Light changing control method and system of stepless light changing mask

Abstract

The invention relates to the technical field of stepless light-changing masks, and discloses a light-changing control method and system for a stepless light-changing mask, and the method comprises the steps: collecting the ambient light intensity and the welding arc light intensity of an electric welding mask along with time, presetting a light transmittance threshold value, and carrying out the dynamic adjustment, and the light transmittance threshold value comprises a maximum value and a minimum value; storing the current light transmittance, the light intensity data, the adjusted threshold value and the timestamp as a historical data set; storing the light transmittance adjustment power and the timestamp as a light changing control data set; when the welding arc light intensity exceeds the adjusted threshold range, matching the optimal historical record from the historical data, and extracting the corresponding adjustment power as the initial power; and setting a dynamic check interval time, starting the timer after the first adjustment, and performing secondary judgment when the dynamic check interval time is up. According to the invention, more accurate and rapid stepless dimming control can be realized, and the visual clarity and safety of welders are improved.

Description

Technical Field

[0001] This invention relates to the field of stepless light-changing face mask technology, and more specifically, to a light-changing control method and system for a stepless light-changing face mask. Background Technology

[0002] During electric welding operations, the welding arc light generates intense visible light, ultraviolet light, and infrared radiation. This radiation can not only damage the welder's eyes (such as photokeratitis) but also affect the quality of the weld. Therefore, welders usually need to wear welding protective masks to prevent direct eye irritation from the intense light.

[0003] Traditional welding masks are mainly divided into two types: fixed-adjustable masks and automatic-adjustable masks. Fixed-adjustable masks have a fixed light transmittance, requiring welders to manually select the appropriate filter level before welding. However, this necessitates frequent removal and replacement of the mask before and after welding, or when observing the weld, impacting work efficiency. Automatic-adjustable masks, on the other hand, utilize liquid crystal filter (LCF) technology to automatically adjust the light transmittance based on the intensity of the welding arc, eliminating the need for manual adjustment during welding and significantly improving operational convenience and safety.

[0004] However, both fixed and automatic light-changing masks have limitations in light transmittance adjustment, namely, the lack of continuous and smooth adjustment. If the light transmittance changes too quickly, the user's field of vision will fluctuate between bright and dark after wearing the mask. If the light transmittance changes too slowly, the welding arc light will be generated before adjustment. In either case, the purpose of wearing the mask is lost, ultimately leading to insufficient light adaptability during welding, affecting the welder's visual comfort and welding quality.

[0005] Therefore, how to achieve more precise and rapid stepless light control to improve welders' visual clarity and safety is a problem that current technology needs to solve. Summary of the Invention

[0006] In view of this, the present invention proposes a method for controlling the light variation of a stepless light-changing mask, aiming to solve the problem that current technologies cannot achieve more precise and rapid stepless light variation control, thereby improving the visual clarity and safety of welders.

[0007] On the one hand, the present invention proposes a method for controlling the light variation of an infinitely variable light mask, which includes: collecting the ambient light intensity and welding arc light intensity of the welding mask over time, and dynamically adjusting a preset transmittance threshold through a nonlinear compensation model, wherein the transmittance threshold includes a maximum value and a minimum value; Store the current transmittance, light intensity data, adjusted threshold and timestamp as historical dataset; store the transmittance adjustment power ΔP and timestamp as light-changing control dataset. When the welding arc intensity exceeds the adjusted threshold range, the optimal historical record is matched from the historical dataset using a similarity algorithm, and its corresponding adjusted power is extracted as the initial power ΔP0. Set a dynamic check interval. Start a timer after the initial adjustment, and perform a second check when the dynamic check interval expires. If the welding arc intensity exceeds the threshold range, calculate the error compensation amount ΔE and generate the correction power ΔP'=ΔP0×f(ΔE); If the welding arc intensity is within the threshold range, keep the current power unchanged.

[0008] Furthermore, when the preset transmittance threshold is dynamically adjusted using a nonlinear compensation model, the maximum and minimum values ​​of the adjusted transmittance threshold are: The maximum threshold value is equal to the product of the initial maximum value and the exponential function, where the exponent term of the exponential function is the negative first dynamic coefficient multiplied by the inverse of the ratio of the welding arc intensity to the unit value; the minimum threshold value is equal to the sum of the initial minimum value and the product of the second dynamic coefficient multiplied by the square root of the difference between the welding arc intensity and the ambient light intensity; the first dynamic coefficient and the second dynamic coefficient satisfy the following relationship: the first dynamic coefficient is equal to the constant 0.1 multiplied by 1 plus the ratio of the standard deviation of the ambient light intensity to its mean multiplied by 0.5; the second dynamic coefficient is equal to the constant 0.05 multiplied by 1 plus the exponential function value of the ambient light intensity with a base of -0.3; Among them, the welding arc light intensity represents the current working light source intensity, the ambient light intensity represents the current background light level, the standard deviation and mean of the ambient light intensity reflect the fluctuation and average level of the light level, respectively; the initial maximum and minimum values ​​are the upper and lower limits of the set transmittance threshold range, and the adjusted maximum and minimum values ​​are the actual control range obtained by dynamic compensation calculation.

[0009] Furthermore, the method for calculating the dynamic inspection interval is as follows: A proportional term is constructed by comparing the basic inspection interval time with the ratio of the change in welding arc intensity per unit time to the benchmark value of the rate of change of light intensity. When the proportional term is greater than 1, the basic interval time is amplified by using it as a factor; otherwise, the basic interval time is kept unchanged or linearly fine-tuned. The benchmark value of the rate of change of light intensity is a fixed constant used as the evaluation baseline for measuring the rate of change. The change in welding arc intensity per unit time is obtained by dividing the intensity difference between the current moment and the previous moment by the interval time.

[0010] Furthermore, the similarity algorithm employs a dynamic time warping algorithm to calculate the matching degree between the current welding arc intensity data sequence and the historical welding arc intensity data sequence, including the following steps: a) Perform Z-score normalization on the current welding arc intensity data sequence and the historical welding arc intensity data sequence; b) Construct a (n+1)×(m+1) cumulative cost matrix, where n and m are the sequence lengths; c) Calculate the minimum path cumulative cost: For any path point formed by the current welding arc intensity data index and the historical data index, traverse the cost value between it and the adjacent path points above, to the left and to the upper left, and take the result with the smallest sum of the three as the cumulative cost value of the path point; the cost value is the absolute difference between the light intensity value corresponding to the current path point and the connected path point, which is used to measure the degree of deviation between the current data and the historical data at the path point.

[0011] d) When the cumulative cost of the minimum path is less than the similarity threshold ε, it is determined to be a valid match.

[0012] Furthermore, the method for calculating the error compensation amount ΔE is as follows: When the current welding arc intensity exceeds the upper limit of the dynamically adjusted threshold, the difference between the current intensity and the upper limit is divided by the upper limit to obtain the first error compensation amount; when the current welding arc intensity is lower than the lower limit of the dynamically adjusted threshold, the difference between the lower limit and the current intensity is divided by the lower limit to obtain the second error compensation amount. The correction coefficients for the first and second error compensation amounts are determined using a piecewise expression based on the numerical range of the error compensation amounts. When the error compensation amount is greater than 0.3, the correction factor is equal to 1 plus twice the error compensation amount; When the error compensation is between 0.1 and 0.3, the correction factor is equal to 1 plus the error compensation multiplied by 0.8; when the error compensation is between 0 and 0.1, the correction factor is equal to 1 plus the error compensation multiplied by 0.2.

[0013] Furthermore, the method also includes: if the welding arc intensity still exceeds the threshold range after three consecutive adjustments, then multi-sensor fusion detection is activated, and welding arc intensity in N directions is collected by N sensors. After calculating the weighted effective arc intensity, the weighted effective arc intensity is used instead of the welding arc intensity for threshold judgment. The calculation method of the weighted effective arc intensity is as follows: Multiply the welding arc intensity measured by each sensor by the corresponding weighting coefficient one by one, and the sum of the products is used as the numerator of the weighted intensity; use the sum of the weighting coefficients as the denominator; divide the two to obtain the weighted effective arc intensity. The weighting coefficient for each sensor is calculated based on the angle difference between the installation angle and the reference direction of the main sensor. Specifically, the absolute value of the angle difference plus one is taken as the reciprocal of the result, which is used as the weighting coefficient for that sensor. The main sensor is a reference sensor with a preset reference direction, and the weight of other sensors decreases as the degree of angular deviation increases.

[0014] Furthermore, when calculating the error compensation amount ΔE and generating the correction power, the following priority is applied: Rapid response phase: When the absolute value of the difference between the welding arc intensity and the current transmittance threshold exceeds 30% of the set threshold, the full power adjustment mode is activated to change the transmittance at the maximum adjustment rate; Precise adjustment phase: When the absolute value of the difference is between 10% and 30% of the set threshold, the gradual adjustment mode is activated, and the adjustment rate is proportional to the size of the difference. Steady-state maintenance phase: When the absolute value of the difference is less than 10% of the set threshold, the fine-tuning mode is activated to perform pulse correction of less than 1% of the transmittance at fixed intervals; The set threshold is 20% of the difference between the maximum and minimum transmittance after adjustment.

[0015] Furthermore, the method also includes an emergency control procedure: Mutation detection: When the difference between two consecutive ambient light intensity samples exceeds three times the previous difference, it is determined to be an environmental mutation event; Safety Lock: Immediately switches the light transmittance to the preset fixed safety level and maintains it for at least 200ms; Recovery verification: During the security lock, ambient light stability is checked every 50ms, and the lock is released when the fluctuation is less than 5% for 3 consecutive samplings; Data Reset: After unlocking, clear historical dataset records within 100ms prior to the mutation.

[0016] Furthermore, the method also includes trend prediction control: Feature extraction: Record the rising edge slope, falling edge slope, and fluctuation frequency of the welding arc intensity within the last 500ms; Pattern matching: The extracted features are compared with a pre-stored library of typical welding patterns based on their similarity. This library includes at least the following patterns: Arc ignition mode: slope > 500 lx / ms and frequency < 5Hz; Droplet transfer mode: slope 100-300 lx / ms and frequency 10-20Hz; Abnormal splashing mode: slope > 800 lx / ms and frequency > 50Hz; Forward control: When a specific mode is matched, transmittance adjustment is initiated 50-100ms before a complete change in light intensity is detected.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: significantly enhanced dynamic environmental adaptability: the transmittance threshold is automatically corrected according to the real-time relationship between ambient light and welding arc light, the maximum transmittance threshold is reduced under strong ambient light (such as outdoor welding) to avoid glare; the minimum transmittance threshold is increased under weak ambient light (such as night maintenance), ensuring that the visibility adaptive adjustment range is expanded by more than 40% compared with the traditional fixed threshold scheme, adapting to the full working environment from -20℃ to 50℃; Dual improvement in light-changing response speed and accuracy: In full-power mode, the transmittance can be changed from 80% to 30% within 20ms (the traditional solution requires 50ms). The fine-tuning mode achieves transmittance adjustment accuracy of ±0.5%, avoiding visual fatigue caused by frequent flickering. Multi-sensor weighted fusion reduces the arc light detection error to ±3% (the single sensor solution has an error of ±15%).

[0018] Breakthrough in emergency safety protection capabilities: When workshop lighting is suddenly turned on (>500lx sudden change), the light transmittance is locked to a safe value within 200ms, the protection response delay is shortened by 60% compared with traditional solutions, the abnormal splashing mode is predicted 80ms in advance, successfully intercepting more than 95% of the risk of injury from welding slag splashing, and abnormal data is automatically cleared when the environment changes suddenly, which improves the accuracy of subsequent control decisions by 35%.

[0019] On the other hand, the present invention proposes a light-changing control system for a stepless light-changing mask, comprising: The dynamic light intensity acquisition module is configured to acquire the ambient light intensity and welding arc light intensity of the welding mask over time. If the welding arc light intensity still exceeds the threshold range after three consecutive adjustments, the multi-sensor fusion detection is activated to acquire light intensity data from N directions. The dynamic threshold adjustment module is configured to, when the welding arc intensity exceeds the adjusted threshold range, match the best historical record from the historical dataset using a similarity algorithm and extract its corresponding adjusted power as the initial power ΔP0; set a dynamic inspection interval time, start a timer after the first adjustment, and perform a second judgment when the dynamic inspection interval time arrives: if the welding arc intensity exceeds the threshold range, calculate the error compensation amount ΔE and generate the corrected power ΔP'=ΔP0×f(ΔE); if the welding arc intensity is within the threshold range, keep the current power unchanged; The phased control module is configured to adjust the initial power based on the difference between the welding arc intensity and the transmittance threshold, and executes the following priority: when the absolute value of the difference between the welding arc intensity and the current transmittance threshold exceeds 30% of the set threshold, the full power adjustment mode is activated to change the transmittance at the maximum adjustment rate; when the absolute value of the difference is between 10% and 30% of the set threshold, the gradual adjustment mode is activated, and the adjustment rate is proportional to the size of the difference; when the absolute value of the difference is less than 10% of the set threshold, the fine-tuning mode is activated to perform pulse corrections of less than 1% transmittance at fixed intervals. The emergency handling module is configured to determine an environmental mutation event when the difference between two consecutive ambient light intensity samples exceeds three times the previous difference; immediately switch the transmittance to a preset fixed safety level and maintain it for at least 200ms; during the safety lock period, check the ambient light stability every 50ms, and unlock when the fluctuation is less than 5% for three consecutive samples; after unlocking, clear the historical dataset records within 100ms before the mutation occurred.

[0020] The trend prediction module is configured to record the rising slope, falling slope, and fluctuation frequency of the welding arc intensity within the last 500ms; compare the currently extracted features with a pre-stored library of typical welding modes; and when a specific mode is matched, initiate transmittance adjustment 50-100ms in advance before detecting a complete change in light intensity.

[0021] It is understandable that the above-mentioned method for controlling the light-changing of an infinitely variable light mask has the same beneficial effects as its system, and will not be elaborated further here. Attached Figure Description

[0022] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings: Figure 1 A flowchart illustrating a method for controlling the light-changing effect of an infinitely variable light mask, as provided in an embodiment of the present invention.

[0023] Figure 2 This is a system functional framework diagram of a light-changing control system for an infinitely variable light-changing mask provided in an embodiment of the present invention. Detailed Implementation

[0024] Exemplary embodiments of the present application will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the disclosure to those skilled in the art. It should be noted that, unless otherwise specified, the embodiments and features described herein can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0025] See Figure 1 As shown, this embodiment of the invention provides a method for controlling the light variation of a stepless light-changing mask, including: collecting the ambient light intensity and welding arc light intensity of the welding mask over time, and dynamically adjusting a preset transmittance threshold through a nonlinear compensation model, wherein the transmittance threshold includes a maximum value and a minimum value; Store the current transmittance, light intensity data, adjusted threshold and timestamp as historical dataset; store the transmittance adjustment power ΔP and timestamp as light-changing control dataset. When the welding arc intensity exceeds the adjusted threshold range, the optimal historical record is matched from the historical dataset using a similarity algorithm, and its corresponding adjusted power is extracted as the initial power ΔP0. Set a dynamic check interval. Start a timer after the initial adjustment, and perform a second check when the dynamic check interval expires. If the welding arc intensity exceeds the threshold range, calculate the error compensation amount ΔE and generate the correction power ΔP'=ΔP0×f(ΔE); If the welding arc intensity is within the threshold range, keep the current power unchanged.

[0026] Understandably, by continuously collecting data on ambient light intensity and welding arc intensity, the system can monitor the welding environment in real time and dynamically adjust the mask's transmittance. By storing historical data and applying similarity algorithms, the system can identify patterns in changes in welding arc intensity and transmittance, quickly matching the most suitable adjustment strategy. During system adjustments, transmittance adjustments are corrected by calculating error compensation, ensuring optimal visual effects throughout the welding process. The dynamic check interval setting allows the system to wait for a period instead of responding immediately to every change in welding arc intensity, ensuring stability and reducing the possibility of over-adjustment. Secondary judgments can further refine adjustments, ensuring each adjustment is based on the current welding state for optimal response. Error compensation corrects deviations in the initial adjustment, making transmittance adjustments more precise. By calculating error compensation, the system can dynamically correct based on the actual welding environment, maintaining the welder's optimal field of vision. When the welding arc intensity is stable and within the preset range, no further adjustments are needed. Maintaining constant power avoids excessive adjustments and unnecessary transmittance fluctuations, ensuring welder visual comfort.

[0027] In this preferred embodiment, the nonlinear compensation model satisfies the following condition: the adjusted threshold range is determined by the following formula: ; Where k1 and k2 are dynamic coefficients, satisfying: ; in, Indicates the intensity of the welding arc light. Indicates ambient light intensity. Indicates the standard deviation of ambient light intensity. This represents the mean ambient light level. This represents the maximum threshold value. This represents the minimum threshold value. This represents the maximum value of the adjusted threshold. This represents the minimum value of the adjusted threshold.

[0028] In this preferred embodiment, the method for calculating the dynamic inspection interval is as follows: ; in, Indicates the dynamic check interval. , =200lx / s is the baseline value for the rate of change of light intensity. This indicates the real-time rate of change of the welding arc light.

[0029] In this preferred embodiment, the similarity algorithm employs the Dynamic Time Warping (DTW) algorithm to calculate the matching degree between the current data sequence and historical data sequences, including the following steps: a) Perform Z-score normalization on the light intensity data sequence; b) Construct a (n+1)×(m+1) cumulative cost matrix, where n and m are the sequence lengths; c) Calculate the minimum path cumulative cost: ; in, This represents the minimum path cumulative cost, where i and j are indices. i represents the index of the current welding arc intensity data, and j represents the index of the historical welding arc intensity data. d) When the cumulative cost is less than the similarity threshold ε, it is determined to be a valid match.

[0030] In this preferred embodiment, the error compensation amount ΔE is calculated as follows: ; The correction function f(ΔE) employs piecewise compensation: .

[0031] In this preferred embodiment, the method further includes: if the welding arc intensity still exceeds the threshold range after three consecutive adjustments, then multi-sensor fusion detection is activated to collect light intensity data in N directions, calculate the weighted effective arc intensity, and use the weighted effective arc intensity to replace the welding arc intensity for threshold judgment. The calculation formula for the weighted effective arc intensity is: ; in, Indicates the weighted effective arc intensity. This represents the welding arc intensity value detected by the i-th sensor. This represents the weighting coefficient of the i-th sensor, and the... ; This represents the installation orientation angle of the i-th sensor; This indicates the reference orientation angle of the main sensor.

[0032] When the system detects that the welding arc intensity still exceeds the threshold range after three consecutive adjustments, it indicates that the current single-sensor detection may not accurately reflect the light intensity changes in the entire welding environment. In this case, the system activates fusion detection from multiple sensors to acquire more comprehensive light intensity data, avoiding misjudgments caused by localized light intensity changes. By collecting light intensity data from N directions, the system can capture the intensity changes of the welding arc from multiple angles. This is because the intensity of the welding arc may vary in different directions, and a single-direction light intensity sensor cannot comprehensively reflect the overall situation.

[0033] This approach activates multiple sensors to obtain more comprehensive light intensity data when the welding arc intensity exceeds a threshold range, collecting information from multiple directions and avoiding misjudgments due to the limitations of a single sensor. By calculating the weighted effective arc intensity and integrating the contributions of multiple sensors, weights are assigned according to the location and importance of each sensor, thus accurately reflecting the overall situation of the welding arc intensity. Using weighted effective arc intensity for threshold determination improves the accuracy of the judgment and ensures more precise and reliable transmittance adjustment.

[0034] In this preferred embodiment, when adjusting the initial power based on the difference between the welding arc intensity and the transmittance threshold, the following priority is applied: Rapid response phase: When the absolute value of the difference between the welding arc intensity and the current transmittance threshold exceeds 30% of the set threshold, the full power adjustment mode is activated to change the transmittance at the maximum adjustment rate; Precise adjustment phase: When the absolute value of the difference is between 10% and 30% of the set threshold, the gradual adjustment mode is activated, and the adjustment rate is proportional to the size of the difference. Steady-state maintenance phase: When the absolute value of the difference is less than 10% of the set threshold, the fine-tuning mode is activated to perform pulse correction of less than 1% of the transmittance at fixed intervals; The set threshold is 20% of the difference between the maximum and minimum transmittance after adjustment.

[0035] Understandably, the intensity of the welding arc may fluctuate significantly during welding, necessitating rapid adjustments to the mask's transmittance to ensure the welder's vision is not obstructed by strong light. The rapid response phase, through quick reactions, prevents the welder from being exposed to excessively strong light.

[0036] When the intensity of the welding arc light does not change as drastically as in the rapid response phase, the system requires more precise adjustment of the light transmittance. The precise adjustment phase employs a gradual adjustment method to avoid over-adjustment and reduce visual fatigue caused by frequent changes in light intensity.

[0037] When the light transmittance is close to the ideal range, no major adjustments are needed; instead, fine adjustments are made to maintain optimal operating conditions. Fine-tuning during the steady-state maintenance phase keeps the light transmittance within the ideal range, avoiding unnecessary changes caused by over-adjustment. The threshold setting ensures that the system can make reasonable adjustments under different operating environments. For example, a larger light transmittance adjustment range may mean greater changes in light intensity in the welding environment, requiring the system to make more sensitive adjustments.

[0038] In this preferred embodiment, the method further includes an emergency control procedure: Mutation detection: When the difference between two consecutive ambient light intensity samples exceeds three times the previous difference, it is determined to be an environmental mutation event; Safety Lock: Immediately switches the light transmittance to the preset fixed safety level and maintains it for at least 200ms; Recovery verification: During the security lock, ambient light stability is checked every 50ms, and the lock is released when the fluctuation is less than 5% for 3 consecutive samplings; Data Reset: After unlocking, clear historical dataset records within 100ms prior to the mutation.

[0039] Understandably, mutation detection means that when the difference between two consecutive ambient light intensity samples exceeds three times the previous difference, the system considers it an environmental mutation event. This means that when the ambient light intensity suddenly changes significantly (such as workshop lights suddenly turning on or off), the system can promptly identify and determine it as a "mutation" event; ensuring that the system can quickly respond to changes in strong light. If such changes are not detected and handled in time, they may affect the welder's vision and even cause eye damage. Safety lock refers to the system immediately switching the light transmittance to a preset fixed safety level and maintaining it for at least 200ms when a sudden change in environmental conditions occurs. This is to provide a safe visual environment immediately in the event of a sudden change in ambient light intensity, preventing welders' eyes from being injured by sudden strong light. By setting a fixed safe light transmittance level, it ensures that welders can work under safe light transmittance when the stability of ambient light changes is uncertain, avoiding visual discomfort caused by blind adjustments.

[0040] The recovery verification is to ensure that changes in ambient light have stabilized, thereby releasing the safety lock so that the face mask can return to normal dynamic adjustment mode. If the ambient light fluctuations are significant, the system will remain locked to prevent frequent face mask switching and potential visual discomfort.

[0041] Data reset is performed to clear inapplicable historical data, so that the system avoids relying on outdated data that has been disrupted by unforeseen events for decision-making, and ensures that subsequent transmittance adjustments are more accurate and stable.

[0042] In this preferred embodiment, the method further includes trend prediction control: Feature extraction: Record the rising edge slope, falling edge slope, and fluctuation frequency of the welding arc intensity within the last 500ms; Pattern matching: The extracted features are compared with a pre-stored library of typical welding patterns based on their similarity. This library includes at least the following patterns: Arc ignition mode: slope > 500 lx / ms and frequency < 5Hz; Droplet transfer mode: slope 100-300 lx / ms and frequency 10-20Hz; Abnormal splash mode: slope > 800 lx / ms and frequency > 50Hz.

[0043] Forward control: When a specific mode is matched, transmittance adjustment is initiated 50-100ms before a complete change in light intensity is detected.

[0044] Understandably, key changes in the welding process are extracted by recording the rise slope, fall slope, and fluctuation frequency of the welding arc intensity within the last 500ms. These features reflect the rate of change (rise slope and fall slope) and frequency (fluctuation frequency) of the welding arc intensity. The welding arc intensity can change very rapidly, and by extracting these features, the mask can accurately capture the dynamic trend of intensity changes. In this step, the system compares the extracted features with a pre-stored library of typical welding modes. This library includes typical modes that may occur in different welding processes, such as: Arc ignition mode: At the beginning of the welding arc, the brightness rises rapidly, the slope is high, and the frequency is low. Droplet transfer mode: During welding, after the arc stabilizes, the brightness changes relatively smoothly, and the frequency is moderate. Abnormal spatter mode: This is an abnormal situation that may occur during welding, usually accompanied by very rapid brightness changes (high slope and high frequency). When the system identifies a specific pattern in the current welding state (such as arc ignition or abnormal spatter) through pattern matching, it predicts the possible changes in light intensity and initiates transmittance adjustment 50-100 milliseconds in advance. This means that the system does not wait until the light intensity change has fully occurred before making adjustments, but responds in advance through prediction, thereby reducing the discomfort caused by changes in light intensity during the welding process.

[0045] It can be seen that the specific method for controlling the beam variation of the stepless beam-changing mask used for electric welding is as follows: Data Acquisition and Threshold Adjustment: Over time, the system collects real-time data on the ambient light intensity and welding arc intensity of the welding mask. Using a preset nonlinear compensation model, the maximum and minimum transmittance thresholds are dynamically adjusted. Based on this data, the adjusted transmittance thresholds ensure that the mask's transmittance adapts to changes in the welding environment.

[0046] Historical data storage and matching: Current transmittance, light intensity data, and their timestamps, along with the adjusted threshold, are stored as a historical dataset. Each power adjustment and timestamp are also recorded and stored as a variable light control dataset. When the welding arc intensity exceeds the dynamically adjusted threshold range, the system matches the optimal adjustment power using historical data as the initial power.

[0047] Dynamic Inspection and Secondary Judgment: The system sets a dynamic inspection interval. A timer is started after the initial power adjustment. When the inspection interval is met, a secondary judgment is performed. If the welding arc intensity still exceeds the adjustment threshold, the system generates a corrected power based on the error compensation and adjusts the mask transmittance. If the welding arc intensity is within the threshold range, the current transmittance remains unchanged.

[0048] Similarity Algorithm and Adjustment Strategy: The system employs the Dynamic Time Warping (DTW) algorithm, which selects the most suitable adjustment power by calculating the matching degree between current light intensity data and historical data. This similarity algorithm ensures accurate data matching through Z-score normalization and cumulative cost matrix, thereby optimizing transmittance adjustment.

[0049] Emergency control and safety mechanisms: In the event of a sudden change in light intensity (such as an ambient light intensity change exceeding a set threshold), the system immediately locks the transmittance to a safe value and maintains it for at least 200 milliseconds. During the lockout period, the system continuously monitors the stability of ambient light to ensure safe operation.

[0050] Multi-stage light control: Based on the difference between the welding arc intensity and the transmittance threshold, the system is divided into a rapid response stage, a precise adjustment stage, and a steady-state maintenance stage. In the rapid response stage, if the difference exceeds 30% of the set threshold, the system rapidly changes the transmittance at its maximum adjustment rate. In the precise adjustment and steady-state maintenance stages, the system gradually adjusts the transmittance to ensure the welder receives optimal visual feedback, avoiding frequent flickering and visual fatigue.

[0051] In summary, this invention significantly enhances dynamic environmental adaptability. It can automatically adjust the transmittance threshold based on the real-time relationship between ambient light and welding arc light. Under strong ambient light (such as outdoor welding), it lowers the maximum transmittance threshold to avoid glare; under weak ambient light (such as nighttime maintenance), it raises the minimum transmittance threshold, ensuring that the adaptive visibility adjustment range is more than 40% larger than traditional fixed threshold schemes, adapting to all working conditions from -20℃ to 50℃. In full-power mode, it can complete the abrupt change in transmittance from 80% to 30% within 20ms (compared to 50ms for traditional schemes), allowing for fine-tuning. This system achieves a transmittance adjustment accuracy of ±0.5%, avoiding visual fatigue caused by frequent flickering. Multi-sensor weighted fusion reduces arc detection error to ±3% (compared to ±15% for single-sensor solutions). When workshop lighting is suddenly turned on (>500lx sudden change), the transmittance is locked to a safe value within 200ms, reducing the protection response delay by 60% compared to traditional solutions. It can predict abnormal spatter patterns 80ms in advance, successfully intercepting more than 95% of the risk of injury from welding slag spatter. Abnormal data is automatically cleared when the environment changes abruptly, improving the accuracy of subsequent control decisions by 35%.

[0052] See Figure 2 As shown, this embodiment of the invention provides a light-changing control system for a stepless light-changing mask, comprising: The dynamic light intensity acquisition module is configured to acquire the ambient light intensity and welding arc light intensity of the welding mask over time. If the welding arc light intensity still exceeds the threshold range after three consecutive adjustments, the multi-sensor fusion detection is activated to acquire light intensity data from N directions. The dynamic threshold adjustment module is configured to, when the welding arc intensity exceeds the adjusted threshold range, match the best historical record from the historical dataset using a similarity algorithm and extract its corresponding adjusted power as the initial power ΔP0; set a dynamic inspection interval time, start a timer after the first adjustment, and perform a second judgment when the dynamic inspection interval time arrives: if the welding arc intensity exceeds the threshold range, calculate the error compensation amount ΔE and generate the corrected power ΔP'=ΔP0×f(ΔE); if the welding arc intensity is within the threshold range, keep the current power unchanged; The phased control module is configured to adjust the initial power based on the difference between the welding arc intensity and the transmittance threshold, and executes the following priority: when the absolute value of the difference between the welding arc intensity and the current transmittance threshold exceeds 30% of the set threshold, the full power adjustment mode is activated to change the transmittance at the maximum adjustment rate; when the absolute value of the difference is between 10% and 30% of the set threshold, the gradual adjustment mode is activated, and the adjustment rate is proportional to the size of the difference; when the absolute value of the difference is less than 10% of the set threshold, the fine-tuning mode is activated to perform pulse corrections of less than 1% transmittance at fixed intervals. The emergency handling module is configured to determine an environmental mutation event when the difference between two consecutive ambient light intensity samples exceeds three times the previous difference; immediately switch the transmittance to a preset fixed safety level and maintain it for at least 200ms; during the safety lock period, check the ambient light stability every 50ms, and unlock when the fluctuation is less than 5% for three consecutive samples; after unlocking, clear the historical dataset records within 100ms before the mutation occurred.

[0053] The trend prediction module is configured to record the rising slope, falling slope, and fluctuation frequency of the welding arc intensity within the last 500ms; compare the currently extracted features with a pre-stored library of typical welding modes; and when a specific mode is matched, initiate transmittance adjustment 50-100ms in advance before detecting a complete change in light intensity.

[0054] In summary, this invention significantly enhances dynamic environmental adaptability. It can automatically adjust the transmittance threshold based on the real-time relationship between ambient light and welding arc light. Under strong ambient light (such as outdoor welding), it lowers the maximum transmittance threshold to avoid glare; under weak ambient light (such as nighttime maintenance), it raises the minimum transmittance threshold, ensuring that the adaptive visibility adjustment range is more than 40% larger than traditional fixed threshold schemes, adapting to all working conditions from -20℃ to 50℃. In full-power mode, it can complete the abrupt change in transmittance from 80% to 30% within 20ms (compared to 50ms for traditional schemes), allowing for fine-tuning. This system achieves a transmittance adjustment accuracy of ±0.5%, avoiding visual fatigue caused by frequent flickering. Multi-sensor weighted fusion reduces arc detection error to ±3% (compared to ±15% for single-sensor solutions). When workshop lighting is suddenly turned on (>500lx sudden change), the transmittance is locked to a safe value within 200ms, reducing the protection response delay by 60% compared to traditional solutions. It can predict abnormal spatter patterns 80ms in advance, successfully intercepting more than 95% of the risk of injury from welding slag spatter. Abnormal data is automatically cleared when the environment changes abruptly, improving the accuracy of subsequent control decisions by 35%.

[0055] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of the present invention. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. A method for controlling the light variation of an infinitely variable light mask, characterized in that, include: The ambient light intensity and welding arc light intensity of the welding mask are collected over time, and the preset transmittance threshold is dynamically adjusted through a nonlinear compensation model. The transmittance threshold includes a maximum value and a minimum value. Store the current transmittance, light intensity data, adjusted threshold and timestamp as historical dataset; store the transmittance adjustment power ΔP and timestamp as light-changing control dataset. When the welding arc intensity exceeds the adjusted threshold range, the optimal historical record is matched from the historical dataset using a similarity algorithm, and its corresponding adjusted power is extracted as the initial power ΔP0. Set a dynamic check interval. Start a timer after the initial adjustment, and perform a second check when the dynamic check interval expires. If the welding arc intensity exceeds the threshold range, calculate the error compensation amount ΔE and generate the correction power ΔP'=ΔP0×f(ΔE); If the welding arc intensity is within the threshold range, keep the current power unchanged.

2. The method for controlling the light variation of the stepless light-changing mask according to claim 1, characterized in that, When the preset transmittance threshold is dynamically adjusted using a nonlinear compensation model, the maximum and minimum values ​​of the adjusted transmittance threshold are: The maximum threshold value is equal to the product of the initial maximum value and the exponential function, where the exponent term of the exponential function is the negative first dynamic coefficient multiplied by the inverse of the ratio of the welding arc intensity to the unit value; the minimum threshold value is equal to the sum of the initial minimum value and the product of the second dynamic coefficient multiplied by the square root of the difference between the welding arc intensity and the ambient light intensity; the first dynamic coefficient and the second dynamic coefficient satisfy the following relationship: the first dynamic coefficient is equal to the constant 0.1 multiplied by 1 plus the ratio of the standard deviation of the ambient light intensity to its mean multiplied by 0.5; the second dynamic coefficient is equal to the constant 0.05 multiplied by 1 plus the exponential function value of the ambient light intensity with a base of -0.3; Among them, the welding arc light intensity represents the current working light source intensity, the ambient light intensity represents the current background light level, the standard deviation and mean of the ambient light intensity reflect the fluctuation and average level of the light level, respectively; the initial maximum and minimum values ​​are the upper and lower limits of the set transmittance threshold range, and the adjusted maximum and minimum values ​​are the actual control range obtained by dynamic compensation calculation.

3. The method for controlling the light variation of the stepless light-changing mask according to claim 1, characterized in that, The method for calculating the dynamic inspection interval is as follows: A proportional term is constructed by comparing the basic inspection interval time with the ratio of the change in welding arc intensity per unit time to the benchmark value of the rate of change of light intensity. When the proportional term is greater than 1, the basic interval time is amplified by using it as a factor; otherwise, the basic interval time is kept unchanged or linearly fine-tuned. The benchmark value of the rate of change of light intensity is a fixed constant used as the evaluation baseline for measuring the rate of change. The change in welding arc intensity per unit time is obtained by dividing the intensity difference between the current moment and the previous moment by the interval time.

4. The method for controlling the light variation of the stepless light-changing mask according to claim 1, characterized in that, The similarity algorithm employs a dynamic time warping algorithm to calculate the matching degree between the current welding arc intensity data sequence and the historical welding arc intensity data sequence, including the following steps: a) Perform Z-score normalization on the current welding arc intensity data sequence and the historical welding arc intensity data sequence; b) Construct a (n+1)×(m+1) cumulative cost matrix, where n and m are the sequence lengths; c) Calculate the minimum path cumulative cost: For any path point formed by the current welding arc intensity data index and the historical data index, traverse the cost value between it and the adjacent path points above, to the left and to the upper left, and take the result with the smallest sum of the three cumulative costs as the cumulative cost value of the path point; the cost value is the absolute difference between the light intensity value corresponding to the current path point and the connected path point, which is used to measure the degree of deviation between the current data and the historical data at the path point. d) When the cumulative cost of the minimum path is less than the similarity threshold ε, it is determined to be a valid match.

5. The method for controlling the light variation of the stepless light-changing mask according to claim 1, characterized in that, The method for calculating the error compensation amount ΔE is as follows: When the current welding arc intensity exceeds the upper limit of the dynamically adjusted threshold, the difference between the current intensity and the upper limit is divided by the upper limit to obtain the first error compensation amount; when the current welding arc intensity is lower than the lower limit of the dynamically adjusted threshold, the difference between the lower limit and the current intensity is divided by the lower limit to obtain the second error compensation amount. The correction coefficients for the first and second error compensation amounts are determined using a piecewise expression based on the numerical range of the error compensation amounts. When the error compensation amount is greater than 0.3, the correction factor is equal to 1 plus twice the error compensation amount; When the error compensation is between 0.1 and 0.3, the correction factor is equal to 1 plus the error compensation multiplied by 0.8; when the error compensation is between 0 and 0.1, the correction factor is equal to 1 plus the error compensation multiplied by 0.

2.

6. The method for controlling the light variation of the stepless light-changing mask according to claim 1, characterized in that, The method further includes: if the welding arc intensity still exceeds the threshold range after three consecutive adjustments, then multi-sensor fusion detection is activated, and welding arc intensity in N directions is collected by N sensors. After calculating the weighted effective arc intensity, the weighted effective arc intensity is used instead of the welding arc intensity for threshold judgment. The calculation method of the weighted effective arc intensity is as follows: Multiply the welding arc intensity measured by each sensor by the corresponding weighting coefficient one by one, and the sum of the products is used as the numerator of the weighted intensity; use the sum of the weighting coefficients as the denominator; divide the two to obtain the weighted effective arc intensity. The weighting coefficient for each sensor is calculated based on the angle difference between the installation angle and the reference direction of the main sensor. Specifically, the absolute value of the angle difference plus one is taken as the reciprocal of the result, which is used as the weighting coefficient for that sensor. The main sensor is a reference sensor with a preset reference direction, and the weight of other sensors decreases as the degree of angular deviation increases.

7. The method for controlling the light variation of the stepless light-changing mask according to claim 1, characterized in that, When calculating the error compensation amount ΔE and generating the correction power, the following priority is applied: Rapid response phase: When the absolute value of the difference between the welding arc intensity and the current transmittance threshold exceeds 30% of the set threshold, the full power adjustment mode is activated to change the transmittance at the maximum adjustment rate; Precise adjustment phase: When the absolute value of the difference is between 10% and 30% of the set threshold, the gradual adjustment mode is activated, and the adjustment rate is proportional to the size of the difference. Steady-state maintenance phase: When the absolute value of the difference is less than 10% of the set threshold, the fine-tuning mode is activated to perform pulse correction of less than 1% of the transmittance at fixed intervals; The set threshold is 20% of the difference between the maximum and minimum transmittance after adjustment.

8. The method for controlling the light variation of the stepless light-changing mask according to claim 1, characterized in that, The method also includes emergency control procedures: Mutation detection: When the difference between two consecutive ambient light intensity samples exceeds three times the previous difference, it is determined to be an environmental mutation event; Safety Lock: Immediately switches the light transmittance to the preset fixed safety level and maintains it for at least 200ms; Recovery verification: During the security lock, ambient light stability is checked every 50ms, and the lock is released when the fluctuation is less than 5% for 3 consecutive samplings; Data Reset: After unlocking, clear historical dataset records within 100ms prior to the mutation.

9. The method for controlling the light variation of the stepless light-changing mask according to claim 1, characterized in that, The method also includes trend prediction control: Feature extraction: Record the rising edge slope, falling edge slope, and fluctuation frequency of the welding arc intensity within the last 500ms; Pattern matching: The extracted features are compared with a pre-stored library of typical welding patterns based on their similarity. This library includes at least the following patterns: Arc ignition mode: slope > 500 lx / ms and frequency < 5Hz; Droplet transfer mode: slope 100-300 lx / ms and frequency 10-20Hz; Abnormal splashing mode: slope > 800 lx / ms and frequency > 50Hz; Forward control: When a specific mode is matched, transmittance adjustment is initiated 50-100ms in advance before a complete change in light intensity is detected.

10. A light-changing control system for a stepless light-changing mask, used to implement the light-changing control method for the stepless light-changing mask according to any one of claims 1-9, characterized in that, include: The dynamic light intensity acquisition module is configured to acquire the ambient light intensity and welding arc light intensity of the welding mask over time. If the welding arc light intensity still exceeds the threshold range after three consecutive adjustments, the multi-sensor fusion detection is activated to acquire light intensity data from N directions. The dynamic threshold adjustment module is configured to, when the welding arc intensity exceeds the adjusted threshold range, match the best historical record from the historical dataset using a similarity algorithm and extract its corresponding adjusted power as the initial power ΔP0; set a dynamic inspection interval time, start a timer after the first adjustment, and perform a second judgment when the dynamic inspection interval time arrives: if the welding arc intensity exceeds the threshold range, calculate the error compensation amount ΔE and generate the corrected power ΔP'=ΔP0×f(ΔE); if the welding arc intensity is within the threshold range, keep the current power unchanged; The phased control module is configured to adjust the initial power based on the difference between the welding arc intensity and the transmittance threshold, and executes the following priority: when the absolute value of the difference between the welding arc intensity and the current transmittance threshold exceeds 30% of the set threshold, the full power adjustment mode is activated to change the transmittance at the maximum adjustment rate; when the absolute value of the difference is between 10% and 30% of the set threshold, the gradual adjustment mode is activated, and the adjustment rate is proportional to the size of the difference; when the absolute value of the difference is less than 10% of the set threshold, the fine-tuning mode is activated to perform pulse corrections of less than 1% transmittance at fixed intervals. The emergency response module is configured to determine an environmental abrupt event when the difference between two consecutive ambient light intensity samples exceeds three times the previous difference; immediately switch the transmittance to a preset fixed safety level and maintain it for at least 200ms; during the safety lock period, check the ambient light stability every 50ms, and unlock when the fluctuation is less than 5% for three consecutive samplings; after unlocking, clear the historical dataset records within 100ms before the abrupt event. The trend prediction module is configured to record the rising slope, falling slope, and fluctuation frequency of the welding arc intensity within the last 500ms; compare the currently extracted features with a pre-stored library of typical welding modes; and when a specific mode is matched, initiate transmittance adjustment 50-100ms in advance before detecting a complete change in light intensity.

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