Welding simulator spot designator system

#In the past, welding trainees were taught the requisite psychomotor skills for welding by practical experience. Typically, this required that the trainee make numerous practice welds utilizing an actual welding machine and workstock until he developed the skills necessary to produce a quality weld. This training method led to the excessive use of materials and electrical energy, and provides no immediate qualitative feed back of performance to the trainee.

#Applicant herein is a co-inventor of an "Arc Welding Simulator Trainer", U.S. Pat. No. 3,867,760, issued Feb. 25, 1975 and hereby incorporated herein by reference. Such a simulator trainer made it possible to develop the necessary skills for welding without exclusive reliance on making actual welds. The apparatus incorporates a movable target, an electrode holder with associated consumable electrodes (welding rod) and sensors for detecting the proper angular and distance relationship between the tip of the welding rod and the target. The trainees performance in making a simulated weld was scored so that after a simulated welding pass the trainee could obtain an indication of his performance. However, the capability of the system for immediate clues as to deviation from a proper welding procedure were limited. For example, so long as the distance between the welding rod tip and target was maintained within pre-set limits, the operator would receive no indication as to which end of the range he was approaching. Only after exceeding the range limits, would he receive an indication by an extinguishing of a light and by a warning tone.

#In a further development of the welding simulator trainer, the mechanical connection between the welding rod tip and target has been eliminated. In apparatus according to the improved construction, non-contact sensors (Hall effect magnetic devices) are utilized to detect both distance of the welding rod tip from the target and the position of the welding rod tip over the moving target. The signals from the sensors are utilized to produce an aural and on-off visual indication to the operator when he deviates beyond settable limits in position or distance.

#FIG. 1 illustrates the spot designator system in use.

#FIG. 2 is a perspective view of the target and its actuating means, illustrating the relationship of the welding rod and target.

#FIG. 3 is an enlarged side elevation view of the target, showing the light reflected from the welding rod tip onto the target.

#Referring now to the drawings, FIG. 1 illustrates the relationship of the system to a welding simulator. The target mechanism 10 is shown supported in a vertical orientation on pole 11 and connected to a control and indicating system 12.

#The target drive mechanism incorporates a housing 18 with a longitudinal opening 22 for the target designator surface 20.

#A trainee 13 holds the electrode holder 14 in relationship to the target mechanism 10. The electrode holder 14 is connected to the target mechanism by cable 30. The operator wears a helmet 16 with loud speaker 17 connected to the target drive mechanism 10 by cable 19.