Weld recording system including camera focus indicia and focus adjustment

Abstract

A disclosed example welding monitoring system includes a camera having a field of view and configured to capture an image of the field of view of the camera; a light source coupled with the camera and configured to project a visible indicator onto an object located within a field of view of the camera such that the visible indicator at least partially overlaps the field of view of the camera; and communication circuitry configured to transmit data representative of the image.

Description

[0001] Related Application

[0002] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 587,315, filed on October 2, 2023, entitled "WELD RECORDING SYSTEMS INCLUDING CAMERA FOCUS INDICATORS AND FOCAL POINT ADJUSTMENT." The entire contents of U.S. Provisional Patent Application Serial No. 63 / 587,315 are expressly incorporated herein by reference. Technical Field

[0003] The present disclosure relates generally to welding monitoring and, more particularly, to a welding recording system including camera focus indicators and focus adjustment. Background Art

[0004] Recording production welding data enables production supervisors to monitor the productivity and quality of automated and manual welding operations. Data logging and monitoring can include collecting data from welding equipment, sending it to the cloud, and retrieving it through a web browser. Such data can include, for example, video recordings of welding operations that may be useful to manufacturing floor supervisors, quality assurance (QA) or quality control (QC) personnel, maintenance personnel, training personnel, etc. In manual welding quality control, video recordings may be valuable for failure mode and effects analysis (FMEA) in lean manufacturing.

[0005] Weld recording also provides an opportunity for the welding instructor to observe how the trainee positions and moves the welding torch while welding. For example, when a welding instructor or manager is asked to assist a trainee or production operator, it may be difficult to squeeze in two welding masks for the observer to observe the arc along with the operator due to physical limitations. Summary of the invention

[0006] A welding documentation system including camera focus indicators and focus adjustment, substantially as illustrated by and described in conjunction with at least one of the figures, as more fully set forth in the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 An example arc welding system including a weld monitoring camera according to aspects of the present disclosure is shown.

[0008] Figure 2 Shows Figure 1 An example embodiment of a welding device.

[0009] Figure 3A An example welding headgear is shown, which may be implemented Figure 1 A welding headset to record welds.

[0010] Figure 3B An example welding camera is shown, which may be implemented Figure 1 (multiple) cameras to record the welding.

[0011] Figure 4 yes Figure 3A and Figure 3B Block diagram of an example implementation of an example welding headgear and / or an example welding camera.

[0012] Figure 5A Picture shows Figure 3A , Figure 3B and / or Figure 4 An example welding headgear and / or an example object within a camera field of view of an example welding camera, and including a visible laser dot indicator of the camera field of view.

[0013] Figure 5B Picture shows Figure 3A , Figure 3B and / or Figure 4 An example welding headgear and / or an example object within a camera field of view of an example welding camera, and including a visible beam indicator of the camera field of view.

[0014] FIG. 5C to FIG. 5E Picture shows Figure 3A , Figure 3B and / or Figure 4 An example welding headgear and / or an example object within the camera field of view of an example welding camera, and including visible indicators of the camera's field of view and focal length.

[0015] Figure 6 is a flowchart representing example machine-readable instructions that may be executed by Figure 3A , Figure 3B and / or Figure 4 A welding headgear and / or welding camera is implemented to record welding type operations using a camera.

[0016] Figure 7 is a flowchart representing example machine-readable instructions that may be executed by Figure 3A , Figure 3B and / or Figure 4 The welding headgear and / or welding camera are implemented to adjust the focus of the camera.

[0017] Figure 8 yes Figure 1 A block diagram of an example implementation of a computing device.

[0018] The drawings are not necessarily drawn to scale. Where appropriate, similar or identical reference numerals are used to represent similar or identical components. DETAILED DESCRIPTION

[0019] Conventional camera-integrated welding helmets allow for the recording and remote viewing of the welding process. However, conventional camera-integrated welding helmets do not provide a way for the welder to effectively understand the position of the camera relative to the object being recorded. As the welding operator is welding, they cannot see where the camera is recording because the camera's field of view may be limited relative to the welding helmet's field of view. Additionally, conventional camera-integrated welding helmets impose high weight, cost, and / or battery life requirements given the amount of data recorded and the amount of image processing performed.

[0020] The disclosed welding recording system provides visible indicators that enable the welder to quickly understand the field of view and / or focus of the camera for easy positioning. In some examples, a distance sensor can be used to improve the focus adjustment, calibration, and / or calculation of indicators that can be used to process the image. In some disclosed examples, the weight, cost, and / or battery requirements of the welding recording system are reduced by transmitting the raw image data to an external computing device for processing, analysis, and / or display.

[0021] As used herein, the term "welding operation" includes actual welding of two or more physical objects (e.g., resulting in a bond, such as welding or brazing), coating, texturing and / or heat treating of physical objects, and / or cutting of physical objects, as well as simulated or virtual welding (e.g., the display of welding without physical welding occurring).

[0022] As used herein, "welding-type power supply" refers to any device that is capable of powering welding, cladding, plasma cutting, induction heating, laser processing (including laser welding, laser hybrid welding, and laser cladding), carbon arc cutting or scraping, and / or resistive preheating when power is applied to it, including but not limited to transformer-rectifiers, inverters, converters, resonant power supplies, quasi-resonant power supplies, switch-mode power supplies, etc., as well as control circuit systems and other auxiliary circuit systems associated therewith.

[0023] As used herein, the term "wearable device" includes any form factor designed or intended to be worn by a person (e.g., personal protective equipment, such as masks, protective masks, clothing, etc.; personal devices, such as head-mounted electronic devices, wrist-mounted devices, body-worn devices, devices worn around the neck, etc.), and any form factor that can be suitable for being worn by a person - although not necessarily designed or intended to be worn by a person (e.g., smartphones, tablet computers and / or other digital processing devices).

[0024] As used herein, the term "port" refers to one or more terminals, connectors, plugs, and / or any other physical interface through which one or more inputs and / or outputs are connected. Example ports include welding cable connectors (where the welding cable is physically attached to the device), gas hose connectors (which can be physically and / or electrically connected for input and / or output of electrical signals and / or power, physical force and / or work, fluids and / or gases).

[0025] The disclosed example welding monitoring system includes: a camera having a field of view and configured to capture an image of the camera's field of view; a light source coupled to the camera and configured to project a visible indicator onto an object within the camera's field of view such that the visible indicator at least partially overlaps the camera's field of view; and a communication circuit system configured to transmit data representing the image.

[0026] In some example welding monitoring systems, the visible indicator includes at least one of a visible laser beam or a visible focused beam. In some example welding monitoring systems, the camera and the light source are mounted on a welding helmet. In some example welding monitoring systems, the angle of the camera and the light source relative to the welding helmet is adjustable.

[0027] In some example welding monitoring systems, the visible indicator indicates the location of the camera's field of view. In some example welding monitoring systems, the visible indicator indicates the boundaries of the camera's field of view. In some example welding monitoring systems, the visible indicator indicates the focal length relative to the object.

[0028] Some example welding monitoring systems further include a filter configured to filter arc light and pass the filtered arc light to the camera. Some example welding monitoring systems further include a distance sensor configured to measure a distance between the camera and an object illuminated by the visible indicator, wherein the camera is configured to automatically focus based on the distance.

[0029] In some example welding monitoring systems, the camera and the light source are mounted on separate housings. In some example welding monitoring systems, the camera is configured to capture an image of a welding arc. In some example welding monitoring systems, the visible indicator is observable through a welding lens.

[0030] Other example welding monitoring systems disclosed include: a camera having a field of view and configured to capture an image of the camera's field of view; a distance sensor configured to measure the distance between the camera and an object within the camera's field of view; and a communication circuit system configured to transmit data representing the image and representing the measured distance.

[0031] In some example welding monitoring systems, the distance sensor comprises a time of flight (ToF) sensor. Some example welding monitoring systems further comprise a computing system configured to receive the data and calculate one or more operator performance indicators of the welding operation based on the image and the measured distance represented in the data. In some example welding monitoring systems, the communication circuit system is configured to transmit the data wirelessly.

[0032] Some example welding monitoring systems further include control circuitry coupled to the camera and the distance sensor, wherein the control circuitry is configured to control the camera to adjust the focus of the camera based on the distance sensor. Some example welding monitoring systems further include a light source coupled to the camera and configured to output a visible indicator, wherein the measured position of the distance sensor and the visible indicator are within the field of view of the camera.

[0033] In some example welding monitoring systems, the control circuit system is configured to adjust the focus of the camera based on visible indicators within the image. In some example welding monitoring systems, the camera and the light source are mounted on a welding helmet.

[0034] refer to Figure 1 , shows an example welding system 10 in which an operator 18 wears a welding headgear 20 and welds a workpiece 24 using a welding torch 22 to which power or fuel is delivered via a conduit 14 by an apparatus 12. The apparatus 12 may include a power or fuel source, optionally a shielding gas source, and a wire feeder that automatically provides welding wire / filler material. Figure 1 The welding or cutting system 10 can be configured to form a weld joint using any known technique, including flame welding techniques (such as oxy-fuel welding) and electric welding techniques (such as shielded metal arc welding (i.e., stick welding), metal inert gas welding (MIG), tungsten inert gas welding (TIG), and plasma cutting).

[0035] Optionally in any embodiment, the welding device 12 can be an arc welding device that provides direct current (DC) or alternating current (AC) to a consumable electrode or non-consumable electrode 16 of a welding torch 22. The electrode 16 delivers the current to a weld point on a workpiece 24. In the welding system 10, the operator 18 controls the position and operation of the electrode 16 by manipulating the welding torch 22 and triggering the start and stop of the current flow. When the current is flowing, an arc 26 is generated between the electrode and the workpiece 24. The conduit 14 and the electrode 16 thus deliver a current and voltage sufficient to generate the arc 26 between the electrode 16 and the workpiece. The arc 26 locally melts the workpiece 24 and the welding wire or electrode (the electrode 16 in the case of a consumable electrode, or optionally a separate welding wire or electrode in the case of a non-consumable electrode) supplied to the weld joint at the weld point between the electrode 16 and the workpiece 24, thereby forming a weld joint when the metal cools.

[0036] The device 12 and the headgear 20 may communicate via a link 25. Such communication may enable the headgear 20 to control settings of the device 12 and / or enable the device 12 to provide information about its settings to the headgear 20. Although a wireless link is shown, the link may be wireless, wired, or optical.

[0037] The external computing device 30 and the headgear 20 may communicate directly or indirectly. For the former, the external computing device 30 and the headgear 20 may communicate via link 27. Indirect communication may include, for example, the headgear 20 sending a time-stamped image and / or other data to the device 12 via link 25, where the device 12 combines the image and / or data with its own data and then forwards the combined data to the external computing device 30 via link 29. Similarly, the external computing device 30 and the device 12 may communicate directly or indirectly. For the former, the external computing device 30 and the device 12 may communicate via link 25. Indirect communication may include, for example, the device 12 sending a time-stamped data to the headgear 20 via link 25, where the headgear 20 combines the data with its captured image and / or data and then forwards the combined data to the external computing device 30 via link 27. Another example is to reduce real-time data traffic on link 25 during welding while keeping the video captured by the headgear 20 synchronized with the device 12. For example, when the operator pulls the trigger at 22, the device 12 sends a start synchronization command to the headgear 20 via link 25. Thereafter, the headgear 20 records a time-stamped video or image caused by the start synchronization command, and the device 12 records welding data caused by the same start synchronization command independently of the headgear 20. When the trigger is released or welding is completed, the headgear 20 uploads the time-stamped video or image to the external computing device 30 via communication link 27, and the device uploads the time-stamped welding data to the external computing device 30 via communication link 29. The external computing device 30 combines the video data and the welding data with a common time stamp, thereby allowing synchronized playback of the two data.

[0038] Links 25, 27 and 29 may use any suitable protocol, such as Bluetooth, Bluetooth Low Energy, WiFi, Zigbee, etc.

[0039] The external computing device 30 may be, for example, a local or remote / cloud workstation(s) or server(s) in a data center. For example, the headgear 20 may transmit images and / or other data (e.g., arc length, temperature, etc.) captured by the headgear 20 to the external computing device 30 for real-time interaction (e.g., observation, annotation, etc.) and / or analysis (e.g., parameters of the welding torch, workpiece, and / or arc). As another example, the headgear 20 may transmit images and / or other data captured by the headgear 20 to the external computing device 30 for recording / storage for later interaction and / or analysis. As another example, the external computing device 30 may transmit information (e.g., visual and / or audio instructions for adjusting various parameters) to the headgear 20 based on analysis of the images and / or other data received from the headgear 20. In an example embodiment, the external computing device 30 is a component of a welder training system in which the movements of the welding operator 18 are tracked by one or more externally mounted cameras 32. During training, the movements of the operator 18 may be tracked by the camera(s) of the headgear 20 (e.g., Figure 4 The video captured by the (multiple) cameras 414) is captured together for synchronized playback on the external computing device 30. One example use of the external computing device 30 is for quality control. During production welding, the equipment 12 captures welding signal data, and the headgear 20 captures video data representing what the operator sees. Both types of data are transmitted to the external computing device 30. Due to the large storage requirements of the video data, the external computing device 30 can be a remote server, which can provide a large amount of storage and / or processing power more conveniently than a local server. When a defect is found, the welding signal data and video data are retrieved from the remote external computing device 30 for playback and fault analysis. Although a wireless link is shown, the link can be wireless, wired, or optical.

[0040] Figure 2 An example welding apparatus according to aspects of the present disclosure is shown. Figure 2 The device 12 includes an antenna 202, a communication port 204, a communication interface 206, a user interface module 208, a control circuit system 210, a power supply circuit system 212, a wire feeder module 214 and a gas supply module 216.

[0041] Antenna 202 may be any type of antenna suitable for the radio frequency, power level, etc., used by communication link 25 .

[0042] Communication port 204 may include, for example, an Ethernet port, a USB port, an HDMI port, a fiber optic communication port, and / or any other suitable port for interfacing with a wired or optical cable.

[0043] The communication interface 206 is operable to interface the control circuit system 210 with the antenna 202 and / or the port 204 for transmission and reception operations. For transmission, the communication interface 206 may receive data from the control circuit system 210, packetize the data, and convert the data into a physical layer signal according to the protocol used on the communication link 25. For reception, the communication interface may receive a physical layer signal via the antenna 202 or the port 204, recover the data (demodulate, decode, etc.) from the received physical layer signal, and provide the data to the control circuit system 210.

[0044] The user interface module 208 may include electromechanical interface components (e.g., screen, speaker, microphone, button, touch screen, gesture recognition, etc.) and related drive circuit systems. The user interface 208 may generate electrical signals in response to user input (e.g., screen touch, button press, voice command, gesture recognition, etc.). The driver circuit system of the user interface module 208 may adjust the signal (e.g., amplify it, digitize it, etc.) and provide it to the control circuit system 210. The user interface 208 may generate auditory, visual and / or tactile outputs (e.g., via speakers, displays and / or motors / actuators / servos / etc.) in response to signals from the control circuit system 210.

[0045] The control circuit system 210 includes circuit systems (e.g., a microcontroller and memory) that are operable to perform the following operations: process data from the communication interface 206, the user interface 208, the power supply circuit system 212, the wire feeder 214 and / or the gas supply 216, and / or output data and / or control signals to these components.

[0046] The power supply circuit system 212 includes circuitry for generating power to be delivered to the welding electrode via the conduit 14. The power supply circuit system 212 may include, for example, one or more switch-mode power supplies, buck converters, inverters, etc. The voltage and / or current output by the power supply circuit system 212 may be controlled by a control signal from the control circuit system 210. The power supply circuit system 212 may also include circuitry for sensing and reporting actual current and / or voltage feedback to the control circuit system 210. In an example embodiment, the power supply circuit system 212 may include circuitry for measuring the voltage and / or current on the conduit 14 (at either or both ends of the conduit 14) so ​​that the reported voltage and / or current is actual, rather than simply an expected value based on calibration.

[0047] The wire feeder module 214 is configured to deliver the consumable wire electrode 16 to the welding torch 22 for delivery to the welding joint. The wire feeder 214 may include, for example, a wire spool for accommodating the welding wire, a wire feeder for pulling the welding wire from the wire spool for delivery to the welding torch 22, and a circuit system for controlling the rate at which the wire feeder delivers the welding wire. The wire feeder may be controlled based on a control signal from the control circuit system 210. The wire feeder module 214 may also include a circuit system for reporting the actual wire feeding speed and / or the amount of remaining welding wire to the control circuit system 210. In an example embodiment, the wire feeder module 214 may include a circuit system and / or mechanical components for measuring the wire feeding speed so that the reported speed is the actual speed rather than simply an expected value based on calibration.

[0048] The gas supply module 216 is configured to provide shielding gas via the conduit 14 for use during the welding process. The gas supply module 216 may include an electrically controlled valve for controlling the on / off of the gas. The valve may be controlled by a control signal from the control circuit system 210 (the control signal may be directed through the wire feeder 214 or directly from the control circuit system 210, as shown in dashed lines). The gas supply module 216 may also include a circuit system for reporting the current gas flow rate to the control circuit system 210. In an example embodiment, the gas supply module 216 may include a circuit system and / or mechanical components for measuring the gas flow rate so that the reported flow rate is the actual flow rate, rather than simply an expected value based on calibration.

[0049] Figure 3A An example welding headgear 300 is shown, which may be implemented Figure 1 A welding headgear 20 is provided to record welding. Figure 3B An example welding camera 350 is shown, which may be implemented Figure 1 (multiple) cameras 32 to record the welding. Figure 4 yes Figure 3A and Figure 3B Block diagram of an example implementation of an example welding headgear 300 and / or an example welding camera 650.

[0050] Figure 3A An example headgear 20 is a mask that includes a housing 306 in which or on which are mounted: one or more cameras 414 including optical components 302, lights 303, one or more filters 304, electromechanical user interface components 308, antenna 402, communication port 404, communication circuit system 406, user interface driver 408, central processing unit (CPU) 410, image processor 416, distance sensor 422, power supply 424 and memory 426. Figure 4The example memory 426 stores machine-readable instructions 428 that can be executed by the processor 410 to implement the examples disclosed herein. In other embodiments, in addition to a mask, the headgear may be, for example, a mask, glasses, goggles, a mask attachment, a glasses attachment, or a goggles attachment. Figure 3B 4, the camera(s) 414 are mounted to a separate welding monitoring camera 350. The components of the headgear 20 may be located on one or more printed circuit boards (PCBs) or flexible circuits. In the example shown as only one illustration, the power supply 424, camera(s) 414, antenna 402, port 404, filter 304, and / or control device 308 are implemented as subsystems separated / coupled from the PCB 430 (e.g., implemented on a separate PCB), while the communication circuit system 406, user interface driver 408, processor 410, and / or memory 426 are located on the PCB 430.

[0051] Each set of optical devices 302 may include, for example, one or more lenses, filters, and / or other optical components for capturing electromagnetic waves in a spectral range, such as from infrared to ultraviolet. In an example embodiment, the optical devices 302 may include different sets of optical devices for two or more cameras for capturing stereoscopic images. The stereo system calculates the size of the field of view based on the four corners of the image. For example, the stereo system calculates the real-world coordinates of the image points based on a predetermined spacing between the cameras or optical sensors, and calculates the real-world distances between these points.

[0052] Lights 303 (e.g., one or more light bulbs, LEDs, and / or other light source types) can be positioned adjacent to camera 414 to illuminate the object(s) being recorded by camera 414. Lights 303 can be secured to camera 414 such that changes in the orientation or positioning of camera 414 change the orientation or positioning of lights 303. In some examples, the focus of lights 303 can be adjusted to vary between a narrower beam and a wider beam using optical focusing elements and / or by controlling which lights of the plurality of lights 303 are turned on.

[0053] In one example, the camera 414 has a high dynamic range (HDR), medium dynamic range, or wide dynamic range (WDR) imaging array, each pixel of which has a logarithmic response within a single frame time, with a dynamic range of more than 120dB to more than 140dB. Example techniques for capturing images of welding scenes using high dynamic range, wide dynamic range, etc. are disclosed in U.S. patent application serial number 14 / 978,141, entitled "Automated Welding Translation Platform," filed on December 22, 2015. The entire contents of U.S. patent application serial number 14 / 978,141 are incorporated herein by reference. Logarithmic response imagers allow observation of typical high contrast arc welding scenes (where high intensity arc light and low light surrounding objects such as joints, weld pools, electrode extensions, etc. are mixed) without saturating the sensor and inhibiting spatial-temporal light adjustments. Logarithmic response imagers can effectively automatically balance exposure and observe details such as weld pool surfaces and seams near bright arcs. The sensor can be CMOS for visible wavelengths (e.g. light reflected by joints, contact tips, electrodes, etc.) or InGaAs for short-wave infrared wavelengths (e.g. light emitted by the solidifying weld pool). Imagers can be either monochrome or color.

[0054] In yet another example, the camera 414 may have an imaging array with multiple responses or exposure times per pixel within a single frame time to extend the dynamic range to account for high contrast issues in viewing welding scenes. For example, the exposure time for a pixel associated with a bright arc may be a fraction of the exposure time for pixels in the surrounding scene, so that the pixel charges more slowly to avoid saturation.

[0055] In yet another example, the camera 414 is a high-speed camera with a frame rate exceeding 500 to 1000 frames per second or significantly faster than the metal transition and weld pool vibration dynamics to avoid aliasing. The camera has a CMOS pixel array with high light responsiveness achieved through short picosecond integration time, synchronized exposure, high-speed parallel readout and other techniques. The frame rate is preferably at least 10 times the physical dynamics of welding (which is typically between 50 Hz and 250 Hz). To reduce the size of the video file, high frame rate image acquisition (e.g., 2 KHz, 10 KHz or higher) can be performed in a burst mode at fixed intervals or under synchronized triggering of the device 12 to capture specific metal droplet transitions or weld pool oscillation events.

[0056] In yet another example, the camera 414 includes a combination of the above-described technologies, such as combined high dynamic range and high frame rate imaging, stereo vision with two HDR imaging, combined HDR imaging, and time-of-flight (ToF) imaging.

[0057] The electromechanical user interface component 308 may include, for example, one or more touch screen elements, speakers, microphones, physical buttons, gesture controls, EEG mind control, etc., which can generate electrical signals in response to user input. For example, the electromechanical user interface component 308 may include a capacitive, inductive, or resistive touch screen sensor.

[0058] Antenna 402 may be any type of antenna suitable for the radio frequency, power level, etc., used by communication link 25 .

[0059] Communication port 404 may include, for example, an Ethernet port, a USB port, an HDMI port, a fiber optic communication port, and / or any other suitable port for interfacing with a wired or optical cable.

[0060] The communication circuit system 406 is operable to interface the processor 410 with the antenna 202 and the port 204 for transmit and receive operations. For transmit operations, the communication circuit system 406 may receive data from the processor 410, packetize the data, and convert the data into physical layer signals according to the protocol used on the communication link 25. The data to be transmitted may include, for example, control signals for controlling the device 12. For receive operations, the communication interface may receive the physical layer signal via the antenna 202 or the port 204, recover the data (demodulate, decode, etc.) from the received physical layer signal, and provide the data to the processor 410. The received data may include an indication of the current settings and / or actual measured output of the device 12, such as voltage, amperage, and / or wire feed speed settings and / or measurements.

[0061] In some examples, the communication circuit system 406 includes a wireless (e.g., Zigbee) coordinator that receives notification of the trigger pull event and sends a signal to the processor 410 (e.g., a wireless node). In response, the processor 410 enables the WiFi wireless broadcast of the communication interface to transmit media (e.g., video and / or audio) via a higher bandwidth protocol (such as FTP, HTTP, and / or any other protocol).

[0062] In some examples, the headgear 20 or camera 32 (e.g., via the processor 410 and the communication circuit system 406) provides media (e.g., video, audio, welding data) to one or more cloud servers to store and / or process the media. In some examples, the headgear 20 accesses an external computing device 30 (e.g., a server or other computing device on a local network, a remote network, a cloud network, etc.) to store, process, measure, and / or control image data. The external computing device 30 can be implemented by one or more devices external to the headgear 20 via an edge and / or peer-to-peer network. In some examples, the headgear 20 stores the media in local flash memory and / or other non-volatile memory within the mask (e.g., in the memory 426). The headgear 20 can implement an HTTP and / or FTP server to implement data transfer.

[0063] In some examples, the headgear 20 uses a peer-to-peer network (also referred to as a point-to-peer network) to transmit data representing live (e.g., real-time) video captured by the camera 414 on the headgear 20 to a smartphone and / or external computing device 30 within wireless communication range. The transmission of the video allows others to observe the welding scene, even if these people cannot directly observe the welding scene (e.g., the welding arc) due to physical limitations in and / or around the welding scene. In some examples, the headgear 20 includes an RTSP server, and the smartphone app and / or computing device that communicates with the mask includes an RTSP client. The RTSP server of the headgear 20 uses the Real-time Transport Protocol (RTP) in conjunction with the Real-time Control Protocol (RTCP) for media streaming.

[0064] The user interface driver 408 is operable to condition (eg, amplify, digitize, etc.) signals from the user interface component(s) 308 .

[0065] Processor 410 processes data from communication circuitry 406, user interface driver 408, and / or image processor 416, and generates control and / or data signals to be output to communication circuitry 406. Signals output to communication circuitry 406 may include, for example, signals for controlling settings of device 12. Such signals may be generated based on signals from user interface driver 408. Signals from communication circuitry 406 may include, for example, current settings of device 12 and / or indications of actual measured outputs (received via link 25).

[0066] One or more cameras 414 are operable to capture images of a field of view near the headgear 20 or the camera 32. The camera 414 can have a fixed or adjustable position and / or angle relative to the housing 306 of the headgear 20 or the housing 356 of the camera 32. For example, an operator can loosen a bracket or other mounting hardware to adjust the angle and / or position of the camera 414, and then secure the bracket or other hardware to fix the angle and / or position of the camera 414.

[0067] The light source 412 is coupled to the camera 414 and projects a visible indicator onto an object within the field of view of the camera 414. For example, the visible indicator can be a laser dot, a light beam, a projected graphic, a projected box or grid identifying the approximate boundaries of the field of view of the camera 414, and / or any other visible indicator. In some examples, the light source 412 projects an indicator that is viewable through the welding lens (e.g., through an activated auto-darkening filter).

[0068] The visible indicator may indicate the position of the field of view of the camera 414 and / or the focal length of the camera 414. The visible indicator is typically smaller than or equal to the field of view of the camera 414. The light source 412 may be rigidly coupled to the housing so that when the position and / or angle of the camera 414 is adjusted relative to the housing 306, the position and / or angle of the light source 412 likewise changes to keep the visible indicator within the field of view of the camera 414.

[0069] An input device, such as a button, may be used to activate and / or deactivate the light source 412. For example, the light source 412 may be activated via a first button, a voice command, and / or any other input to the welding headgear 20 or the external camera(s) 32, and deactivated via a second button, a voice command, and / or any other input and / or via a timeout.

[0070] Figure 5A An example object (e.g., welding workpiece 502) is illustrated within field of view 504 of camera 414. Figure 5A As shown, a visible laser dot indicator 506 is projected onto the welding workpiece 502 to indicate the location of the field of view of the camera 414. When the welding headgear 20 is moved and / or reoriented, the visible laser dot indicator 506 will also move to indicate the location of the field of view.

[0071] Figure 5B An example welding workpiece 502 is illustrated within the field of view of the camera 414 and includes a visible beam indicator 508 of the field of view of the camera 414. The visible beam indicator 508 is larger than the laser spot indicator 506 and can be focused to increase or decrease the size of the visible beam indicator 508.

[0072] FIG. 5C to FIG. 5EAn example weld workpiece 502 is illustrated within the field of view of the camera 414 and includes a visible graphical indicator 510 that indicates the location of the field of view and the focal length of the camera 414. To generate the visible graphical indicator 510, the light source 412 may include two light sources that generate different portions of the graphical indicator 510 (e.g., FIG. 5C to FIG. 5E As the projection distance between the light source 412 and the workpiece 502 changes, different projection angles cause the graphics to change corresponding positions.

[0073] exist Figure 5C In the example of , the graphical indicator 510 indicates that the focal length of the camera 414 is approximately equal to the surface on which the graphical indicator 510 is visible. Figure 5D , graphical indicator 510 indicates that the focal length of camera 414 is shorter than the distance from camera 414 to the surface on which graphical indicator 510 is visible. Figure 5E , graphical indicator 510 indicates that the focal length of camera 414 is longer than the distance from camera 414 to the surface on which graphical indicator 510 is visible.

[0074] In some examples, light source 412 may adjust to compensate for changes in the focus of camera 414. For example, if the focal length of camera 414 changes from being longer or shorter than the distance to the surface to being equal to the distance to the surface, light source 412 may automatically or manually adjust to move graphical indicator 510 to Figure 5C After adjustment, further changes in the distance between the camera 414 and the surface will cause the spacing between the graphical indicators 510 to change accordingly.

[0075] Back to Figure 4 , the welding headgear 20 and / or the external camera 32 further includes a distance sensor 422 that measures the distance between the distance sensor 422 and the target surface. Figure 3A , Figure 3B and Figure 4 In the example of , distance sensor 422 is positioned and arranged to measure the distance between camera 414 and an object (e.g., an object illuminated by a visible indicator) within the field of view of camera 414. Distance sensor 422 can be a ToF sensor, a LIDAR sensor, an ultrasonic sensor, and / or any other type of distance sensor.

[0076] In some examples, the processor 410 performs autofocus of the camera 414 based on the distance measured by the distance sensor 422. For example, the processor 410 can configure the camera 414 to set the focal length of the camera 414 to be equal to the distance measured via the distance sensor 422. Additionally or alternatively, the processor 410 can perform autofocus of the camera 414 based on a mark placed on the welding torch 22 and / or the workpiece 24. For example, the processor 410 can use the mark to automatically focus the camera 414 to achieve the desired image clarity, thereby obtaining the correct focal length. The mark can be a predetermined code element (e.g., a QR code or graphic), a retroreflective mark, and / or any other type of visible mark.

[0077] Any of the camera 414, the light source 412, and / or the distance sensor 422 may be protected by an arc filter 420 (e.g., part of the optics 302) configured to attenuate light from the arc light and pass the filtered light to the camera 414, the light source 412, and / or the distance sensor 422. The optics 302 may include a separate arc filter 420 for each of the camera 414, the light source 412, and / or the distance sensor 422, and / or may use the same arc filter 420 for two or more of the camera 414, the light source 412, and / or the distance sensor 422.

[0078] In some examples, the welding headgear 20 and / or the external camera 32 transmit raw and / or lightly processed image data to the external computing device 30 for further processing and display. By transmitting raw or lightly processed image data, the computing requirements and / or power requirements on the welding headgear 20 and / or the external camera 32 can be reduced, thereby reducing the weight and / or size of the components installed on the welding headgear 20 and / or the external camera 32. In some examples, to assist in image processing, the processor 410 can control the camera 414 to generate frames with different exposure times (e.g., alternating long exposures and short exposures), and can transmit raw or lightly processed image data from images with different exposure times.

[0079] The camera(s) 414 may be operable to capture electromagnetic waves of any suitable wavelength(s), such as from infrared to ultraviolet. In an example embodiment, there may be two cameras 414 for capturing stereo images, from which 3D positioning information may be obtained by processing the captured images. Each camera 414 may include one or more high dynamic range image sensors (e.g., a dynamic range of about 140 dB or greater) so that an observer of the image can see both the welding arc and the workpiece simultaneously. In some examples, images from multiple image sensors are combined to generate a composite image having a higher dynamic range than that supported by any image sensor alone.

[0080] In some examples, the image processor 416 controls the camera 414 to perform optical and / or digital image stabilization. For example, one or more inertial measurement units (IMUs) such as multi-axis gyroscopes, multi-axis accelerometers, and / or multi-axis magnetometers can detect, encode, and / or measure the movement of the mask (e.g., rotation, vibration, travel, and shaking of the mask when the wearer's head moves following the arc). Based on the measured movement, the image processor 416 compensates for the movement by, for example, using microactuators and / or microelectromechanical systems (MEMS) (such as piezoelectric crystals) to move the lens and / or imager. Additionally or alternatively, the image processor 416 can implement electronic image stabilization (EIS). By using image stabilization technology, torch motion data and / or torch angle data relative to the weld joint can be extracted from the captured image. This data may be very useful for subsequent training of welders to weld joints that are difficult or impossible to shoot with cameras in fixed positions (e.g., 360-degree 5G positioning and / or 6G positioning pipeline welding). Additionally or alternatively, sensors for a fixed mounted camera may be included to track the movement of the mask and use the position and / or orientation of the mask to transform the image captured by the camera 414 in the mask.

[0081] Some example cameras 414 include high dynamic range imagers or image sensor arrays (e.g., at least 120 dB of dynamic range) and / or native wide dynamic range imagers (e.g., at least 140 dB of dynamic range) on the headgear 20. In other examples, the welding system includes a medium dynamic range (MDR) imager with a dynamic range of at least 100 dB to reduce the component cost of the mask. An example MDR imager that can be used is a camera provided by ON The model sold is MT9V024.

[0082] In some examples, the headgear 20 further includes a light source oriented to illuminate the welding scene. The illumination can be an active light source, such as an LED array. To conserve battery power of the headgear 20, the light source can be activated while the camera 414 is capturing an image and it is determined that additional illumination is beneficial (e.g., the light intensity received by the camera 414 is less than a threshold). Additionally or alternatively, the active light source can be activated and / or deactivated via an operator interface (e.g., a voice command). Additionally or alternatively, the headgear 20 can be provided with a passive light source, such as a reflective outer surface. Such a passive light source can reflect the energy of the arc to illuminate the welding scene.

[0083] The image processor 416 may include an exposure controller that receives an arc signal from a power supply or wire feeder (e.g., via a wired or wireless data connection, such as the communication circuit system 406) as a feedforward signal to adjust the exposure time of the optical sensor and / or image processing. Specifically, the image processor 416 may use the arc voltage to determine whether there is an arc in the scene. If the sensed arc voltage (e.g., excluding the welding cable voltage and / or the electrode extension voltage) is greater than 14V, the image processor 416 determines that there is an arc, and in response, reduces the exposure to show details of dark areas (such as joints and wire extensions). For relatively bright scenes, the image processor 416 may also use a more aggressive image compression ratio and / or digital image filter. Conversely, when the sensed arc voltage is less than 14V, the image processor 416 determines that there is no arc and the scene is dark. In response to determining that there is no arc, the image processor 416 uses a longer exposure time and a less aggressive image compression ratio and / or digital image filter.

[0084] In some examples, in addition to or in lieu of the arc signal, the image processor 416 also uses arc power as a proxy for arc brightness. For example, the image processor 416 can use the level of arc voltage or arc current (or the product of voltage and current, i.e., arc power) to predict the brightness of the scene, thereby adjusting the exposure and selecting a corresponding image processing algorithm and its parameters. Therefore, the image processor 416 is more effectively adapted to situations in which the arc is started and / or stopped, and / or a welding process using rapid changes in arc brightness (e.g., a frequency of 20 Hz to 250 Hz), such as in pulse welding and short circuit welding.

[0085] In an example embodiment, the processor 410 receives synchronization signal(s) that trigger the camera 414 to start and / or stop video recording. The synchronization signal may be generated by the circuitry of the headgear 20 or may be generated by circuitry external to the headgear 20. The synchronization signal may, for example, be: generated by the circuitry of the device 12 and received via the antenna 402; generated by the sensor(s) (e.g., a passive IR sensor or a photodiode) and transmitted to the camera 414 via a wired or wireless interface between the camera 414; and the like. The synchronization signal may, for example, be in response to: a pull of a welding gun trigger; a change in the output of a photodiode that captures ambient light intensity; detection of a welding arc in an image captured by the camera 414 using an image processing algorithm; and / or any other suitable stimulus.

[0086] The headgear 20 and / or camera(s) 32 may include, for example, infrared and / or ultrasonic sensors, accelerometers, gyroscopes, etc.

[0087] The power source 424 may include, for example, a battery (e.g., a lithium-ion or sodium-ion or lithium polymer or dual-carbon battery), circuitry for charging the battery from an AC and / or DC power source, and circuitry for regulating / delivering energy from the battery to other circuitry in the headgear 20.

[0088] In some examples, camera 414 may capture images using at least one of: recording high dynamic range images, recording high dynamic range video, recording wide dynamic resolution images, recording wide dynamic resolution video, recording time-of-flight images, and / or recording three-dimensional images using a structured light camera with three-dimensional depth perception. In some such examples, capturing images includes using an optical sensor with a logarithmic response. The higher frame rate video feed generated by camera 414 may require communication circuit system 406 to employ a higher bandwidth transmission protocol, and / or may involve temporarily storing all or part of the captured images and subsequently transmitting a more complete set of images for processing and analysis.

[0089] In some examples, the welding headgear 20 and / or the external camera 32 provide media to one or more cloud servers to store and / or process the media. In some examples, the mask accesses a cloud network to store, process, measure, and control image data. The cloud network can be implemented by one or more devices outside the mask via an edge and / or peer-to-peer network. In some examples, the welding headgear 20 and / or the external camera 32 store media (e.g., video and / or audio) in local flash memory and / or other non-volatile memory within the mask. The mask further implements an HTTP and / or FTP server. In some examples, a smartphone within wireless communication range acts as an edge resource fog network, HTTP client, and / or FTP client by executing an application. The example smartphone accesses media stored in the mask storage device. In some examples, the smartphone provides storage, processing, and / or analysis capabilities. The welding equipment and / or the smartphone can be an edge resource for configuring, aggregating, caching, and protecting the video and audio captured by the mask.

[0090] In some examples, the welding headgear 20 and / or the external camera 32 transmits live video captured by a recording device on the mask to a smartphone and / or computing device within wireless communication range using a peer-to-peer network (also known as a point-to-peer network). The transmission of the video allows others to observe the welding scene, even if these people cannot directly observe the welding scene (e.g., the welding arc) due to physical limitations in and / or around the welding scene. In some examples, the mask includes an RTSP server, and the smartphone app and / or computing device that communicates with the mask includes an RTSP client. The mask's RTSP server uses the Real-time Transport Protocol (RTP) in combination with the Real-time Control Protocol (RTCP) for media streaming.

[0091] In some examples, the camera 414 and / or the processor 410 can perform optical and / or digital image stabilization. The welding headgear 20 and / or the external camera 32 can include one or more inertial measurement units (IMUs), such as multi-axis gyroscopes, multi-axis accelerometers, and / or multi-axis magnetometers, to detect, encode, and / or measure movement of the mask (e.g., rotation, vibration, travel, and shake of the mask as the wearer's head follows the arc). Based on the measured movement, the welding headgear 20 and / or the external camera 32 compensates for the motion by moving the lens and / or imager, for example, using microactuators and / or microelectromechanical systems (MEMS) such as piezoelectric crystals. Additionally or alternatively, the welding headgear 20 and / or the external camera 32 can implement electronic image stabilization (EIS). By using image stabilization techniques, welder training systems such as Miller Electric TM Sales ) A mask-mounted camera can be used as an alternative or in addition to a fixed position camera to extract torch motion data and / or torch angle data relative to a weld joint. Such data can be very useful for subsequent training of welders to weld joints that are difficult or impossible to capture with a fixed position camera (e.g., 360 degree 5G positioning and / or 6G positioning pipe welding). Additionally or alternatively, a welding helmet can include a sensor for a fixed mounted camera to track the movement of the mask and use the position and / or orientation of the mask to transform the image captured by the camera in the mask.

[0092] In some examples, the headgear 20 can include a heads-up display (HUD) 418 or similar display on the external camera 32 to display information associated with the camera's recording and / or other information. For example, the processor 410 can display information to the wearer via the HUD 418, such as markings indicating the field of view or focus of the camera 414. The field of view markings can be generated and reflected onto the inner cavity of the welding headgear, and aiming can be performed based on the focal length of the camera 414 to align the marking HUD 418 with the field of view of the camera 414.

[0093] Additional data may be provided to the HUD 418 for display (e.g., via the processor 410 and / or the communication interface 306), such as travel speed, contact tip to workpiece distance (CTWD), wire feed speed, voltage and / or amperage, and / or any other welding parameter data or technical data. Additionally or alternatively, the HUD 418 may display information such as remaining consumables (e.g., welding wire, shielding gas, engine fuel, etc.) and / or service alerts or warnings from the welding equipment.

[0094] Although the reference Figure 3A , Figure 3B and Figure 4An example embodiment of the headgear 20 is described, but other embodiments may be used. For example, any of the example antenna 402, the example port 404, the example communication circuit system 406, the example user interface driver 408, the example processor 410, (multiple) example cameras 414, the example image processor 416, (multiple) example distance sensors 422, the example power supply 424, the example memory 426, and / or the example instructions 428 can be implemented using hardware, software, firmware, and / or any combination of hardware, software, and / or firmware. For example, the example antenna 402, the example port 404, the example communication circuit system 406, the example user interface driver 408, the example processor 410, (multiple) example cameras 414, the example image processor 416, (multiple) example distance sensors 422, the example power supply 424, the example memory 426, and / or the example instructions 428 can be implemented using one or more integrated circuits and / or discrete circuits, such as general-purpose processors, special-purpose processors (e.g., digital signal processors), programmable logic devices. Furthermore, implementations may include combining components and / or functionality into a single integrated circuit package and / or distributing components and / or functionality among multiple integrated circuit packages.

[0095] The example external computing device 30 can perform analysis on the received image and / or distance information. For example, the external computing device 30 can use image processing techniques to measure operator performance indicators of the welding operation based on the image and the measured distance represented in the data. Example operator performance indicators can include arc length, travel angle, working angle, travel speed, and / or target. The external computing device 30 can report the measured operator performance indicators by recording the welding operation, such as for inspection, traceability, and / or training purposes.

[0096] Figure 6 is a flow chart representing example machine readable instructions 600 that may be executed by Figure 3A , Figure 3B and / or Figure 4 The welding headgear 20 and / or welding camera 32 are implemented to record welding type operations using a camera (e.g., camera 414). Figure 3A and Figure 4 Example instructions 600 are described with reference to example welding headgear 20 .

[0097] In block 602, processor 410 initializes camera 414 and communication circuit system 406. For example, processor 410 may control camera 414 to set focus and / or communicate with one or more external devices (e.g., Figure 1 device 12, external computing device 30) to establish communication.

[0098] In block 604, the processor 410 determines whether a focus indicator input has been received. For example, the operator may press a focus indicator button on the welding headgear 20, which is received via the user interface driver 408. If a focus indicator input has been received (block 604), then in block 606, the processor 410 controls the light source 412 to project a visible indicator onto the field of view of the camera 414. For example, the visible indicator may be a laser beam, a focus beam, a graphic indicator, and / or any other visible indicator.

[0099] If a focus indicator input has been received (block 604), or after controlling the light source 412 to project an indicator (block 606), in block 608, the processor 410 determines whether to change the focus. For example, the operator may select an input button or other device to command the processor 410 to adjust the focus (and / or focal length) of the camera 414. If the focus is to be changed (block 608), then in block 610, the processor 410 adjusts the focus of the camera 414. The following reference Figure 7 Example instructions for implementing block 610 are disclosed.

[0100] After adjusting the focus (block 610), or if the focus has not changed (block 608), the processor 410 determines whether welding has started in block 612. For example, the processor 410 may receive input from an arc light sensor or an auto-darkening filter, a trigger communication from the welding device 12, and / or any other indication that welding has started. If welding has started (block 612), the processor 410 captures an image using the camera 414 in block 614.

[0101] In box 616, the distance sensor 422 measures the distance from the focal point of the camera 414. In box 618, the processor 410 transmits the image data (e.g., raw image data) and the distance data. For example, the processor 410 can wirelessly transmit the image and distance data to the external computing device 30 for processing, analysis and / or storage. In some examples, the processor 410 wirelessly transmits the data at intervals and shuts down the communication interface 406 or a portion of the communication interface 406 to save power. For example, the processor 410 can temporarily store the image data and then transmit the image data at a predetermined later time or interval.

[0102] In block 620, processor 410 determines whether welding has ended. For example, processor 410 may determine whether welding has ended using the same inputs as determining whether welding has begun (block 612). If welding has not ended (block 620), control returns to block 614.

[0103] When welding is complete, example instructions 600 end.

[0104] Figure 7 is a flow chart representing example machine-readable instructions 700 that may be executed by Figure 3A , Figure 3B and / or Figure 4 The welding headgear and / or welding camera may be implemented to adjust the focus of the camera 414. The instructions 700 may be implemented Figure 6 610 to adjust the focus of the camera 414. Figure 3A and Figure 4 Example instructions 600 are described with reference to example welding headgear 20 .

[0105] In block 702, processor 410 controls light source 412 to project a visible indicator onto the field of view of camera 414. For example, light source 412 may project a laser dot or other indicator onto a surface within the field of view of camera 414. In block 704, processor 410 measures a distance to the visible indicator (e.g., the surface on which the visible indicator is projected) via distance sensor 422.

[0106] In block 706, processor 410 updates the focus of camera 414 based on the measured distance. For example, processor 410 may control camera 414 to automatically adjust the focus to match the distance measured by distance sensor 422 via software and / or hardware.

[0107] In block 708, processor 410 determines whether input has been received to save the focal length. For example, when the operator has identified a desired surface that camera 414 should focus on, and the focal length has been set to the desired surface, processor 410 may receive input from the operator (e.g., via user interface driver 408) to save the set focal length (e.g., to prevent further changes unless requested by the operator). If input has not been received to save the focal length (block 708), control returns to block 702 to continue updating the focal length.

[0108] When receiving the input to save the focal length, the processor 410 stores the current focal length and sets the focus of the camera 414 based on the focal length. For example, the processor 410 can use the current focal length as a fixed focal length and not change the focal length relative to the stored focal length until the operator requests another adjustment.

[0109] Figure 8 yes Figure 1 0048 is a block diagram of an example implementation of an external computing device 30. Figure 8An example external computing device 30 may be a general purpose computer, a laptop computer, a tablet computer, a mobile device, a server, and / or any other type of computing device. In some examples, the external computing device 30 may be implemented using one or more physical machines in a cloud computing environment, and in some examples, implemented using one or more virtual machines in a data center.

[0110] Figure 8 The example external computing device 30 includes a processor 802. The example processor 802 can be any general-purpose central processing unit (CPU) from any manufacturer. In some other examples, the processor 802 can include one or more special-purpose processing units, such as a graphics processing unit and / or a digital signal processor. The processor 802 executes machine-readable instructions 804, which can be stored locally at the processor (e.g., in an included cache), stored in a random access memory 806 (or other volatile memory), stored in a read-only memory 808 (or other non-volatile memory such as flash memory), and / or stored in a mass storage device 810. The example mass storage device 810 can be a hard disk drive, a solid-state storage drive, a hybrid drive, a RAID array, and / or any other mass data storage device.

[0111] The bus 812 enables communications between the processor 802 , the RAM 806 , the ROM 808 , the mass storage device 810 , the network interface 814 , and / or the input / output interface 816 .

[0112] The example network interface 814 includes hardware, firmware and / or software to connect the external computing device 30 to a communication network 818 such as the Internet. For example, the network interface 814 may include wireless and / or wired communication hardware compliant with IEEE 802.X for sending and / or receiving communication data.

[0113] Figure 8 The example I / O interface 816 includes hardware, firmware, and / or software to connect one or more input / output devices 820 to the processor 802 to provide input to and / or output from the processor 802. For example, the I / O interface 816 may include a graphics processing unit for interfacing with a display device, a universal serial bus port for interfacing with one or more USB-compliant devices, FireWire, a field bus, and / or any other type of interface. The example I / O device(s) 820 may include: a keyboard, a keypad, a mouse, a trackball, a pointing device, a microphone, an audio speaker, a display device, an optical media drive, a multi-touch screen, a gesture recognition interface, a magnetic media drive, and / or any other type of input and / or output device.

[0114] The example external computing device 30 may access the non-transitory machine-readable medium 822 via the I / O interface 816 and / or the I / O device(s) 820 . Figure 8 Examples of machine-readable media 822 include optical disks (e.g., compact disks (CDs), digital versatile / video disks (DVDs), Blu-ray disks, etc.), magnetic media (e.g., floppy disks), portable storage media (e.g., portable flash drives, secure digital (SD) cards, etc.), and / or any other type of removable and / or installed machine-readable media.

[0115] As used herein, the terms "circuit" and "circuitry" refer to physical electronic components (i.e., hardware) and any software and / or firmware ("code") that can configure, be executed by, and / or otherwise be associated with hardware. As used herein, for example, a specific processor and memory may constitute a first "circuit" when executing a first line or more lines of code, and may constitute a second "circuit" when executing a second line or more lines of code. As used herein, "and / or" refers to any one or more of the multiple items connected by "and / or" in a list. As an example, "x and / or y" refers to any element in a three-element set {(x), (y), (x, y)}. In other words, "x and / or y" refers to "one or both of x and y". As another example, "x, y, and / or z" refers to any element in a seven-element set {(x), (y), (z), (x, y), (x, z), (y, z), (x, y, z)}. In other words, "x, y, and / or z" refers to "one or more of x, y, and z". As used herein, the term "exemplary" means serving as a non-limiting example, instance, or illustration. As used herein, the terms "such as" and "for example" elicit a list of one or more non-limiting examples, instances, or illustrations. As used herein, a circuit system is "operable" to perform a function when the circuit system includes the necessary hardware and code (if necessary) to perform the function, regardless of whether the performance of the function is disabled or not enabled (e.g., by a user-configurable setting, a factory adjustment, etc.).

[0116] The device and / or method of the present disclosure can be implemented with hardware, software, or a combination of hardware and software. The present method and / or system can be implemented in a centralized manner in at least one computing system, processor, and / or other logic circuit, or in a distributed manner with different elements spread over several interconnected computing systems, processors, and / or other logic circuits. Any type of computing system or other device adapted to perform the method described herein is suitable. A typical combination of hardware and software can be a processing system with a program or other code, integrated in a welding power supply, which controls the welding power supply when loaded and executed so that it implements the method described herein. Another typical implementation may include a dedicated integrated circuit or chip, such as a field programmable gate array (FPGA), a programmable logic device (PLD) or a complex programmable logic device (CPLD) and / or a system on chip (SoC). Some implementations may include a non-transient machine-readable (e.g., computer-readable) medium (e.g., flash memory, an optical disk, a magnetic storage disk, etc.), which stores one or more lines of code that can be executed by a machine to enable the machine to perform the process described herein. As used herein, the term "non-transitory machine-readable medium" is defined to include all types of machine-readable storage media and to exclude propagating signals.

[0117] Although the present method and / or system has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and may be substituted with equivalents without departing from the scope of the present method and / or system. In addition, many modifications may be made to adapt specific circumstances or materials to the teachings of the present disclosure without departing from the scope of the present disclosure. For example, the frames and / or components of the disclosed examples may be combined, divided, rearranged and / or otherwise modified. Therefore, the present method and / or system is not limited to the specific embodiments disclosed. Alternatively, the present method and / or system will include all embodiments that fall within the scope of the appended claims, both literally and according to the doctrine of equivalents.

Claims

1. A welding monitoring system, comprising: a camera having a field of view and configured to capture an image of the camera's field of view; a light source coupled to the camera and configured to project a visible indicator onto an object within the camera's field of view such that the visible indicator at least partially overlaps the camera's field of view; as well as Communications circuitry is configured to transmit data representing the image.

2. The welding monitoring system according to claim 1, wherein: The visible indicator includes at least one of a visible laser beam or a visible focused light beam.

3. The welding monitoring system of claim 1, wherein: The camera and the light source are mounted on a welding helmet.

4. The welding monitoring system according to claim 3, wherein: The angles of the camera and the light source relative to the welding helmet are adjustable.

5. The welding monitoring system of claim 1, wherein: The visible indicator indicates the location of the camera's field of view.

6. The welding monitoring system of claim 5, wherein: The visible indicator indicates the boundaries of the camera's field of view.

7. The welding monitoring system of claim 5, wherein: The visible indicator indicates a focal distance relative to the object.

8. The welding monitoring system of claim 1, further comprising an optical filter configured to filter arc light and transmit the filtered arc light to the camera.

9. The welding monitoring system of claim 1, further comprising a distance sensor configured to measure a distance between the camera and an object illuminated by the visible indicator, wherein: The camera is configured to automatically focus based on the distance.

10. The welding monitoring system of claim 1, wherein: The camera and the light source are mounted on separate housings.

11. The welding monitoring system of claim 1, wherein: The camera is configured to capture images of a welding arc.

12. The welding monitoring system of claim 1, wherein: The visible indicator mark can be viewed through the welding lens.

13. A welding monitoring system comprising: a camera having a field of view and configured to capture an image of the camera's field of view; a distance sensor configured to measure the distance between the camera and an object within the camera's field of view; as well as Communications circuitry is configured to transmit data representative of the image and representative of the measured distance.

14. The welding monitoring system of claim 13, wherein: The distance sensor includes a time of flight (ToF) sensor.

15. The welding monitoring system of claim 13, further comprising a computing system configured to receive the data and calculate one or more operator performance indicators for the welding operation based on the image and the measured distances represented in the data.

16. The welding monitoring system of claim 15, wherein: The communication circuitry is configured to transmit the data wirelessly.

17. The welding monitoring system of claim 13, further comprising control circuitry coupled to the camera and the distance sensor, wherein: The control circuitry is configured to control the camera to adjust a focus of the camera based on the distance sensor.

18. The welding monitoring system of claim 17, further comprising a light source coupled to the camera and configured to output a visible indicator, wherein: The measuring position of the distance sensor and the visible indicator are within the field of view of the camera.

19. The welding monitoring system of claim 18, wherein: The control circuitry is configured to adjust the focus of the camera based on visible indicators within the image.

20. The welding monitoring system of claim 13, wherein: The camera and the light source are mounted on a welding helmet.

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