Arc welding simulator trainer

Claim 2

An arc welding simulator for teaching an operator the various motor skills comprising: a work surface componet including a movable simulated welding puddle; means for moving said puddle with a predetermined movement simulating a weld path; a welding rod holder component to be manually manipulated by the operator relative to the work surface component; a simulated welding rod component movably supported by said holder for following said movable puddle; means for moving said welding rod relative to the holder at a rate simulating consumption of the welding rod; means on the welding rod for sensing the distance between the end of the welding rod and the puddle which distance comprises a simulated arc length; said components providing practice for the behavior skills involved in the welding process; and sensor circuits operatively connected to selected components for providing immediate feedback signals to the operator indicative as to his proficiency in the various behavior skills during his simulated welding pass.

Claim 3

The simulator of claim 1 wherein the means for moving said welding rod is controlled by the length of arc means whereby movement of the welding rod can be stopped whenever the length of arc falls outside a predetermined set of parameters.

Claim 4

The simulator of claim 1 wherein the means for moving said puddle is controlled by the length of arc means whereby the motion of the puddle can be stopped whenever the length of arc falls outside a predetermined set of parameters.

Claim 5

The simulator of claim 1 wherein said means for simulating the length of arc has a set of parameters the limits of which can be varied depending on the proficiency of the operator.

Claim 6

The simulator of claim 1 wherein means are mounted on the holder for detecting the angular divergence of the welding rod with respect to the work surface from a predetermined set of parameters, said means being adjustable about a plurality of axes to account for different orientations of the work surface.

Claim 7

The simulator of claim 5 wherein said detector means includes a light source, a photo cell to receive said light source, and a ball supported on a concave surface centrally positioned between said light source and the photo cell, whereby the ball will interrupt said light source and prevent any signal from being generated when the holder is supported within the predetermined set of parameters.

Claim 8

The simulator of claim 6 wherein is provided a means for varying the quality of feedback error signal so as to guide the operator back to within the correct preset limits and de-energize said signal.

Claim 9

The simulator of claim 1 wherein one of said components includes a radiating energy source, and another of said components has a means responsive to said energy source for controlling the movement of one of said components.

Claim 10

The simulator of claim 1 as applies to arc welding wherein said rod terminates at the surface-engaging end with a telesopically movable extension made of light transmitting material simulating the length of arc between the end of the welding rod and the surface, said rod having a light source to illuminate said extension, said extension movable to position a respective feedback sensor having preset parameters as to the allowable length of arc.

Claim 11

The simulator of claim 9 wherein said sensor is a limit switch having a pair of contacts, and said extension is movable to position a contact arm adapted to engage said contacts at both ends of its travel, said pair of contacts being adjustable with respect to the contact to change the parameters of the sensor.

Claim 12

The simulator of claim 10 wherein said sound generator is inactivated by closing of the limit switch.

Claim 13

The simulator of claim 9 wherein said sensor is connected to a sound generator for emitting a hissing sound to simulate the sound generated by an actual welding arc.

Claim 14

The simulator of claim 12 wherein means are provided for varying the pitch of the hissing sound depending on the length of the simulated arc length.

Claim 15

The simulator of claim 9 wherein means are provided for advancing said puddle target in a predetermined tracking path, said puddle target having a photo cell electrically connected to said advancing means and to a respective feedback circuit, said photo cell being activated by the simulated welding rod whenever the illuminated welding rod extension is maintained by the operator to be in contact with the puddle target, said feedback sensor circuit being maintained in an inoperative condition whenever the photo cell is illuminated.

Claim 16

The simulator of claim 14 wherein said photo cell is electrically connected to a sound generator which generates an audio signal whenever the photo cell is deactivated indicating to the operator his tracking error.

Claim 17

The simulator of claim 15 wherein is provided a means for varying the quality of feedback error signal so as to guide the operator back to within the correct preset limits and de-energize said signal.

Claim 18

An arc welding simulator for teaching an operator the various motor skills comprising: a simulated work surface component having a movable simulated puddle target; drive means for moving said target in a zig-zag path; said target having a light sensitive sensor circuit and a tone generator; a welding rod holder component to be manually manipulated by the holder; a simulated welding rod component movably supported by said holder for contact with a surface of said target said target; said rod terminating at the surface engaging end with a telescopically movable extension capable of transmitting light to energize said light sensitive sensor of the target, said extension simulating the length of arc between the end of the welding rod and the work surface, said rod supporting a light source for illuminating said extension, a feedback sensor, said extension movable to position the feedback sensor having preset parameters as to the allowable length of arc and connected in a circuit with said aforementioned drive means; said holder having drive means for drawing said rod through the holder to simulate rod consumption; both of said drive means being connected in a circuit including said length of arc feedback sensor; whereby failure of the operator to maintain the predetermined simulated arc length will cause the sensor to inactivate said drive means and stop target movement and rod movement.

Claim 19

An arc welding simulator for teaching an operator the various motor skills comprising: a simulated work surface component having a movable simulated puddle target; drive means for moving said target in a zig-zag path; said target having a light sensitive sensor circuit and a tone generator; a welding rod holder component to be manually manipulated by the holder; a simulated welding rod component movably supported by said holder for contact with a surface of said target said target; said rod terminating at the surface engaging end with a telescopically movable extension capable of transmitting light to energize said light sensitive sensor of the target, said extension simulating the length of arc between the end of the welding rod and the work surface, said rod supporting a light source for illuminating said extension, a feedback sensor, said extension movable to position the feedback sensor having preset parameters as to the allowable length of arc and connected in a circuit with said aforementioned drive means; said holder having drive means for drawing said rod through the holder to simulate rod consumption; both of said drive means being connected in a circuit including said length of arc feedback sensor; whereby failure of the operator to maintain the predetermined simulated arc length will cause the sensor to inactivate said drive means and stop target movement and rod movement.