Welding simulator

A kit for an associated processor based computing device executing coded instructions for displaying an interactive virtual welding environment and having an associated input device for interfacing with an end user, comprising:

• a readily releasable attachment adapted to fixedly connect to the associated input device, wherein the readily releasable attachment resembles a welding tool displayed in the interactive virtual welding environment;
• at least one quantitative performance guide that displays a real-time feedback value related to a position and an orientation of the input device used in the virtual welding environment, wherein each performance guide indicates the position and orientation of said input device within a range of acceptable values for said position and orientation of said input device for an acceptable weld, said feedback including providing feedback in which said at least one quantitative performance guide flashes, changes color or plays an audible sound which indicates when said input device is outside said range of acceptable values for the virtual welding operation;
• and
• a welding coupon that corresponds to a virtual article displayed in the interactive virtual welding environment for guiding the end user while interacting with the virtual welding environment via manipulations of the associated input device with respect to the welding coupon, said virtual article having an operational deficiency and an operational state that is changeable between operative and inoperative, said change from the inoperative to the operational state requiring at least the steps of analyzing the operational deficiency, selecting an appropriate welding process, adjusting the welding power supply settings, and choosing a particular electrode for performing said virtual welding operation.

A system, comprising:

• processor-based computing device associated with a display, the processor-based computing device being configured to execute computer-executable instructions to generate an interactive virtual welding environment output on the display, the virtual welding environment including a virtual article on which a virtual welding activity is performed;
• an input device associated with the processor-based computing device, the input device comprising:
• one or more sensors configured to detect spatial orientation and movement of the input device when manipulated by a user performing the virtual welding activity on the virtual article, and to generate a sensor output specifying the spatial orientation and movement of the input device;
• and
• means for communicating the sensor output to the processor-based computing device;
• and a physical welding coupon that corresponds to the virtual article displayed in the interactive virtual welding environment, the physical welding coupon guides the user with manipulating the input device to interact with the virtual article to perform the virtual welding activity in the interactive virtual welding environment,
• wherein, based on the sensor output communicated by the input device, the processor-based computing device displays a performance guide that indicates at least one of the spatial orientation or movement of the input device relative to a range of acceptable values corresponding to an acceptable weld, and
• wherein the virtual article has an operational deficiency discernable by one or more virtual clues, and wherein the processor-based computing device directs the user to perform one or more virtual welding operations that change an operational state of the virtual article from inoperative to operative, and wherein the virtual welding operations require at least two virtual welding operations having a progression of difficulty.

A method for training welding activity, comprising:

• providing a processor based computing device operable to execute coded instructions, an imaging device that can display a virtual welding environment responsive to the execution of the coded instructions, and an input device operatively connected to the processor based computing device, wherein the input device senses movement in the real world;
• displaying one or more virtual objects in the virtual welding environment having an operational deficiency discernable by one or more virtual clues;
• displaying at least one quantitative performance guide to provide a real- time feedback value related to one or more of a roll and a pitch of the input device used in the virtual welding environment, wherein each performance guide indicates the position and orientation of said input device within a range of acceptable values for said position and orientation of said input device for an acceptable weld, said at least one performance guide including feedback in which said at least one quantitative performance guide flashes, changes color or plays an audible sound which indicates when said input device is outside said range of acceptable values for the virtual welding operation;
• directing an end user to analyze the one or more virtual clues for deriving a solution to correct the operational deficiency, said step of directing further comprising at least the steps of analyzing the operational deficiency. selecting an appropriate welding process. adjusting the welding power supply settings. and choosing a particular electrode for performing said virtual welding operation;
• and,
• directing an end user to perform one or more virtual welding operations that change the operational state of the virtual article and wherein when the step of directing requires two or more virtual welding operations, each succeeding virtual weld is made using a progression of difficulty.