National Shipbuilding Research ProgramNSRP

DISTRIBUTION STATEMENT

3D Vision for

Welder Training

and Production Welding

March, 2017

Charleston, SC

Agenda

• Summary of Project / Goals

• Progress

• Plan Forward

Project Team

• Anna Bourdais, Workforce Dev. Panel Chairwoman• Ingalls Shipbuilding,

• Frances Pearce, NSRP Program Manager• ATI,

• James S. Williford, Program Technical Officer• Ingalls Shipbuilding,

• Steven Edelson, Prime Contractor• Visible Welding

• Steven@VisibleWelding.com

Project Overview

• Create a stereo weld video system to add depth-perception to weld-by-camera

• Test usefulness for weld training.

• Test usefulness for recruiting students.

• Test usefulness for mirror (blind) welding.

Goals• Improve training by giving students a new tool and

“aha” welding insights.

• Incrementally recruit “on-the-fence” students with modern VR-like technology.

• Improve blind-welding to shorten shipyard repair times and improve quality.

Depth Perception Comes fromStereo Cameras and 3D Goggles

• Each independent video goes to one eye of the goggles

Stereo VR Goggles

StereoWeld Cameras

Image Processing

Image Processing

Phases• Phase I: Enhanced Student Workstation

• Design, build stereo weld camera system for students.

• In-use testing of the 3D effect.

• Preliminary evaluation and improvement recommendations

• Phase II: Updated system for further testing• Update first system with improvements

• Create second system, if needed

• In-use testing and evaluation

• Conclusions and recommendations

Overall Schedule• Q1, 2017 Implement stereo camera

hardware and software

• Q2 * Complete software* Integrate first system

• Q3 (phase 2) * Field Testing* 2nd system

• Q4 Reporting and Tech transfer.

Stereo Camera Fixture• Two Cameras with Lens sub-assemblies

• Electronics

• 2 Lens controllers

• Exposure synchronization

• USB hub and power

• Thumb adjustments

• Camera spacing and Convergence angles

Camera Modules are derived from V2016-Z Camera

• Two Cameras

• Aiming Gears

Solid Model

Adjustment Specs• Hand adjustments (e.g. thumbscrew)

• Spacing of cameras (lens centers)

• Min: touching (lens centers approx 1.5 inch)

• Max: 4”

• Typical person’s eyes are about 2.5” apart

• Convergence angle of cameras

• Min: 0º (parallel)

• Max: 30º (cross-eyed)

Stereo Camera Lenses Must be Adjusted Identically

• We must match/track Zoom and Focus

• Zoom and Focus use stepper motors to allow repeatability

• Fixture with special software measuring lenses to build focus/zoom curves

• Create a focus/zoom database.

Zoom - Focus Fixture• Targets spaced at known distances

• Semi-automatic program gathers data

Sample Zoom Focus Curves

0

100

200

300

400

500

600

700

800

900

1000

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67

3 in

6 in

9 in

12 in

18 in

24 in

30 in

48 in

60 in

72 in

• Use Zeiss goggles under Miller helmets

Video Under Miller Helmet

3D Vision for Welder Training

and Production Welding

NSRP PP 2017- 420

Steven Edelson

Visible Welding

Steven@VisibleWelding.com