Abstract: A system for characterizing manual welding exercises and providing valuable training to welders that includes components for generating, capturing, and processing data. The data generating component further includes a fixture, workpiece, at least one calibration devices each having at least two point markers integral therewith, and a welding tool. The data capturing component further includes an imaging system for capturing images of the point markers and the data processing component is operative to receive information from the data capturing component and perform various position and orientation calculations.

Abstract: A system for training welders that includes a data generating component, a data capturing component and a data processing and visualization component. The data generating component operates in real time and derives data from an actual manually-executed weld and further includes a weld process-specific jig, a calibration block positioned on the jig, wherein the geometric configuration of the calibration block is specific to a particular type of weld joint, a weld coupon positioned on the welding process-specific jig adjacent to the calibration block, a welding gun for use by a trainee, wherein the welding gun is operative to form the weld; and at least one target mounted on the welding gun that is recognized by the data processing and visualization component for providing multidimensional position and orientation feedback to the trainee.

Abstract: A method and system for monitoring and characterizing the creation of a manual weld is disclosed. The system generally includes a welding gun having a target, an imaging system, a processor, and a display. During the creation of a manual weld, the imaging system captures a plurality of images of the target. The processor analyzes the plurality of images of the target to calculate a plurality of position and orientation characteristics associated with the manipulation of the welding gun during the welding process. The display illustrates at least one of the plurality of position and orientation characteristics to provide feedback regarding the creation of the weld. In one embodiment, the disclosed method and system may be utilized as a tool for training welders.