Ryszard Jastrzêbski EWE Eng. - Barbara Yalinkilicli MSc (phisics) Institute of Joining Metals, Krakow
Dr Mieczys³aw Cenin (electronics) The Institute of  Psychology - Wroclaw University
Grzegorz Padula Eng, Cracow Technical University

 

 

The possibilities of using space technology in welding.

(exactly referred presentation) 

      It is with great pleasure that we are able to present to you today a paper concerning the use of space technology and direct man-machine interface devices within the welding field. The World Centre for Materials Joining Technology is for us, an important place to present our research and we would like to thank you for this opportunity. This is not only just because of the high scientific status it possesses but also the historical value of this place. Experience inherited from Polish pilots who once fought in the skies over Great Britain has somewhat helped us in the research of extreme situations that often occur within welding and it is to them we dedicate this presentation.

 

We prepared the following plan of complex research on automatic welding:

 

A/ programming the unconscious thinking with the TKS method enables to achieve repeating training results in the position of the Gauss curve competence results.

B/ connecting the brain with a camera through touch-vibrating  impulses enables welding by blind and testing the ways of how to analyse by the weldery

C/ connecting the brain with a welding machine computer by influencing the skin with electric impulses enables the controlling of current and voltage by the welder

D/ connecting the welding machine with a computer enable the welding machine to control the hands programming the brain instead of using the TKS method.

E/ Experience collected in testing the influence on unconscious control enabled

 

Scientists who have done research into automatic welding have introduced specifications relating to welding processes that describe the voltages and currents used when welding. It is a mistake to transfer these results into manual welding. A welder does not know what voltage and current he is using during the welding process. The welder can only explain to the controller what parameters he has regulated when he welds a correct joint so that voltage and current is the same as on the WPS. It is also incorrect to adopt the linear or positional heat source model when welding by hand – these models have been positive when analysing the temperature scheme while automatic welding.

 

 

Picture  show different ways of introducing heat into the liquid (from above and below while melting and welding)

 

 

The difference between automatically welded joints and hand welded joints with an enormous overload of energy and the amount of heat introduced to the material is regulated by the thickness of liquid under the arc, called ‘the isolator’ which cuts of the heat source from the melted surface.

 

 

Figure show the amount of directed heat in correlation to the position of the arc in the initial, central and last part of the welding pool.

 

    In this case the dynamics of side movements has a lot bigger influence on the heat used on melting the material and the amount of heat fed to the plate than the linear energy. In certain examples, linear energy has the same influence on heat processes as the atmosphere when welding. So, how do you control the heat processes while hand welding?

 

 

Figure  show that under very different welding parameters a welder trained in the TKS method can weld almost identical joints.

 

 

    Classified information kept concealed for over 30 years and used only in space programs for research on a direct interface between the pilots brain and a computer has helped us.   The world welding industry does not have such expensive specialists. In Poland there is another situation where military specialists of psychological engineering are available for lower salaries. A modern human being lives in a world with a high degree of information that he can obtain by looking. Therefore, it is not surprising that this sense is overloaded. That is why every experiment to replace the sight or hearing, even if only partly, is very usable and needed. The first historical example of such a method was the blind-writing with the help of Braille’s alphabet in 1826.  In the nineteen–twenties (1920’s) there was some work done on adapting relays of acoustic communication equipment for transmission of information to the kineatethic sense on the skin.  These signals were not adjusted to the sensitivity of the receptors  The following experiments were conducted in 1957 when F.A. Geldard proved that a person is able to process 38 five letter words in a minute through the skin using a correctly projected skin-vibrating communication system.  Even better results are achieved by electrical impulses adjusted in the following ways: three levels of voltage, time of the impulse (0.5-2,0 seconds) and the placement of electrodes in 5 different positions (on the appendages and the torso).  This means that one can use 45 different skin-electrical signals, each containing 1.7 bit.  In Poland similar problems were addressed in the seventies by prof W. Starkiewicz.   He constructed the “Elektroftalm” – a unique device that replaced sight for the blind. A camera carried by a blind person processed the image of the surroundings into touch-vibrating impulses using a device placed on the forehead that controlled hundreds of electromagnetic relays. In this way a basic image of the surrounding was created which helped the blind person to orientate in a basic way. In those days the device was very costly and heavy. It also emitted a lot of heat through the electromagnetic relays.

 

 

 

 

Picture show  “Elektroftalm” – a device that enabled blind persons too “see” via an video camera-brain interface using the touch sense ("Augenoptik" No 2 /1975)

 

Relaying information through touch is especially important in such situations as those that occur when the operators sight canal is fully occupied or overloaded and the hearing canal can not be used because of a high noise level. This situation can occur e.g. when a pilot is landing in very difficult conditions.   The pilot uses hundreds of devices (signalising, measuring and steering) located on a big console. This is why the possibility of not recognising a solitary signal in relation to controlling the plane and its security is too high. The influence and costs of accidents are such that it is cost-effective and necessary to research on a large area to find original solutions to these problems. Similar situations occur in many other areas of human work activities, not only in job situations but also while personnel training. Currently described solutions can easily be modernised by computer technology and telemetric signal forwarding. A very advanced miniaturisation is achieved for which less energy is required and the heat output is minimised.  The forwarded information is more precise and it has a higher tolerance to disturbing signals.

Figure:   Mieczyslaw Cenin with the „USPJ” working on his Ph. D. work.   (Picture earlier published in  "Augenoptik" No 2 /1975)

 

A concept was created for using such devices when training precision welding by forwarding welding parameters directly to the brain that correctly modified and filtrated images of the weld-pool. 

Learning processes were worked out in the welders’ training TKS method for introducing thinking algorithms into the unconscious.  Polish scientists have proved that information is pre-processed in different ways (by hearing, sight, touch or kineasthetic senses) but always end in the same mind that processed them. The important thing is that the unconscious does the information processing at the same speed as learning and this can occur for example when reading which slows down and hinders faster reading. This leads us to the conclusion that different activities carried out by people, can have an influence on the speed of information processing.

 

 

Information received by seing, hearing, touching and the kinestethic sense are primarly processed in order to reduce the memory needed to memorize them. This is typical reactions called ,,stimulus -reactions,, known from psycho – technic research processing a huge biological computer that is programmed through out the whole life. Welders’ training on background ot the hierarchical  model of processing

If these two levels cannot be dealing with the information forwarded to the conscious which is the 3 level.

Conscious processing have limited memory and limited reaction reflex and it is similar to talking. So it is understood that the second montioned level is required in welding.

The second level was already used by the ancient egyptians that programmed their leaders and people through religious events under big stress. Programming the logic in level of the welding processes, welding results instead off an Gauss competence curve all persons will have the same predisposition that help to perform precision welding. Instead of training politics as the egiptians did., you may train engineers and welders in this way teaching them fast thinking .

Learning on the conscious level require learning without stress just like in technical universities. Learning in the unconscious level is the opposite and it requires stress and is typical in military excersise.

For example : in the military an intelligent person under stress cannot solve an easy question but is strongly focused on the mission and has got strong respect for his offices. Learning this level depends on humatics or matematical skills. Technical universities teach matematics because the students learn the unconsciousness of logical thinking. Humanists learn while doing a job, that is why they often are better specialists than matematic talents.

 

 

This has been used for precision welding and filling outiregularier by changing the trajectory movement using the technique showed on figure

 

 

Photo shows filling out bead with the thickness wariable 0,5mm -5mm by changing the trajectory movement using the technique showed earlier.

 

These models have got their similar examples in the informatic technology. Humanistic talent is known as neuron webs, matematics talents known is image decompresion. Using these two talents you can get the perfect way by processing information. That means to learn the person to compare with a pattern. In info technology this is connected with processing information by a strictly chosen logic that come from both metods. This system has got the same examples in scientific subjects.

     All subjects use describing methods dividing factors that influence on welding quality into cathegories. Each cathegory is divided into some levels that describe the influent of  chosen valve with the accuracy of 20%. The humanistics brain enables to register results from different combinations creating the neuron web connections. The physics brain cannot deal with such an amount in the conscious.

Therefore all – ics ending subjects as for instance physics, linguistics and matematics build an hierarchical system of information analysing, similar to a pyramide scheme. This system has a negative side, a 2 % fault meanwile doing a incorrect reading gives a 300 % fault.

For example the difference betweeen ∆X gives a very precious result only when the distance between two dots are not furter than ∆X.

In subjects ending on – ing like welding the two first mentioned methods are used based on the neuron web. They collect information that enabled to create fundamental solide statements for building a precision hierarchied system. This is a classic system of image comparision  

  

        The following conclusions have been made on the basis of earlier classified information.  

a.       the application of an interface between the mind of a welder and a welding-device computer can revolutionise the hand welding, and as a result, enable the computer to coordinate the welders’ hand movements.

b.      modernised thirty year old welding devices helps to teach the blind how to weld.

c.       these devices can help to verificate the unconscious thinking algorithms used in the welders’ training method TKS.

d.      collecting these researches can help to build intelligent welding robots.  

 

/1/ R. Jastrzebski, Z.Ciszek, M.Cenin, K.Kluza: The psychophysics of welding: the polish TKS method of welders’ training, programming the movement of the welder through changing the way of thinking and transporting these examples into the unconscious level. The World of Welding, Summer 2003 p.16, USA                             

          /2/ Р. Ястшембский, Я. Зелинский, Т. Скакуй, Я. Ярош, М. Ценин: ПСИХОФИЗИЧЕСКИЕ ОСНОВЫ КООРДИНАЦИИ ДВИЖЕНИЯ С РЕЗУЛЬТАТАМИ НАБЛЮДЕНИЯ, Naukowo Techniczne seminarium. : Progressive wedling technologies in the industry. Insitute of E.O. Paton in Kiev, p. 14-16, 20-22 may, 2003, Kiev, Ukraine  

          /3/ Jastrzêbski R., Wêgrzecka M., Borowiec J., Kalandyk W., Cenin M.: “La psychophysique de soudage résuot les problèmes de coordination des mouvements et de l`observation”. Soudage et Techniques Connexes, vol. 56-no 7/8 2002, p. 3-9, France. Reprinted in Souder, vol. 26 no 4/2002, p. 2-11, France and Przegl¹d Spawalnictwa no. 6/3003 p. 19-23, Poland  

          /4/ Jastrzêbski R., Skakuj T., Jarosz J.: “La psicología cognitiva y la transformación de los datos en el cerebro humano en el entrenamiento de los soldadores”. Soldadura y Tecnologías de Unión, vol. 76 Julio/Agosto 2002, p. 22-32, Spain  

          /5/ / Jastrzêbski R., Godniak M., Skakuj T., Stencel A.: “Zastosowanie psychologii poznawczej i biomechaniki ruchu miêœni w szkoleniu spawaczy”, “Use of cognitive psychology and muscle movement mechanics in welder training”, “La aplicación de la psicología cognitiva y la biomecánica de los movimientos de los músculos en el entrenamiento de los soldadores”, “L`application de la psychologie cognitive et de la mécanique des mouvements musculaires dans l`entraînement des soudeurs”,. „Познавательная психология и биомеханика движения мышц в обучении сварщиков”. “Aplicação da psicologia cognitiva e biomecânica de movimento dos músculos no treino dos soldadores”.,. Dozór Techniczny, no 5/2000, p. 103-106, Poland, The World of Welding, Winter 2001. Hobart Institute,  USA, Soldadura y Tecnologías de Unión, no 6-7/2001, p. 21-26, Spain, Soudage et Techniques Connexes, no 11-12/2001, p. 47-51, France, Сварщик. – 2002. – № 6. – p. 48 – 49, 51.Ukraine, Russia, Technologia Qualidade  2003, no 46, Portugal   

          /6/ Р. Ястшембский (Jastrzebski R.): Роботизация капитального ремонта доменной печи.(Robot executed blast furnace reline) – Металлург. – 1989. – № 2. – p. 29 – 30.  Moscow, Russia  

 

The printed text in Materials of Commission XII, Intermediate Meeting , TWI, 26-27 February 2004 you can get it as a document of International Institute of Welding nr XII-1787-2004,  www.iiw-iis.org