Description:FIELD OF THE INVENTION

[0001] The present invention relates to a welding assistive device, designed to support users in performing precise and efficient welds on workpieces, enhancing the quality of the welding process by providing guidance, stability, and ease of operation, ultimately improving accuracy, reducing errors, and increasing productivity for various welding tasks across different materials and applications.

BACKGROUND OF THE INVENTION

[0002] Welding of a workpiece is a critical process in manufacturing and construction, where two or more metal parts are joined together by applying heat and sometimes pressure, often with the addition of a filler material. The need for welding arises from its ability to create strong, durable joints that can withstand various stresses, ensuring the integrity of structures, machinery, and products. Welding is essential in industries such as automotive, aerospace, construction, and shipbuilding, where high-strength connections are required. Its importance lies in its versatility, as it can be used to join different types of metals, alloys, and thicknesses, making it applicable to a wide range of applications. Additionally, welding plays a significant role in repairing damaged structures or components, extending their lifespan and reducing costs. The process also allows for the creation of complex shapes and designs that would otherwise be difficult or impossible to achieve with other manufacturing methods.

[0003] Traditional methods of assistance in welding primarily involve manual techniques where the welder uses handheld tools, such as welding torches and clamps, to join metal pieces. In these methods, the welder relies on their skill to maintain proper heat, angle, and precision during the welding process. Additional support tools like welding jigs or fixtures may be used to hold the workpieces in place, ensuring alignment. However, these methods come with several drawbacks. They depend heavily on the welder’s expertise, leading to inconsistencies in weld quality and potential errors, especially in complex or high-precision work. Manual methods also increase the risk of human error, such as poor bead formation or incorrect heat application, which can weaken the weld. Moreover, traditional techniques are often slower and require more physical effort, resulting in longer production times. The lack of automation or real-time feedback also limits the ability to monitor and adjust the welding process for optimal results.

[0004] US2017326673A1 comprises a welding mask, a welding velocity sensor attached on the welding mask and configured to detect a welding velocity; a visualization device attached to the welding mask and arranged to show a representation of the welding velocity and of consequent heat input to a welder.

[0005] US2015034618A1 is a welding apparatus that comprises a welding unit for welding a workpiece. The welding unit comprises a welding assistance system for generating control commands by evaluating a voice dialogue performed with a welder, and a weld control unit for setting weld control parameters in dependence upon the control commands. A welding system includes a plurality of such welding apparatuses, wherein the welding assistance system is connected to the weld control units of the welding apparatuses via a data network. A method for welding a workpiece by means of a welding unit comprises providing a welding assistance system, evaluating a voice dialogue performed with a welder operating the welding unit, producing control commands for a weld control unit, and setting weld control parameters in dependence upon the produced control commands.

[0006] Conventionally, many devices pertain to welding apparatuses designed for basic welding tasks; however, these devices do not assist users in performing precise welds on workpieces. Additionally, these devices lack features that guide the user on the parameters to be maintained for welding, due to which achieving optimal results in these devices is very difficult. As a result, these traditional devices may lead to inconsistent welds, inefficient techniques, and difficulties in maintaining accuracy, which can negatively impact the quality and precision of the final weld, especially when working with complex or highly detailed workpieces.

[0007] To overcome the limitations of conventional welding devices, there is a need in the art to develop a device that assists users in performing precise welds on workpieces by ensuring that the welding process aligns with the specific dimensions of the workpiece. This device would guide the user on maintaining the correct welding angle and speed, thereby improving accuracy and efficiency. By providing real-time feedback and support, it would enable users to achieve consistent, high-quality welds, reduce the risk of errors, and streamline the welding process, especially for complex or detailed workpieces that require precision and careful handling.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a device that assists users in performing welds on workpieces, ensuring the welding process aligns with the specific dimensions of the workpiece, thereby enhancing accuracy, efficiency, and overall weld quality, while minimizing errors and improving the consistency of results across different welding tasks and applications.

[0010] Another object of the present invention is to develop a device that assist users by providing guidance on maintaining the correct welding speed and angle, ensuring optimal weld quality and precision while minimizing errors, thereby improving the efficiency, safety, and consistency of the welding process for various workpieces across different applications.

[0011] Another object of the present invention is to develop a device that enable users to adjust the height and orientation of the table during the welding process, offering enhanced flexibility and comfort, allowing for optimal positioning of the workpiece, and improving the user's ability to perform precise and efficient welds by accommodating various working conditions and ergonomic needs.

[0012] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0013] The present invention relates to a welding assistive device designed to aid users in performing welds on workpieces by providing support in positioning, stabilizing, and guiding the welding tools, enhancing precision, safety, and efficiency while reducing operator fatigue and the likelihood of errors or injuries during the welding process.

[0014] According to an embodiment of the present invention, a welding assistive device, comprising a welding table with plurality of hydraulic legs for performing welding, a microphone mapped over the table receives voice command of the user regarding elevating and orienting the table at specific height and angle, an artificial intelligence based imaging unit installed over the welding table determines dimensions of the workpiece, a motorized sliding unit installed with each side of the welding table position a motorized clamp configured with each of the sliding unit around the workpiece, an inverted L-shaped telescopic rod installed between each of the clamps and sliding units position the clamps in proximity to the workpiece to grip the workpiece to restrict movement of the workpiece, an infra-red sensor installed over the table monitor thickness of the workpiece, a speaker installed over the table notify the user regarding the evaluated diameter of the welding filler rod, a holographic projection unit installed over the table guide the user while conducting welding over the workpiece as monitored by a thermal camera installed over the table, a holding unit arranged over the table accommodate the welding torch after welding, a temperature sensor installed over the table monitors temperature of the welding torch, a motorized hinge joint installed with a side of the holding unit orient a flap configured with the hinge joint over the accommodated welding torch for covering and preventing the user from accidently touching the welding torch.

[0015] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates a perspective view of a welding assistive device.

DETAILED DESCRIPTION OF THE INVENTION

[0017] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0018] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0019] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0020] The present invention relates to a welding assistive device, designed to support users in performing welds on workpieces by providing enhanced control, precision, and safety, incorporating features that assist in positioning, stabilizing, and guiding the welding tools, ultimately improving the quality and efficiency of the welding process while reducing operator fatigue and the risk of errors or injuries during the welding operation.

[0021] Referring to Figure 1, a perspective view of a welding assistive device, comprising a welding table 101 installed with plurality of hydraulic legs 102, a microphone 103 mapped over the table 101, an artificial intelligence based imaging unit 104 installed over the welding table 101, a motorized sliding unit 105 installed with each side of the welding table 101 with a motorized clamp 106 by means of an inverted L-shaped telescopic rod 107, a speaker 108 installed over the table 101, a holographic projection unit 109 installed over the table 101, a thermal camera 110 installed over the table 101, a holding unit 111 arranged over the table 101 with a flap 112 by means of a motorized hinge joint 115, and a telescopic bar 113 installed with proximal side of the table 101 attached with a transparent shield 114.

[0022] The device proposed herein includes a welding table 101 integrated with plurality of hydraulic legs 102 installed beneath the table 101 for providing support to the table 101 over the surface. The welding table 101 is a sturdy surface used to support workpieces during welding, designed to withstand high temperatures and provide stability. Typically made from steel or cast iron for durability and heat resistance, the table includes features to securely hold materials in place during the welding process.

[0023] In order to activate functioning of the device, a user is required to manually switch on the device by pressing a button positioned on the table 101, wherein the button used herein is a push button. Upon pressing of the button, the circuits get closed allowing conduction of electricity that leads to activation of the device and vice versa.

[0024] Upon activation of the device by the user, an inbuilt microcontroller embedded within the table 101 and linked to the switch generates a command to activate a microphone 103 mapped over the table 101 to enable the user to provide voice command regarding a requirement of elevating and orienting the table 101 at specific height and angle.

[0025] In response to input commands of the user, the microcontroller regulates actuation of hydraulic legs 102 to adjust height and orientation of the table 101 at user-specified height and angle. The hydraulic legs 102 is powered by a hydraulic unit consisting of a hydraulic cylinder, hydraulic compressor, hydraulic valve and piston that work in collaboration for providing the required extension/retraction to the legs 102. The microcontroller actuates the valve to allow passage of hydraulic fluid from the compressor within the cylinder, the hydraulic fluid further develops pressure against the piston and results in pushing and extending the piston. The piston is connected with the legs 102 and due to applied pressure the legs 102 extends and similarly, the microcontroller retracts the legs 102 by closing the valve resulting in retraction of the piston. The microcontroller regulates the extension/retraction of the legs 102 for adjusting height and orientation of the table 101 at user-specified height and angle.

[0026] An artificial intelligence based imaging unit 104 installed over the welding table 101 is activated by the microcontroller to determine dimensions of the workpiece. The imaging unit 104 comprises of an image capturing arrangement including a set of lenses that captures multiple images in the surrounding, and the captured images are stored within memory of the imaging unit 104 in form of an optical data. The imaging unit 104 also comprises of a processor that is integrated with artificial intelligence protocols, such that the processor processes the optical data and extracts the required data from the captured images. The extracted data is further converted into digital pulses and bits and are further transmitted to the microcontroller. The microcontroller processes the received data and determines dimensions of the workpiece.

[0027] In response to the determined dimensions of the workpiece, the microcontroller actuates a motorized sliding unit 105 installed with each side of the welding table 101 to translate and position a motorized clamp 106 configured with each of the sliding unit 105 around the workpiece. The motorized sliding unit 105 includes sliding rack and rail, such that the clamp 106 is mounted over the rack that are electronically operated by the microcontroller for moving over the rail. The microcontroller activates the sliding unit 105 for performing the sliding operation. The sliding unit 105 is powered by a DC (direct current) motor that is activated by the microcontroller by providing required electric current to the motor. The motor comprises of a coil that converts the received electric current into mechanical force by generating magnetic field, thus the mechanical force provides the required power to the rack to provide sliding movement to the clamp 106 in order to translate and position a motorized clamp 106 configured with each of the sliding unit 105 around the workpiece.

[0028] The microcontroller then regulates actuation of an inverted L-shaped telescopic rod 107 installed between each of the clamp 106 and sliding unit 105 to extend/retract in accordance with the detected dimensions to position the clamp 106 in proximity to the workpiece. The inverted L-shaped telescopic rod 107 is linked to a pneumatic unit, including an air compressor, air cylinders, air valves and piston which works in collaboration to aid in extension and retraction of the rod 107. The pneumatic unit is operated by the microcontroller, such that the microcontroller actuates valve to allow passage of compressed air from the compressor within the cylinder, the compressed air further develops pressure against the piston and results in pushing and extending the piston. The piston is connected with the rod 107 and due to applied pressure the rod 107 extends and similarly, the microcontroller retracts the inverted L-shaped telescopic rod 107 by closing the valve resulting in retraction of the piston. Thus, the microcontroller regulates the extension/retraction of the rod 107 in order to position the clamp 106 in proximity to the workpiece.

[0029] Upon positioning of the clamp 106 in proximity to the workpiece, the motorized clamp 106 is actuated by the microcontroller to grip the workpiece to restrict movement of the workpiece. The motorized clamp 106 is a fastening equipment used to hold or secure workpiece tightly together to prevent movement or separation workpiece. Clamping unit comprises a pair of curved motorize clamp 106, attached with motor to grip the front wheel and crossbar of bicycle. Motor is actuated by the microcontroller to open/close the motorize clamp 106 to grip the workpiece to restrict movement of the workpiece.

[0030] An infra-red sensor installed over the table 101 monitors thickness of the workpiece. The infrared (IR) sensor monitors the thickness of a workpiece by emitting infrared light onto the surface and measuring the reflected light. The sensor detects the amount of light that returns after interacting with the workpiece. By analyzing the time it takes for the infrared light to reflect back or measuring changes in the intensity of the reflected light, the sensor determines the distance between the sensor and the surface. This data is then used by the microcontroller to calculate the thickness of the workpiece, and accordingly activate a speaker 108 installed over the table 101 to produce a voice command to notify the user regarding the evaluated diameter of the welding filler rod.

[0031] The speaker 108 works by receiving signals from the microcontroller, converting them into sound waves through a diaphragm’s vibration, and producing audible sounds with the help of amplification and control circuitry in order to notify the user regarding the evaluated diameter of the welding filler rod.

[0032] A thermal camera 110 installed over the table 101 monitors welding over the workpiece by the user. The thermal camera 110 monitors welding over a workpiece by capturing infrared radiation emitted from the heated areas during the welding process. As the welding torch heats the workpiece, the camera 110 detects temperature variations on the surface, translating them into thermal images or heat maps. These images highlight areas of excessive heat or inadequate heat distribution, helping to identify potential issues like overheating, insufficient bonding, or inconsistencies in the weld. The thermal camera 110 provides real-time feedback, allowing the microcontroller to activate a holographic projection unit 109 provided with the table 101 in view of guiding the user while conducting welding over the workpiece.

[0033] The holographic projection unit 109 works by creating and projecting holograms, which are three dimensional images formed by the interference of light waves. Firstly, the laser light from the holographic projection unit 109 is split into two beams, the object beam which interacts with the workpiece and light waves are altered based on the shape and features of the workpiece and the reference beam which remains unchanged. The altered object beam and the reference beam intersect to create an interference pattern. This pattern is reordered on a photosensitive surface such as a holographic plate. The interference pattern contains information about the phase and amplitude of the light waves preserving the three-dimensional details of the workpiece during projection, a laser beam is directed onto the recorded interference pattern diffracting the laser light, reconstructing the original wavefronts from the workpiece and the reference beams. The reconstructed wavefronts create a three-dimensional image that appears to float in space in view of guiding the user while conducting welding over the workpiece, regarding angle and speed for movement of the filler and welding torch for appropriate welding of the workpiece.

[0034] A temperature sensor installed over the table 101 monitors temperature of the welding torch. The temperature sensor mentioned herein is an infrared (IR) based temperature sensor that operates by detecting infrared radiation emitted by the welding torch. The sensor includes an IR detector that receives radiation from the welding torch and converts the radiation into an electrical signal. This signal's intensity correlates with the temperature of the welding torch, as hotter the welding torch emit more IR radiation, which is then sent to the microcontroller in the form of an electrical signal. The microcontroller processes the signal to determine temperature of the welding torch.

[0035] The table 101 is equipped with a holding unit 111 designed to securely accommodate the welding torch after use, providing a safe and convenient place for the user to rest the torch, helping prevent accidental burns, reduces the risk of damage to the torch, and ensures the workspace remains organized and free from hazards during and after welding.

[0036] In case the monitored temperature is detected to exceed a predefined threshold value, the microcontroller regulates actuation of a motorized hinge joint 115 installed with a side of the holding unit 111 to orient a flap 112 configured with the hinge joint 115 over the accommodated welding torch for covering and preventing the user from accidently touching the welding torch. The motorized hinge joint 115 comprises of a pair of leaf that is screwed with the surfaces of the flap 112 and the holding unit 111. The leaf are connected with each other by means of a cylindrical member integrated with a shaft coupled with a DC (Direct Current) motor to provide required movement to the hinge. The rotation of the shaft in clockwise and anti-clockwise aids in opening and closing of the hinge respectively. Hence the microcontroller actuates the hinge that in turn provides movement to the flap 112 for covering and preventing the user from accidently touching the welding torch.

[0037] In case the imaging unit 104 determines splattering while conducting the welding, the microcontroller actuates a telescopic bar 113 installed with proximal side of the table 101 to extend and position transparent shield 114 attached with the bar 113 in front of the user for preventing the user from the splattering. The extension/retraction of the telescopic bar 113 is regulated by the microcontroller in the same manner as the inverted L-shaped telescopic rod 107, by employing the pneumatic unit, for positioning the transparent shield 114 in front of the user for preventing the user from the splattering.

[0038] In the event that, during welding, the microcontroller, through the infrared sensor, detects that the temperature of the workpiece exceeds a predefined threshold range, the microcontroller sends a signal to activate the speaker 108, notifying the user of the detected excessive temperature. This alert helps prevent overheating, potential damage to the workpiece, and ensures the user can make timely adjustments to the welding parameters, maintaining safety and quality in the welding process.

[0039] Lastly, a battery is installed within the device which is connected to the microcontroller that supplies current to all the electrically powered components that needs an amount of electric power to perform their functions and operation in an efficient manner. The battery utilized here, is preferably a dry battery which is made up of Lithium-ion material that gives the device a long-lasting as well as an efficient DC (Direct Current) current which helps every component to function properly in an efficient manner. As the device is battery operated and do not need any electrical voltage for functioning. Hence the presence of battery leads to the portability of the device i.e., user is able to place as well as moves the device from one place to another as per the requirements.

[0040] The present invention works best in the following manner, where the welding table 101 integrated with plurality of hydraulic legs 102 for providing support to the table 101 over the surface. Upon activation of the device by the user, the microcontroller generates the command to activate the microphone 103 to enable the user to provide voice command regarding the requirement of elevating and orienting the table 101 at specific height and angle. In response to input commands of the user, the microcontroller regulates actuation of hydraulic legs 102 to adjust height and orientation of the table 101 at user-specified height and angle. The artificial intelligence based imaging unit 104 installed over the welding table 101 is activated by the microcontroller to determines dimensions of the workpiece. In response to the determined dimensions of the workpiece, the microcontroller actuates the motorized sliding unit 105 to translate and position the motorized clamp 106 around the workpiece. The microcontroller then regulates actuation of the inverted L-shaped telescopic rod 107 to extend/ retract in accordance with the detected dimensions to position the clamp 106 in proximity to the workpiece. Upon positioning of the clamp 106 in proximity to the workpiece, the motorized clamp 106 is actuated by the microcontroller to grip the workpiece to restrict movement of the workpiece. The infra-red sensor monitors thickness of the workpiece and accordingly activate the speaker 108 to produce the voice command to notify the user regarding the evaluated diameter of the welding filler rod. The thermal camera 110 monitors welding over the workpiece by the user, allowing the microcontroller to activate the holographic projection unit 109 in view of guiding the user while conducting welding over the workpiece.

[0041] In continuation, the temperature sensor installed over the table 101 monitors temperature of the welding torch. In case the monitored temperature is detected to exceed the predefined threshold value, the microcontroller regulates actuation of the motorized hinge joint 115 orient the flap 112 over the accommodated welding torch for covering and preventing the user from accidently touching the welding torch. In case the imaging unit 104 determines splattering while conducting the welding, the microcontroller actuates the telescopic bar 113 to extend and position the attached transparent shield 114 in front of the user for preventing the user from the splattering. In the event that, during welding, the microcontroller, through the infrared sensor, detects that the temperature of the workpiece exceeds the predefined threshold range, the microcontroller sends the signal to activate the speaker 108, notifying the user of the detected excessive temperature.

[0042] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) A welding assistive device, comprising a welding table 101 positioned over a ground surface, characterized in that:

i) plurality of hydraulic legs 102 installed beneath said table 101 for providing support to said table 101 over said surface, wherein a microphone 103 is mapped over said table 101 to receive voice command of said user regarding elevating and orienting said table 101 at specific height and angle based on which a microcontroller linked with said microphone 103 actuates one or more hydraulic actuators linked with said legs 102 to extend and orient said table 101 at a user-specified height and angle;

ii) an artificial intelligence based imaging unit 104 installed over said welding table 101 and integrated with a processor for capturing and processing images of a workpiece over which welding is to be conducted, wherein based on said captured images, said microcontroller linked with said imaging unit 104 determines dimensions of said workpiece;

iii) a motorized sliding unit 105 installed with each side of said welding table 101 and actuated by said microcontroller to position a motorized clamp 106 configured with each of said sliding unit 105 around said workpiece, wherein an inverted L-shaped telescopic rod 107 installed between each of said clamp 106 and sliding unit 105 that actuates to extend in accordance with said detected dimensions to position said clamp 106 in proximity to periphery of said workpiece followed by actuation of said clamp 106 to grip said workpiece to restrict movement of said workpiece;

iv) an infra-red sensor installed over said table 101 to monitor thickness of said workpiece based on which said microcontroller evaluates diameter of a welding filler rod to be used for welding said workpiece, wherein a speaker 108 installed over said table 101 to produce a voice command to notify said user regarding said evaluated diameter of said welding filler rod;

v) a holographic projection unit 109 installed over said table 101 that actuates to project holographic images in view of guiding said user while conducting welding over said workpiece as monitored by a thermal camera 110 installed over said table 101, wherein said microcontroller guides said user regarding angle and speed for movement of said filler and welding torch for appropriate welding of said workpiece; and

vi) a holding unit 111 arranged over said table 101 to accommodate said welding torch after welding, wherein a temperature sensor is installed over said table 101 to monitor temperature of said welding torch and in case said monitored temperature exceeds a threshold value, said microcontroller actuates a motorized hinge joint 115 installed with a side of said holding unit 111 to orient a flap 112 configured with said hinge joint 115 over said accommodated welding torch for covering and preventing said user from accidently touching said welding torch.

2) The device as claimed in claim 1, wherein in case said imaging unit 104 determines splattering while conducting said welding, said microcontroller actuates a telescopic bar 113 installed with proximal side of said table 101 to extend and position a transparent shield 114 in front of said user for preventing said user from said splattering.

3) The device as claimed in claim 1, wherein in case while conducting welding, said microcontroller via said infrared sensor determines temperature of said workpiece exceeding a threshold range, said microcontroller directs said speaker 108 to notify said user regrading said detected temperature.

4) The device as claimed in claim 1, wherein a vibration sensor and crack detection sensor is integrated with said table 101 to monitor vibration intensity produced during said welding and presence of crack over said workpiece and in case said monitored vibrations exceeds a threshold limit or presence of crack is detected, said microcontroller notifies said user via said speaker 108.