Virtual Reality
The Revolution in Welding Training
Chris Bailey
Lincoln Electric Company
May 10, 2011
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World-Class Products
Arc welding equipment:
 Power sources
 Wire feeding systems
 Robotic welding packages
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World-Class Products
Consumables
 Stick electrodes
 MIG, Flux-Cored, Submerged Arc, Stainless
Steel, Aluminum and Non-Ferrous Wires
 Brazing and Soldering Alloys
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World-Class Products
• Plasma & Oxy-Fuel
Cutting
• Vernon Tool™ Pipe &
Tube Cutting Equipment
• Soldering & Brazing
Equipment
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Industry-Specific Solutions
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Transportation / Automotive
• Process & Power Generation
• Offshore
• Pipeline
• Maintenance & Repair
• Structural Steel &
Construction
• Heavy Fabrication
• Shipbuilding
• Pipe Mill
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Global Presence
42 Manufacturing Facilities
in 21 Countries
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Virtual Reality
The Revolution in Welding Training
Lessons Learned in the
Development of a Welding
Training Simulator
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Virtual Reality
The Revolution in Welding Training
Presentation Outline
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Introduction
Evolution of a Virtual System
Does Virtual Training Work?
What Did We Expect?
What Surprised Us?
Open Discussion
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What is Virtual Reality ?
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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
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Virtual Reality Applications
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Flight Simulators
Medical Procedure
Simulations
Driving Simulators
Combat Simulations
Heavy Equipment
Operation
• Cranes
• Drills
Twistedsifter.com
Reduce cost and increase
the rate of skill transfer
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Evolution of Training Systems
Fronius
Arc123
CS Wave
VRTEX 360
DVS
VRSim
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Ordinance School
Aberdeen Proving Grounds
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Virtual Reality Weld Training
Systems Installed
2003
2004
2005
2006
2007
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2008
2009
2010
Virtual Reality Training
All Looking for the Same Thing
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Training Drivers
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Faster
Better
More Standardized
Greater Throughput
Shipyard Drivers
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Aging Workforce is Retiring
Fewer Vocational Welding Programs
Widening Skilled Trades Gap for Shipbuilding
Longer Lead Time for Skilled Welders
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Virtual Reality Training
Aspects of VR Training
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VR is not a Replacement for Existing Training
Methods, but a Compliment to Traditional
Methods
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More Exposure for Students (More Reps)
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New Generations Expect an Environment more
Fused with Computers
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Reduced Waste
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Increased Safety
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Cost Effective
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Virtual Reality Training
Aspects of VR Training
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Reduced the Overall Training Time
When Compared to Conventional
Methods
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Certification Results Improved
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Improved the Image of Welding
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Recruitment of Welders Improved
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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
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Goal of These Studies
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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
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Virtual Reality vs Traditional Weld Training
Pre-study
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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
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Virtual Reality vs Traditional Weld Training
Experimental Design (VR 50)
• 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
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Virtual Reality vs Traditional Weld Training
Experimental Design (VR 50)
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Two-man team approach
One individual welding and
one individual reviewing the
instructor monitor
Alternate for equal activity
Virtual Reality vs Traditional Weld Training
Experimental Design (VR 50)
Performance Criteria
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Certification on a simple pass fail basis
• Quality determined by actual review of samples
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Virtual Reality vs Traditional Weld Training
Experimental Design (VR 50)
Outcomes Performance
Welding Type
Electrode
Group 1 (TW)
% Pass
Group 2 (VR)
% Pass
2F
6010
91%
100%
3F
7018
6010
1G
7018
6010
7018
81.90% 54.60% 45.50% 45.50% 54.60%
100%
81.90% 81.90%
91%
91%
3G
6010
36.40%
45.50%
In terms of Groove Welds (1G and 3G), VR group
demonstrated a significantly higher level of Synthesis
and Evaluation capability
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Virtual Reality vs Traditional Weld Training
Experimental Design (VR 50)
Performance Criteria
Experiment Details and
Additional Outcomes
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Virtual Reality vs Traditional 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
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Virtual Reality vs Traditional Weld Training
Experimental Design (VR 50)
Measurement – Muscle Activity
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EMG
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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)
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Virtual Reality vs Traditional Weld Training
Experimental Design (VR 50)
Measurement – Muscle Activity
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Muscles
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Deltoid
Trapezius
Extensor Digitorum
Flexor Carpi Radialis
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Virtual Reality vs Traditional Weld Training
Experimental Design (VR 50)
Measurement – Posture
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Posture – Angles at joints
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Posture model and landmarks
Shoulder
R Elbow R Wrist
R Hand
L Hand
L Elbow
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L Wrist
Marker based video analysis
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Attach small marker to their skin or tight fitting
clothing on the body landmarks
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Virtual Reality vs Traditional Weld Training
Experimental Design (VR 50)
Physiological Development Outcome
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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
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Virtual Reality vs Traditional Weld Training
Experimental Design (VR 50)
Cognitive Development Outcomes
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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
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Virtual Reality vs Traditional Weld Training
Experimental Design (VR 50)
Team Interaction Evaluation
Four Dimensions of Team Learning
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Continuous improvement seeking
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Dialogue promotion and open communication
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Collaborative learning
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Strategic and proactive leadership promoting team
development
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Virtual Reality vs Traditional Weld Training
Experimental Design (VR 50)
Dialogue Promotion and Open Communication
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Virtual Reality vs Traditional Weld Training
Experimental Design (VR 50)
Collaborative Learning
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2F
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1G
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3F
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3G
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Virtual Reality vs Traditional Weld Training
Experimental Design (VR 50)
Unintended Consequences
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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.
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Virtual Reality vs Traditional Weld Training
Experimental Design (VR 50)
Teaching Challenges
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Acceptance – Broaden the Appeal
• From Shop Floor to Executive Suite
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Integration
• Curriculum
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Effective Delivery
• Over Multiple Modes
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Transitioning to the Booth
• Not only Virtual to Real, but also Theory to Practice
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Sources
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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.
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Virtual Reality
The Revolution in Welding Training
Chris Bailey
Lincoln Electric Company
May 10, 2011
41
Virtual Reality Welding Training
Installations
Correctional Facilities
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