Systems and methods to design part weld processes
Systems and methods to design part weld processes are disclosed. An example system for monitoring welding of components of a workpiece with multiple arc welds in a fixture includes: one or more weld sensors configured to collect data associated with the multiple arc welds; and a computing device configured to: access a weld program; provide weld instructions defined in the weld program and associated with a sequence of welds for the workpiece, the weld instructions comprising a visual slide including an image of the workpiece and a visual indication of a first location of a first weld; based on the weld program, display the visual slide at a first zoom level; based on the weld program, display the visual slide at a second zoom level; and monitor first weld data from the one or more sensors during a first weld to determine a status of the first weld.
1 . A system for generating weld instructions for welding of components of a workpiece, the system comprising:
a processor configured to:
receive a video input of a welding process;
identify one or more features associated with the welding process based on the video input;
search a library for the one or more identified features;
identify an activity related to the workpiece based on the one or more identified features;
determine an activity location of the activity based on the one or more identified features;
generate one or more welding instructions based on the activity and the activity location; and
display the welding instructions.
2 . The system of claim 1 , further comprising one or more sensors configured to collect data associated with the welding process and provide the data to the processor, and wherein the processor is configured to identify the one or more features based at least in part on the data.
3 . The system of claim 2 , wherein the one or more sensors are at least one of a voltage sensor, a current sensor, a wire speed sensor, a brightness sensor, or a clamping sensor.
4 . The system of claim 1 , wherein the activity location is a location of a weld on the workpiece.
5 . The system of claim 1 , wherein the weld instructions comprise one or more visual slides, and the processor is further configured to present the one or more visual slides to a user.
6 . The system of claim 5 , wherein the processor is further configured to display a first portion of the one or more visual slides at a first zoom level obtained from a previously designed slide or series of slides, the previously designed slide or series of slides including zoom instructions that include the first zoom level.
7 . The system of claim 6 , wherein the processor is further configured to display a second portion of the one or more visual slides at a second zoom level different than the first zoom level obtained from the previously designed slide or series of slides, the previously designed slide or series of slides including zoom instructions that include the second zoom level.
8 . The system of claim 1 , wherein the activity comprises a fitting activity, a clamping activity, a welding activity, a cleaning activity, a maintenance activity, or a consumable replacement activity.
9 . The system of claim 8 , wherein the activity comprises the welding activity.
10 . A non-transitory machine readable medium for generating weld instructions for welding of components of a workpiece, comprising machine readable instructions which, when executed, cause a processor to:
receive a video input of a welding process;
identify one or more features associated with the welding process based on the video input and data associated with the welding process that is collected by one or more sensors, the one or more sensors comprising at least one of a voltage sensor, a current sensor, a wire speed sensor, a brightness sensor, or a clamping sensor;
search a library based on the one or more identified features;
identify a welding activity or welding component related to the workpiece based on the one or more identified features;
determine a location of the welding activity or the welding component relative to the workpiece; and
generate one or more welding instructions based on the location of the welding activity or the welding component.
11 . The non-transitory machine readable medium of claim 10 , wherein the location of the welding activity or the welding component is a location of a weld on the workpiece.
12 . The non-transitory machine readable medium of claim 10 , wherein the weld instructions comprise one or more visual slides, and the processor is further configured to present the one or more visual slides to a user.
13 . The non-transitory machine readable medium of claim 12 , wherein the one or more visual slides are edited based on user input.
14 . The non-transitory machine readable medium of claim 12 , wherein the processor is further configured to store the one or more visual slides for later retrieval.
15 . The non-transitory machine readable medium of claim 12 , wherein the processor is further configured to display a first portion of the one or more visual slides at a first zoom level obtained from a previously designed slide or series of slides, the previously designed slide or series of slides including zoom instructions that include the first zoom level.
16 . The non-transitory machine readable medium of claim 15 , wherein the processor is further configured to display a second portion of the one or more visual slides at a second zoom level different than the first zoom level, the second zoom level being obtained from the previously designed slide or series of slides, the previously designed slide or series of slides including zoom instructions that include the second zoom level.
17 . A system for generating weld instructions for welding of components of a workpiece, the system comprising:
one or more sensors configured to collect data associated with a welding process, the one or more sensors comprising at least one of a voltage sensor, a current sensor, a wire speed sensor, a brightness sensor, or a clamping sensor;
a processor configured to:
receive the data collected by the one or more sensors;
receive a video input of the welding process;
identify one or more features associated with the welding process based on the video input and the data collected by the one or more sensors;
search a library for the one or more identified features;
identify a welding activity or welding component related to the workpiece based on the one or more identified features;
determine a location of the welding activity or the welding component relative to the workpiece and based on the one or more identified features; and
generate one or more welding instructions based on the welding activity or the welding component and the location of the welding activity or the welding component.
18 . The system of claim 17 , wherein the weld instructions comprise one or more visual slides, and the processor is further configured to present the one or more visual slides to a user.
19 . The system of claim 18 , wherein the processor is further configured to display a first portion of the one or more visual slides at a first zoom level obtained from a previously designed slide or series of slides, the previously designed slide or series of slides including zoom instructions that include the first zoom level.
20 . The system of claim 19 , wherein the processor is further configured to display a second portion of the one or more visual slides at a second zoom level different than the first zoom level obtained from the previously designed slide or series of slides, the previously designed slide or series of slides including zoom instructions that include the second zoom level.