JP7505708B2 - WELDING TRAINING SYSTEM, WELDING TRAINING METHOD, AND PROGRAM - Google Patents

Description

The present invention relates to a welding training system, a welding training method, and a program that support training in welding work.

As virtual reality technology advances, various systems have been proposed that use the technology to assist in training welding operations. For example, Patent Document 1 discloses a real-time virtual reality welding system that includes a programmable processor-based subsystem, a spatial tracking device operatively connected to the subsystem, a simulated welding tool that can be spatially tracked by the spatial tracking device, and a display device. With this system, a welding puddle (molten pool) having real-time molten metal fluidity and heat dissipation characteristics can be simulated in a virtual reality space, and the simulated welding puddle can be displayed in real time on a display device. Trainees can learn various responses by checking the shape and color of the welding puddle displayed in the virtual space.

JP 2018-124584 A

The conventional systems described above focus on making the welding puddle displayed on the display device as realistic as possible. However, if the trainee's skill level is not sufficient, even if a situation close to reality can be seen on the screen, there is a risk that appropriate training cannot be achieved because welding work in that situation is too difficult.

The present invention was made in consideration of these circumstances, and its main purpose is to provide a welding training system, welding training method, and program that enable even trainees with insufficient skill levels to receive appropriate training.

The inventors have determined that when a trainee with an insufficient skill level is trained, it is appropriate to start with a low level of difficulty and gradually increase the level of difficulty, and have found that in welding work, such a method can be achieved by changing the appearance of the welding work situation observed through the window of the welding mask. Based on this finding, the inventors have made the following invention. That is, a welding training system according to one aspect of the present invention is a welding training system that supports training of welding work by displaying the welding work situation in a virtual space on a display unit, and is characterized in that it comprises an adjustment unit that can adjust the transparency of the window of the welding mask in the virtual space to multiple levels, and a display control unit that displays the welding work situation in the virtual space on the display unit with a brightness according to the adjusted transparency.

In the above aspect, the adjustment unit may gradually decrease the transparency as the number of training sessions increases.

In the above embodiment, the adjustment unit may adjust the transparency depending on the skill level of the trainee.

In addition, in the above aspect, the device may further include a determination unit that determines a skill level of the trainee based on the trainee's operation of an object in the virtual space, and the adjustment unit may adjust the transparency according to the determined skill level.

In the above aspect, the object may be an object corresponding to a welding machine used in welding work, and the determination unit may determine the skill level of the trainee based on the movement speed of the object corresponding to the welding machine.

In the above aspect, the adjustment unit may adjust the transparency depending on the type of welding.

In addition, in the above embodiment, the number of transparency stages for one type of welding may be different from the number of transparency stages for another type of welding.

A welding training method according to one aspect of the present invention is a welding training method that supports training in welding work by displaying the status of welding work in a virtual space on a display unit, characterized in that the transparency of a window portion of the welding surface in the virtual space is adjusted to multiple levels, and the status of welding work in the virtual space is displayed on the display unit at a brightness corresponding to the adjusted transparency.

A program according to one aspect of the present invention is a program for causing a computer to function as a welding training device that assists in training welding work by displaying the status of welding work in a virtual space on a display unit, and causes the computer to function as an adjustment unit that can adjust the transparency of the window portion of the welding surface in the virtual space in multiple stages, and a display control unit that causes the display unit to display the status of welding work in the virtual space at a brightness corresponding to the adjusted transparency.

The present invention makes it possible to provide appropriate training even when the trainee's skill level is insufficient.

1 is a block diagram showing a configuration of a welding training system according to a first embodiment; FIG. 2 is a functional block diagram showing the configuration of an information processing device (welding training system). FIG. 13 is a diagram showing an example of a displayed screen. FIG. 13 is a diagram showing an example of the layout of a transparency database. 4 is a flowchart showing the procedure of the operation of the information processing device (welding training system). FIG. 11 is a block diagram showing the configuration of a welding training system according to a second embodiment.

The following describes preferred embodiments of the present invention with reference to the drawings. Note that the following embodiments are merely examples of methods and devices for embodying the technical concept of the present invention, and the technical concept of the present invention is not limited to those described below. The technical concept of the present invention may be modified in various ways within the technical scope described in the claims.

(Embodiment 1)
[System Configuration]
1 is a block diagram showing a configuration of a welding training system according to embodiment 1. A welding training system 100 according to the present embodiment is configured by an information processing device 1.

The information processing device 1 is communicatively connected to a head mounted display (HMD) 2, and images are displayed on a display unit 21 provided in the HMD 2 according to display control from the information processing device 1. The information processing device 1 is also communicatively connected to an input device 3 operated by the trainee, and executes various processes using information input from the input device 3.

In this embodiment, the trainee operates the input device 3 as if it were a welding device such as a welding torch while observing the image displayed on the display unit 21 of the HMD 2. The input device 3 is configured as a hand controller that the trainee can operate with his or her hand. This hand controller has a position sensor, and the detection result of the position sensor is output from the input device 3 to the information processing device 1. Similarly, the HMD 2 has a position sensor, and the detection result of the position sensor is output from the HMD 2 to the information processing device 1.

Next, the detailed configuration of the information processing device 1 will be described. The information processing device 1 is a computer including a CPU, RAM, ROM, non-volatile memory, an input/output interface, and a communication interface. The CPU of the information processing device 1 executes information processing according to a program loaded from the ROM or non-volatile memory to the RAM.

The above program may be supplied to the information processing device 1 via an information storage medium such as an optical disk or a memory card, or may be supplied via a communication network such as the Internet or a LAN.

Figure 2 is a functional block diagram showing the configuration of the information processing device 1. The information processing device 1 includes an input information acquisition unit 11, a position calculation unit 12, a skill level determination unit 13, a transparency adjustment unit 14, a transparency database (DB) 15, an image generation unit 16, and a display control unit 17. These functional units are realized by the CPU of the information processing device 1 executing information processing according to a program.

The input information acquisition unit 11 acquires various pieces of information input from the input device 3 and the HMD 2. The information input from the input device 3 includes position information indicating the position of the input device 3 operated by the trainee, and selection information indicating the content selected by the trainee using the input device 3. Furthermore, the information input from the HMD 2 includes position information indicating the position of the HMD 2.

The position calculation unit 12 calculates the position of each object displayed in the virtual space based on the position information input from the input device 3 and the HMD 2.

The skill level determination unit 13 determines the skill level of the trainee based on the information input from the input information acquisition unit 11 or the position calculation unit 12.

The transparency adjustment unit 14 adjusts the transparency (hereinafter sometimes simply referred to as "transparency") of the window portion of the welding surface in the virtual space. The higher the transparency of the window portion, the lighter and more transparent the color of the window portion becomes, and conversely, the lower the transparency, the darker and more opaque the color of the window portion becomes. When the color of the window portion becomes more transparent, each object observed through the window portion appears bright, making welding work in the virtual space easier. In contrast, when the color of the window portion becomes more opaque, each object observed through the window portion appears dark, making welding work in the virtual space more difficult. In this embodiment, the difficulty of welding work is changed by adjusting the transparency of the window portion of the welding surface.

Note that since light is generated during actual welding, similar light must also be generated during welding work in virtual space. In this embodiment, the information processing device 1 also generates an image that includes such light, but if the window portion of the welding mask is made transparent in that case, the light will be too bright and it will be impossible to confirm the status of the welding work. For this reason, the information processing device 1 reduces the brightness of the light generated during welding compared to that in real space and displays it in the virtual space. This makes it possible to confirm the status of the welding work in the virtual space even if the window portion of the welding mask is made transparent.

The transparency DB15 is a database that stores the set values of the transparency of the window portion of the above-mentioned welding surface. Details of this transparency DB15 will be described later. Note that the transparency DB15 may be provided outside the information processing device 1 as long as it is accessible by the information processing device 1.

The image generation unit 16 generates an image to be displayed in the virtual space based on the position of each object detected by the position calculation unit 12 and the transparency of the window portion of the welding surface adjusted by the transparency adjustment unit 14.

The display control unit 17 instructs the HMD 2 to display the image generated by the image generation unit 16. As a result, the image generated by the image generation unit 16 is displayed on the display unit 21 of the HMD 2.

Figure 3 is a diagram showing an example of a screen displayed on the display unit 21 of the HMD 2. In the example shown in Figure 3, the screen 40 includes a torch object 41 corresponding to a torch, which is a welding device, a welding rod object 42 corresponding to a welding rod attached to the torch, and a base material object 43 corresponding to the material to be welded (base material). In addition, the screen 40 includes a window object 44 corresponding to a window portion of the welding surface.

The inside of the window object 44 is displayed with a brightness that corresponds to the transparency of the window as described above. In the example shown in FIG. 3, the torch object 41, the welding rod object 42, and the base material object 43 are all located inside the window object 44, so each of these objects 41 to 43 is displayed with a brightness that corresponds to the transparency of the window.

The torch object 41 and the welding rod object 42 move within the virtual space in response to the trainee's operation of the input device 3. Then, welding is performed according to the positional relationship between the welding rod object 42 and the base material object 43. The status of the welding work in this virtual space is displayed on the display unit 21 of the HMD 2. Note that, as described above, the light generated during this welding is displayed with reduced brightness compared to that in real space.

The position of the window object 44 in the virtual space is determined according to the position of the HMD 2 worn by the trainee. The status of the welding work in the virtual space is displayed through this window object 44.

Figure 4 is a diagram showing an example of the layout of the above-mentioned transparency DB15. As shown in Figure 4, the transparency of the window portion of the welding surface is specified for each type of welding and each skill level of the trainee.

In this embodiment, three types of welding are defined: arc welding, semi-automatic welding, and TIG (Tungsten Inert Gas) welding. The skill levels of trainees are defined as three levels, levels 1 to 3. The lowest skill level is level 1, and the highest is level 3.

In this embodiment, the transparency is set to a value between 0 and 1. When the transparency is 0, the window portion of the welding surface is transparent, and when the transparency is 1, the window portion of the welding surface is opaque.

In the example shown in Figure 4, four transparency levels are set for arc welding: 0, 0.3, 0.6, and 0.9, with 0 associated with level 1, 0.3 and 0.6 associated with level 2, and 0.9 associated with level 3. Similarly, three transparency levels are set for semi-automatic welding: 0, 0.45, and 0.9, with 0 associated with level 1, 0.45 associated with level 2, and 0.9 associated with level 3. Furthermore, six transparency levels are set for TIG welding: 0, 0.18, 0.36, 0.54, 0.72, and 0.9, with 0 and 0.18 associated with level 1, 0.36 and 0.54 associated with level 2, and 0.72 and 0.9 associated with level 3.

In this embodiment, the number of transparency stages is three for semi-automatic welding, which is a relatively low level of difficulty. On the other hand, the number of stages is six for TIG welding, which is a relatively high level of difficulty. In this way, in this embodiment, the number of transparency stages is varied depending on the level of difficulty of the welding work. If the actual welding work is low in difficulty, the trainee can handle it even if the level of difficulty in the training is increased significantly, but if the welding work is high in difficulty, the trainee will have difficulty handling it if the same is done, so in that case it is appropriate to increase the level of difficulty in the training gradually. Therefore, it is preferable to reduce the number of transparency stages for low-difficulty welding and increase the number of transparency stages for high-difficulty welding.

[System Operation]
Next, the operation of the welding training system 100 configured as above will be described with reference to the flowchart shown in FIG.
The trainee wears the HMD 2 and checks the type of training displayed on the display unit 21 of the HMD 2. The types of training include the type of welding (arc welding, semi-automatic welding, TIG welding), the type of base material (fillet, V-groove), and the way of placing the base material (downward, vertical, horizontal). The trainee determines the desired type of welding, base material, and way of placing the base material, and selects it using the input device 3.

When the information processing device 1 receives the selection made by the input device 3 as described above (S101), it determines the skill level of the trainee (S102). In this case, similar to the type of training described above, the information processing device 1 performs processing such as determining that the skill level selected by the trainee using the input device 3 is the skill level of the current trainee. Alternatively, the information processing device 1 may store in advance a database in which trainees and skill levels are associated with each other, and automatically determine the skill level of the current trainee by referring to the database.

Next, the information processing device 1 determines the transparency of the window portion of the welding mask to be used in the current training based on the type of welding acquired in step S101 and the skill level of the trainee determined in step S102 (S103). For example, if "arc welding" is selected as the type of welding and the skill level of the trainee is level 1, according to the example shown in FIG. 4, the transparency is determined to be 0. Note that if multiple transparency values are set for the same skill level, the smallest transparency value is used.

This completes the preparation process for starting training. Next, the information processing device 1 executes a welding work training process in accordance with a predetermined program (S104). In this welding work training process, position information indicating the position of the input device 3 operated by the trainee and position information indicating the position of the HMD 2 worn by the trainee are continuously input to the information processing device 1. Based on the position information, the information processing device 1 calculates the positions of each object, such as the torch object 41, welding rod object 42, base material object 43, and window object 44, in the virtual space, and generates an image according to the calculation results. The image generated in this manner is transmitted from the information processing device 1 to the HMD 2 and displayed on the display unit 21 of the HMD 2.

In the above welding work training process, the information processing device 1 uses the transparency determined in step S103 to generate an image inside the window object 44. Specifically, the image is generated according to the following formula.
displayColor = maskColor × α + backgroundColor × (1 − α)
In this formula, α is the transparency of the window of the welding surface, and as mentioned above, takes a value between 0 and 1. Also, maskColor indicates the color of the window, which is black, backgroundColor indicates the scenery seen through the window, and displayColor indicates the scenery displayed on the screen.

As is clear from the above formula, the information processing device 1 generates an image so that the display within the window object 44 has a brightness that corresponds to the transparency α. Here, when the transparency α is close to 0, the color of the window approaches transparency, and the inside of the window object 44 is displayed brighter. This reduces the difficulty of welding work in the virtual space. On the other hand, when the transparency α is close to 1, the color of the window approaches opaqueness, and the inside of the window object 44 is displayed darker. This increases the difficulty of welding work in the virtual space.

After a certain amount of training has been performed by the welding work training process in step S104, the information processing device 1 determines whether or not to end the training (S105). For example, when the trainee uses the input device 3 to instruct the end of the training, or when the number of training sessions and the time period have reached a predetermined number of sessions and time, the training is determined to be ended (YES in S105), and the process ends.

When the information processing device 1 determines that the training should be continued rather than terminated (NO in S105), it executes a transparency adjustment necessity determination process to determine whether or not it is necessary to adjust the transparency of the window portion of the welding mask in the next welding work training process (S106). In this process, for example, when the number of training sessions reaches a predetermined number, it is determined that it is necessary to lower the transparency. In this way, by gradually lowering the transparency as the number of training sessions increases, it is possible to realize training at a level of difficulty appropriate for a trainee who has acquired skills through training.

The information processing device 1 may also determine the skill level of the trainee after the current training ends, and if the transparency associated with the determined skill level differs from the transparency in the current training, determine that the transparency needs to be adjusted. For example, if the movement speed of an object corresponding to welding equipment operated by the trainee, such as the torch object 41, becomes constant (if the variance of the movement speed becomes smaller than a predetermined threshold), the information processing device 1 determines that the trainee's skill has improved and increases the trainee's skill level by one level, and if the transparency associated with the latest skill level differs from the transparency in the current training, determines that the transparency needs to be adjusted.

In addition, when the position of the welding rod object 42 changes due to the trainee's operation, the information processing device 1 may determine that the trainee's skill has improved based on the angle of the welding rod object 42 relative to the base material object 43, and may perform the same processing as above to determine whether or not the transparency needs to be adjusted. In addition, when the trainee is able to complete a task or the like set during training, the information processing device 1 may determine that the trainee's skill has improved and determine whether or not the transparency needs to be adjusted.

In contrast to increasing the skill level as described above, the skill level of the trainee may also be lowered as a result of the welding work training process. For example, if the moving speed of the object corresponding to the welding equipment is not constant, or if the above-mentioned tasks cannot be completed, the information processing device 1 may determine that the skill level of the trainee should be lowered. In this case, the transparency associated with the lowered skill level is compared with the transparency in the current training, and it is determined whether or not the transparency needs to be adjusted.

If the information processing device 1 determines that the transparency adjustment is not necessary as a result of the above-mentioned transparency adjustment necessity determination process (NO in S107), the information processing device 1 returns to step S104 without changing the transparency, and thereafter executes the same process as described above.

On the other hand, if it is determined that the transparency needs to be adjusted (YES in S107), the information processing device 1 returns to step S103 and determines the transparency to be used for the next training from among the transparency levels defined in the transparency DB 15. For example, if the number of training sessions has reached a predetermined number, a transparency level one level lower than the transparency level used in the current training session will be selected. Also, if the skill level is to be raised or lowered, the transparency level associated with the latest skill level will be selected. The information processing device 1 then executes the processes from step S104 onwards.

As described above, in this embodiment, it is possible to adjust the transparency of the window portion of the welding surface as appropriate. This allows the difficulty of the welding work in the virtual space to be manipulated, making it possible to provide appropriate training that matches the trainee's skill level. For example, by gradually lowering the transparency, it is possible to gradually increase the difficulty of the welding work in the virtual space, thereby enabling the trainee's skills to be smoothly improved.

In addition, if the transparency of the window of the welding surface is close to opaque, the welding work in training may be more difficult than welding work in real space. When trainees undergo such training, there is an advantage in that they feel that the welding work actually performed in real space is easy.

(Embodiment 2)
In the second embodiment, the information processing device and HMD in the first embodiment are configured into one device. Fig. 6 is a block diagram showing the configuration of a welding training system in the second embodiment. As shown in Fig. 6, a welding training system 200 in this embodiment is configured with an HMD, and includes an information processing unit 201 and a display unit 202. The information processing unit 201 corresponds to the information processing device 1 in the first embodiment, and the display unit 202 corresponds to the display unit 21. Furthermore, the welding training system 200 is connected to an input device 3 so as to be able to communicate with the input device 3 in the same manner as in the first embodiment.

The information processing unit 201 executes the same process as the information processing device 1 in the first embodiment, and causes the display unit 202 to display the status of the welding work in the virtual space. As a result, in the present embodiment, the same effect as in the first embodiment can be obtained.

(Other embodiments)
In each of the above embodiments, a head mounted display is used, however, the present invention is not limited to this, and other wearable devices such as a glasses-type display may be used.

In addition, in each of the above embodiments, the transparency of the window portion of the welding mask is determined by the system, but the trainee may determine it himself and notify the system using the input device 3 or the like. For example, it is conceivable that the trainee may wish to change the transparency before, during, or after training. In such a case, the trainee may determine the transparency at his/her own discretion and notify the system, which may then adjust the transparency and execute the above-mentioned welding work training process.

In addition, in each of the above embodiments, the brightness of the light generated during welding is reduced compared to that in real space and displayed in the virtual space, but the present invention is not limited to this. If the transparency is set to a value that does not make the window portion of the welding surface transparent, the light generated during welding may be displayed with the same brightness as in real space.

In addition, in each of the above embodiments, the number of transparency stages is varied depending on the difficulty of the welding work, but in a similar manner, the number of transparency stages may be varied depending on the skill level of the trainee. At a high skill level, the trainee can cope with a large increase in the difficulty of the training, whereas at a low skill level, the trainee will have difficulty in the same way, and in that case it is appropriate to gradually increase the difficulty of the training. Therefore, it is preferable to reduce the number of transparency stages for trainees with low skill levels and increase the number of transparency stages for trainees with high skill levels.

REFERENCE SIGNS LIST 1 Information processing device 11 Input information acquisition unit 12 Position calculation unit 13 Skill level determination unit 14 Transparency adjustment unit 15 Transparency database 16 Image generation unit 17 Display control unit 2 Head-mounted display 21 Display unit 3 Input device 41 Torch object 42 Welding rod object 43 Base material object 44 Window object 100, 200 Welding training system

Claims (3)

A welding training system that supports training in welding work by displaying the state of welding work in a virtual space on a display unit,
and an adjustment unit that adjusts the difficulty of the welding work in the virtual space by adjusting the brightness of the display on the display unit. A welding training method for supporting training of welding work by having a computer display a welding work situation in a virtual space on a display unit, comprising:
A welding training method, characterized in that the computer adjusts the difficulty of the welding work in the virtual space by adjusting the brightness of the display on the display unit. A program for causing a computer to function as a welding training device that supports training in welding work by displaying the state of welding work in a virtual space on a display unit, comprising:
The computer,
a program for causing the display unit to function as an adjustment unit that adjusts the difficulty of the welding work in the virtual space by adjusting the brightness of the display on the display unit.

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