Patents by Inventor PAUL C. BOULWARE
PAUL C. BOULWARE has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 10475353Abstract: 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 device 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.Type: GrantFiled: April 16, 2018Date of Patent: November 12, 2019Assignee: LINCOLN GLOBAL, INC.Inventors: Paul C. Boulware, Douglas Alan Clark, Christopher C. Conrardy, Jeremy Michael Green
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Patent number: 10113993Abstract: A system for non-destructively characterizing laser welds that includes at least one phased array probe that includes a plurality of ultrasonic transducer elements arranged in an array at one end of the probe, wherein the transducer elements are operative to both generate ultrasonic signals and to receive reflections thereof, wherein the transducer elements are further arranged into discrete subgroups, and wherein each subgroup may be activated independently of the other subgroups and at different time intervals; a combination of materials for allowing the probe to conform to a contoured surface of a laser weld while enabling sound energy to be transferred directly into a laser weld under test conditions, wherein the combination of materials further includes a flexible membrane mounted on the end of the probe and a fluid filled chamber material disposed between the membrane and the array of ultrasonic transducer elements; and a data processor in communication with the at least one phased array probe that inclType: GrantFiled: April 6, 2016Date of Patent: October 30, 2018Assignee: Edison Welding Institute, Inc.Inventors: Roger Spencer, Paul C. Boulware, Jeong K. Na
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Publication number: 20180233065Abstract: 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 device 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.Type: ApplicationFiled: April 16, 2018Publication date: August 16, 2018Inventors: Paul C. Boulware, Douglas Alan Clark, Christopher C. Conrardy, Jeremy Michael Green
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Publication number: 20170341146Abstract: A powder handling system that includes a first powder deposition device for depositing a primary powder on a surface at a predetermined speed; and a second powder deposition device for depositing a secondary powder onto the primary powder in at least two directions relative to the surface, wherein the second powder deposition device includes a reservoir for containing the secondary powder; and a rotating shaft connected to the reservoir, wherein the rotating shaft includes a speed of rotation, an angle of rotation, a number of rotations, and a notch geometry, and wherein the rotating shaft is adapted to deposit the secondary powder onto the primary powder at a predetermined rate of deposition, and wherein the predetermined rate of deposition is controlled by adjusting the speed of rotation of the shaft, adjusting the angle of rotation of the shaft, adjusting the number of rotations of the shaft, adjusting the notch geometry of the shaft, or a combination thereof.Type: ApplicationFiled: May 24, 2017Publication date: November 30, 2017Inventors: Mahdi JAMSHIDINIA, Paul C. BOULWARE, Lance CRONLEY, Jacob MARCHAL, Heimdall MENDOZA
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Patent number: 9759691Abstract: A method for characterizing a spot weld, including acquiring a sequence of A-scans from an ultrasonic phased array, wherein the A-scans describe individual portions of a field of view of the phased array; manually applying an interface gate and a flaw gate to each individual A-scan within the sequence of A-scans; calculating a gate ratio between a maximum amplitude under the interface gate and a maximum amplitude under the flaw gate for each individual A-scan; plotting the gate ratio for each individual A-scan as a function of location within the phased array field of view to generate a weld fusion map; using a predetermined threshold to differentiate fused locations from unfused locations on the weld fusion map; and calculating predetermined weld metrics, wherein the predetermined weld metrics include area, diameter, width, length, percent fused, or combinations thereof.Type: GrantFiled: April 20, 2016Date of Patent: September 12, 2017Assignee: Cumberland & Western Resources, LLCInventors: Paul C. Boulware, Roger Spencer, Jeong K. Na
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Patent number: 9733219Abstract: An automated system for non-destructively evaluating spot welds that includes at least one matrix phased array probe; a fixture adapted to be mounted on a robot or other mechanical actuator, wherein the fixture is further adapted to retain the at least one matrix phased array probe; and an enclosure that includes at least one input for connecting to the at least one matrix phased array probe, ultrasonic phased array transmitting and receiving circuitry in electrical communication with the at least one input, at least one data processor running software that includes at least one algorithm for processing data received from the probe and generating discrete specifications of evaluated welds, wherein the discrete specifications further include pass indications or fail indications regarding weld acceptability; and at least one output for outputting the discrete specifications of evaluated welds.Type: GrantFiled: May 22, 2015Date of Patent: August 15, 2017Assignee: Cumberland & Western Resources, LLCInventors: Roger Spencer, Bill Colgan, Paul C. Boulware, Ron Brown, Jeong K. Na, Scott A. Newhouse
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Publication number: 20160320344Abstract: A system for non-destructively characterizing laser welds that includes at least one phased array probe that includes a plurality of ultrasonic transducer elements arranged in an array at one end of the probe, wherein the transducer elements are operative to both generate ultrasonic signals and to receive reflections thereof, wherein the transducer elements are further arranged into discrete subgroups, and wherein each subgroup may be activated independently of the other subgroups and at different time intervals; a combination of materials for allowing the probe to conform to a contoured surface of a laser weld while enabling sound energy to be transferred directly into a laser weld under test conditions, wherein the combination of materials further includes a flexible membrane mounted on the end of the probe and a fluid filled chamber material disposed between the membrane and the array of ultrasonic transducer elements; and a data processor in communication with the at least one phased array probe that inclType: ApplicationFiled: April 6, 2016Publication date: November 3, 2016Applicant: EDISON WELDING INSTITUTE, INC.Inventors: Roger SPENCER, Paul C. BOULWARE, Jeong K. NA
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Publication number: 20160231291Abstract: A method for characterizing a spot weld, including acquiring a sequence of A-scans from an ultrasonic phased array, wherein the A-scans describe individual portions of a field of view of the phased array; manually applying an interface gate and a flaw gate to each individual A-scan within the sequence of A-scans; calculating a gate ratio between a maximum amplitude under the interface gate and a maximum amplitude under the flaw gate for each individual A-scan; plotting the gate ratio for each individual A-scan as a function of location within the phased array field of view to generate a weld fusion map; using a predetermined threshold to differentiate fused locations from unfused locations on the weld fusion map; and calculating predetermined weld metrics, wherein the predetermined weld metrics include area, diameter, width, length, percent fused, or combinations thereof.Type: ApplicationFiled: April 20, 2016Publication date: August 11, 2016Inventors: Paul C. BOULWARE, Roger SPENCER, Jeong K. NA
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Publication number: 20160093233Abstract: 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 device 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.Type: ApplicationFiled: August 17, 2015Publication date: March 31, 2016Inventors: Paul C. Boulware, Douglas Alan Clark, Christopher C. Conrardy, Jeremy Michael Green
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Patent number: 9269279Abstract: 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.Type: GrantFiled: July 28, 2014Date of Patent: February 23, 2016Assignee: Lincoln Global, Inc.Inventors: Victor Matthew Penrod, Paul C. Boulware, Christopher C. Conrardy, Constance T. Reichert LaMorte
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Patent number: 9230449Abstract: 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.Type: GrantFiled: December 13, 2010Date of Patent: January 5, 2016Assignee: Lincoln Global, Inc.Inventors: Christopher C. Conrardy, Victor M. Penrod, Paul C. Boulware, Constance T. Reichert Lamorte
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Patent number: 9221117Abstract: 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.Type: GrantFiled: July 6, 2012Date of Patent: December 29, 2015Assignee: Lincoln Global, Inc.Inventors: Christopher C. Conrardy, Paul C. Boulware
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Publication number: 20150253288Abstract: An automated system for non-destructively evaluating spot welds that includes at least one matrix phased array probe; a fixture adapted to be mounted on a robot or other mechanical actuator, wherein the fixture is further adapted to retain the at least one matrix phased array probe; and an enclosure that includes at least one input for connecting to the at least one matrix phased array probe, ultrasonic phased array transmitting and receiving circuitry in electrical communication with the at least one input, at least one data processor running software that includes at least one algorithm for processing data received from the probe and generating discrete specifications of evaluated welds, wherein the discrete specifications further include pass indications or fail indications regarding weld acceptability; and at least one output for outputting the discrete specifications of evaluated welds.Type: ApplicationFiled: May 22, 2015Publication date: September 10, 2015Inventors: Roger SPENCER, Bill COLGAN, Paul C. BOULWARE, Ron BROWN, Jeong K. NA, Scott A. NEWHOUSE
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Patent number: 9063059Abstract: A system for characterizing a spot weld including an acoustic probe that further includes a plurality of ultrasonic transducer elements arranged in a curved array, wherein the transducer elements are operative to generate ultrasonic signals and to receive reflections thereof; and a combination of materials for allowing the probe to conform to a contoured surface of the spot weld while enabling sound energy to be transferred directly into the spot weld under test conditions; a phased array excitation unit coupled to the array of transducer elements for ultrasonically exciting transducer elements; and a controller coupled to the phased array excitation unit for controlling the operation of the phased array unit, gathering and processing information from the ultrasonic transducers, and generating a two-dimensional, color coded image that characterizes the integrity of the spot weld.Type: GrantFiled: May 10, 2012Date of Patent: June 23, 2015Assignee: EDISON WELDING INSTITUTE, INC.Inventors: Jeong K. Na, Roger Spencer, Paul C. Boulware
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Publication number: 20150056586Abstract: 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.Type: ApplicationFiled: July 28, 2014Publication date: February 26, 2015Applicant: EDISON WELDING INSTITUTE, INC.Inventors: Victor Matthew PENROD, Paul C. BOULWARE, Christopher C. CONRARDY, Constance T. REICHERT LaMORTE
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Publication number: 20120310551Abstract: A system for characterizing a spot weld including an acoustic probe that further includes a plurality of ultrasonic transducer elements arranged in a curved array, wherein the transducer elements are operative to generate ultrasonic signals and to receive reflections thereof; and a combination of materials for allowing the probe to conform to a contoured surface of the spot weld while enabling sound energy to be transferred directly into the spot weld under test conditions; a phased array excitation unit coupled to the array of transducer elements for ultrasonically exciting transducer elements; and a controller coupled to the phased array excitation unit for controlling the operation of the phased array unit, gathering and processing information from the ultrasonic transducers, and generating a two-dimensional, color coded image that characterizes the integrity of the spot weld.Type: ApplicationFiled: May 10, 2012Publication date: December 6, 2012Applicant: EDISON WELDING INSTITUTE, INC.Inventors: Jeong K. Na, Paul C. Boulware, Roger Spencer
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Publication number: 20120298640Abstract: 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.Type: ApplicationFiled: July 6, 2012Publication date: November 29, 2012Applicant: EDISON WELDING INSTITUTE, INC.Inventors: Christopher C. Conrardy, Paul C. Boulware
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Publication number: 20110117527Abstract: 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.Type: ApplicationFiled: December 13, 2010Publication date: May 19, 2011Applicant: EDISON WELDING INSTITUTE, INC.Inventors: Christopher C. Conrardy, Victor M. Penrod, Paul C. Boulware, Constance T. Reichert Lamorte
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Publication number: 20110006047Abstract: 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.Type: ApplicationFiled: July 8, 2009Publication date: January 13, 2011Inventors: VICTOR MATTHEW PENROD, CONSTANCE T. REICHERT LAMORTE, PAUL C. BOULWARE, CHRISTOPHER C. CONRARDY