding in the real world;
• a portable system for simulating arc welding;
• a cost effective system for simulating arc welding;
• a rugged system for simulating arc welding;
• a simple and easy to operate system for simulating arc welding;
• a safe system for simulating arc welding;

• a system for simulating arc welding that motivates the target semi-literate user and literate user alike;
• a system for simulating arc welding that includes an exhaustive database of theoretical content to educate the target semi-literate user along with practical training; and
• a system for simulating arc welding that can interact with other such systems and can be monitored and maintained remotely.
Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

WE CLAIM:
1. A portable system for simulating arc welding comprising:
• a simulated hand welding torch comprising a holder and a simulated consumable welding rod in the form of an elongate threaded rod;
• a reversible stepper motor fitted to said torch for displacing the threaded rod linearly along an axis operatively forward and backward;
• a simulated portable work space adapted to define:
o a simulated work piece defining a simulated job to be weld;
o two cameras fitted within said work space, the cameras adapted to capture sets of parameters corresponding to every movement of said welding rod, said parameters being associated with a simulated welding operation including the location of the tip relative to the simulated job;
• a computer adapted to receive said sets of parameters from the
cameras for processing, said computer comprising:
o a game engine adapted to render 3D visuals of a real welding experience and sound via an audio feedback;
o a first repository adapted to store said sets of parameters;
o a comparator adapted to compare the captured set of parameters with the stored set of parameters and generate a score for the user of said system; and
o a processor adapted to receive the captured set of parameters to generate control signals to maintain the tip of said welding rod at a predetermined distance from the work piece

for effecting simulation of the weld, said processor further adapted to generate corresponding graphical output for said game engine; o a welding controller adapted to receive said control signals from said processor and control said stepper motor to drive said welding rod towards the work piece at the beginning of the simulated weld process and away from the work piece during the simulated weld process to simulate consumption of said welding rod; and o a second repository of theoretical content for integrating with said 3D visuals; and • at least one display means and at least one speaker adapted to co-operate with said game engine.
2. The portable system for simulating arc welding as claimed in claim 1 further comprising an LED light source disposed towards the end of said welding rod proximal the work piece, said LED light source adapted to light up when the tip of said welding rod is at said predetermined distance from the work piece for effecting simulation of the weld .
3. The portable system for simulating arc welding as claimed in claim 1, wherein said predetermined distance of the tip of said welding rod from the work piece corresponds to simulated arc length for effecting simulation of the weld.
4. The portable system for simulating arc welding as claimed in claim 1, wherein the captured set of parameters is selected from the group consisting of x, y, z co-ordinates of the tip of said welding rod, distance

of the tip of said welding rod from the work piece, angle of said welding rod, speed of movement of said welding rod, number of threads of the welding rod displaced linearly and the length of the welding rod displaced linearly during the simulation of the weld.
5. The portable system for simulating arc welding as claimed in claim 1, wherein the cameras are concealed within said work space.
6. The portable system for simulating arc welding as claimed in claim 1, wherein said control signals are transmitted to the welding torch via either a wireless or a wired communication media.
7. The portable system for simulating arc welding as claimed in claim 1 further comprising a monitoring unit adapted to monitor predetermined health parameters of the portable system.
8. An interactive system comprising a plurality of portable systems for simulating arc welding as claimed in claim 1, wherein each of said portable systems comprises a monitoring unit adapted to monitor predetermined health parameters of the associated portable system and further adapted to co-operate with a central remote server adapted to display the health status of each of said portable systems corresponding to the monitored health parameters and further adapted to maintain said portable systems remotely.
9. The interactive system as claimed in claim 8, wherein said computer of each of said portable systems for simulating arc welding co-operates with each of said other portable systems for simulating arc welding.

10. The interactive system as claimed in claim 8, wherein said control signals for any of said portable systems for simulating arc welding corresponding to said stored set of parameters is received from another portable system for 'simulating arc welding.
11. A method of simulating arc welding performed in a portable simulated work space defining a simulated work piece, said method comprising the steps of:

• providing a simulated hand welding torch comprising a holder and a simulated consumable welding rod in the form of an elongate threaded rod serving as a rack;
• engaging said welding rod with a stepper motor serving as a pinion;
• capturing sets of parameters corresponding to every movement of said welding rod, said parameters being associated with a simulated welding operation including the location of the tip relative to the simulated job;
• storing the sets of captured parameters;
• comparing the captured set of parameters with the stored set of parameters and generating a score for the user of said system;
• receiving the captured set of parameters and generating control signals to maintain the tip of said welding rod at a predetermined distance from the work piece for effecting simulation of the weld on a display;
• receiving said control signals and controlling the movement of said welding rod in x, y and z plane such that said welding rod is driven

towards the work piece at the beginning of the simulated weld process and away from the work piece during the simulated weld process to simulate consumption of said welding rod;
• rendering 3D visual images corresponding to the movement of said welding rod;
• integrating sound with said 3D visual images; and
• integrating theoretical content with said 3D visual images.

12. The method of simulating arc welding as claimed in claim 11, wherein the step of capturing sets of parameters includes at least one step selected from the group consisting of motion recognition, image tracking and point tracking.
13. The method of simulating arc welding as claimed in claim 11, wherein the step of capturing sets of parameters comprises the step of capturing at least one of x, y, z co-ordinates of the tip of said welding rod, distance of the tip of said welding rod from the work piece, angle of said welding rod, speed of movement of said welding rod, number of threads of the welding rod displaced linearly and the length of the welding rod displaced linearly during the simulation of the weld.