Comparative Analysis of Real-Time and Simulated Monitoring Techniques for MIG Welding

Abstract This study introduces two methodologies designed to monitor welding procedures, furnish feedback to users, and thereby refine the welding technique of novice welders. The first method introduces a low-cost welding simulator utilizing augmented reality (AR) technology. This simulator provides real-time visual feedback on essential welding parameters such as the contact tip to work distance (CTWD), work angle, travel angle, displacement, and travel speed. The second approach involves a welding sensor unit (WSU) attached to the actual welding torch, enabling monitoring and analysis of welding parameters in a real welding environment. Experimental verification of both methods demonstrates their effectiveness and accuracy. The simulator accurately replicates human performance within the real welding environment, enabling real-time visual feedback to enhance welding techniques. The WSU, equipped with economical sensors, is feasible for monitoring real-world welding scenarios. These methodologies have diverse applications, including welder training, quality control, and the generation of synthetic data for research and industrial purposes. An investigation into the influence of welding parameters on weld bead formation underscores the critical role these parameters play in shaping both the geometry and quality of welds. Through careful analysis, it becomes evident that factors such as Contact Tip to Work Distance (CTWD), travel speed, and working angles significantly impact the appearance and integrity of weld beads.