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Virtual Reality The Revolution in Welding Training

Virtual Reality The Revolution in Welding Training. Chris Bailey Lincoln Electric Company May 10, 2011. World-Class Products. Arc welding equipment: Power sources Wire feeding systems Robotic welding packages. World-Class Products. Consumables Stick electrodes

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Virtual Reality The Revolution in Welding Training

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  1. Virtual RealityThe Revolution in Welding Training Chris Bailey Lincoln Electric Company May 10, 2011

  2. World-Class Products Arc welding equipment: • Power sources • Wire feeding systems • Robotic welding packages

  3. World-Class Products Consumables • Stick electrodes • MIG, Flux-Cored, Submerged Arc, Stainless Steel, Aluminum and Non-Ferrous Wires • Brazing and Soldering Alloys

  4. World-Class Products • Plasma & Oxy-Fuel Cutting • Vernon Tool™ Pipe & Tube Cutting Equipment • Soldering & Brazing Equipment

  5. Industry-Specific Solutions • Transportation / Automotive • Process & Power Generation • Offshore • Pipeline • Maintenance & Repair • Structural Steel & Construction • Heavy Fabrication • Shipbuilding • Pipe Mill

  6. Global Presence 42 Manufacturing Facilities in 21 Countries

  7. Virtual RealityThe Revolution in Welding Training Lessons Learned in the Development of a Welding Training Simulator

  8. Virtual RealityThe Revolution in Welding TrainingPresentation Outline • Introduction • Evolution of a Virtual System • Does Virtual Training Work? • What Did We Expect? • What Surprised Us? • Open Discussion

  9. What is Virtual Reality ? • The concept of Virtual Reality uses: • Computer technology to create a simulated, three dimensional world • Goal - Immersion or the feeling that the user is in that world • Tracking technology that allows the user to interact with the environment in a meaningful way • Goal – Teach a skill using these interactions

  10. Twistedsifter.com Virtual Reality Applications • Flight Simulators • Medical Procedure Simulations • Driving Simulators • Combat Simulations • Heavy Equipment Operation • Cranes • Drills Reduce cost and increase the rate of skill transfer

  11. Evolution of Training Systems Fronius Arc123 CS Wave VRTEX 360 DVS VRSim

  12. Ordinance School Aberdeen Proving Grounds

  13. Virtual Reality Weld Training

  14. Virtual Reality Training All Looking for the Same Thing • Training Drivers • Faster • Better • More Standardized • Greater Throughput • Shipyard Drivers • Aging Workforce is Retiring • Fewer Vocational Welding Programs • Widening Skilled Trades Gap for Shipbuilding • Longer Lead Time for Skilled Welders

  15. Virtual Reality TrainingAspects of VR Training VR is not a Replacement for Existing Training Methods, but a Compliment to Traditional Methods More Exposure for Students (More Reps) New Generations Expect an Environment more Fused with Computers Reduced Waste Increased Safety Cost Effective

  16. Virtual Reality TrainingAspects of VR Training Reduced the Overall Training Time When Compared to Conventional Methods Certification Results Improved Improved the Image of Welding Recruitment of Welders Improved

  17. Virtual Reality Training in Welding: An analysis of the physiological and cognitive impact in the pursuit of training Richard T. Stone Ph.D., AEP, CSP, FACS Iowa State University

  18. Goal of These Studies Study the Effectiveness of Using a VR Device to Train Welders Investigate Cognitive and Physiological Aspects of VR Training Use Study Outcomes to Further Refine Current VR Design

  19. Virtual RealityvsTraditional Weld TrainingPre-study • Worked with and Evaluated 16 Expert Welders • Lincoln Electric and Vermeer Provided Resources and Support for Study Operations • UA 33 Pledged 40 Volunteers to Serve in the Experiment • Black 1070 was Converted to a 6 Station Welding Facility, 1066 was Partially Converted to a 2 Station VR Welding Facility • All Experimenters were Trained in Welding Techniques • Developed Benchmarks

  20. Two Groups One trained with VR device for 50% of the time and traditional methods for 50% of the time One trained in traditional methods100% of the time Training for 2 weeks each with 8 – 12 hour days) Two Electrode Groups E6010 E7018 Four Joint Configurations 2F, 3F, 1G, 3G Virtual RealityvsTraditional Weld Training Experimental Design (VR 50)

  21. Virtual RealityvsTraditional Weld Training Experimental Design (VR 50) • Two-man team approach • One individual welding and one individual reviewing the instructor monitor • Alternate for equal activity

  22. Virtual RealityvsTraditional Weld Training Experimental Design (VR 50)Performance Criteria • Certification on a simple pass fail basis • Quality determined by actual review of samples

  23. Virtual RealityvsTraditional Weld Training Experimental Design (VR 50)Outcomes Performance In terms of Groove Welds (1G and 3G), VR group demonstrated a significantly higher level of Synthesis and Evaluation capability

  24. Virtual RealityvsTraditional Weld Training Experimental Design (VR 50)Performance Criteria Experiment Details and Additional Outcomes

  25. Virtual RealityvsTraditional Weld Training Experimental Design (VR 50)Physical Measures Primary Analysis: The investigation of Muscular Activation and Postural Analysis Objective: Determine the degree to which groups move, respond, and develop when compared to expert welders

  26. EMG Electromyography (EMG) is a technique for evaluating and recording the electrical activity produced by skeletal muscles It detects the electrical potential generated by muscle cells when these cells are electrically or neurologically activated Analyzed using marker based video analysis (track body postures) Virtual RealityvsTraditional Weld TrainingExperimental Design (VR 50)Measurement – Muscle Activity

  27. Virtual RealityvsTraditional Weld TrainingExperimental Design (VR 50)Measurement – Muscle Activity • Muscles • Deltoid • Trapezius • Extensor Digitorum • Flexor Carpi Radialis

  28. Virtual RealityvsTraditional Weld TrainingExperimental Design (VR 50)Measurement – Posture Posture – Angles at joints Posture model and landmarks Shoulder R Elbow R Wrist R Hand L Hand L Elbow L Wrist Marker based video analysis Attach small marker to their skin or tight fitting clothing on the body landmarks

  29. Virtual RealityvsTraditional Weld TrainingExperimental Design (VR 50)Physiological Development Outcome VR and TW group members utilized muscles of importance in a way that was (highly correlated) similar to expert welders (3G and 3F) VR and TW groups were found significantly different from one another in overall muscle activation (1G) VR group more likely to adopt unusual body posture when compared to TW or expert welders

  30. Virtual RealityvsTraditional Weld TrainingExperimental Design (VR 50)Cognitive Development Outcomes • VR group and TW group were not significantly different from one another in terms of their understanding of horizontal Filet Welds (2F) • In terms of Groove Welds (1G and 3G) the VR group demonstrated a significantly higher level of synthesis and evaluation capability

  31. Virtual RealityvsTraditional Weld TrainingExperimental Design (VR 50)Team Interaction Evaluation Four Dimensions of Team Learning • Continuous improvement seeking • Dialogue promotion and open communication • Collaborative learning • Strategic and proactive leadership promoting team development

  32. Virtual RealityvsTraditional Weld TrainingExperimental Design (VR 50)Dialogue Promotion and Open Communication

  33. Virtual RealityvsTraditional Weld TrainingExperimental Design (VR 50)Collaborative Learning

  34. 2F

  35. 1G

  36. 3F

  37. 3G

  38. Virtual RealityvsTraditional Weld TrainingExperimental Design (VR 50)Unintended Consequences • Greater Impact on Cooperation/Teaming • Experimental Mindset (body posture) • The “Root Pass Phenomenon” (“The Quick Discard”) • The Competitive Challenge • Encourages Experimentation “The VR machine provided a conduit by which participants were not only more likely to communicate, but more likely to value the communication and improve their skills.” - Richard Stone, Ph.D.

  39. Virtual RealityvsTraditional Weld TrainingExperimental Design (VR 50)Teaching Challenges • Acceptance – Broaden the Appeal • From Shop Floor to Executive Suite • Integration • Curriculum • Effective Delivery • Over Multiple Modes • Transitioning to the Booth • Not only Virtual to Real, but also Theory to Practice

  40. Sources Stone, R.T., Watts, K., Zhong, P., & Wei, C-S.(2010). Physiological and cognitive effects of virtual reality integrated training. Stone, R.T., Watts, K., Zhong, P. (2010). Virtual Reality Integrated Weld Training.

  41. Virtual RealityThe Revolution in Welding Training Chris Bailey Lincoln Electric Company May 10, 2011

  42. Virtual Reality Welding TrainingInstallations Correctional Facilities

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