Adaptive Welding Filter Sensor Fusion
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Solution Overview
Problem
Welding operators face challenges in setting parameters for automatic darkening filters due to varying welding arc intensities and interference from ambient light, which affects the accuracy of photoelectric sensors and requires frequent adjustments.
Innovation Solution
An automatic darkening filter with adaptive parameter adjustment, comprising a welding arc intensity detection unit, solar power supply module, CPU, and light valve, which calculates the difference between welding arc and ambient light intensities to control the light valve's scale number, and includes a welding action detection unit to determine the start time of difference calculation, using optical and infrared sensors for accurate detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If photoelectric sensors are used to detect welding arc intensity, then the welding arc can be detected and the light valve can be controlled, but the detection accuracy is affected by ambient light interference
Solution Approach 1:
The patent segments the detection function into two separate sensors: a photoelectric sensor for detecting welding arc intensity and an ambient light sensor for detecting ambient light intensity. This segmentation allows each sensor to specialize in one type of light detection, improving the accuracy of welding arc detection by separating it from ambient light interference.
Solution Approach 2:
The patent implements a feedback mechanism where the ambient light intensity detected by the ambient light sensor is fed back to the control unit. The control unit then adjusts the light valve's scale number based on both the welding arc intensity and ambient light intensity, creating a closed-loop control system that compensates for ambient light interference in real-time.
2Adaptability or versatility
If users manually adjust parameters to adapt to different welding conditions, then the filter can be customized for specific welding types and currents, but the operation complexity and time consumption increase
Solution Approach 1:
The patent enables the automatic darkening filter to adjust itself automatically based on real-time detection of welding arc intensity and ambient light intensity. The control unit automatically calculates the appropriate scale number and adjusts the light valve without requiring user intervention, making the system self-adapting to different welding conditions.
Solution Approach 2:
The patent makes the light valve's scale number dynamic rather than static. The scale number automatically changes in response to real-time welding conditions and ambient light levels, allowing the filter to adapt dynamically to varying welding types, currents, and environmental conditions without manual reconfiguration.
3Adaptability or versatility
If the light valve scale number is fixed, then the device structure is simpler, but it cannot adapt to varying welding arc intensities and ambient light conditions
Solution Approach 1:
The patent uses feedback from two sensors (photoelectric sensor and ambient light sensor) to automatically adjust the light valve's scale number. The control unit continuously monitors welding arc intensity and ambient light intensity, and automatically modifies the scale number to maintain optimal protection, eliminating the need for manual parameter adjustment while adapting to varying conditions.
Solution Approach 2:
The patent replaces manual mechanical adjustment mechanisms with an automated electronic control system. The control unit uses electronic signals from the sensors to automatically adjust the light valve's scale number, substituting the need for mechanical dials, switches, or other manual adjustment components with an intelligent electronic control system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The filter automatically adjusts the light valve's scale number to accurately match welding conditions, reducing the need for frequent user adjustments and improving efficiency by eliminating interference from ambient light, ensuring optimal protection for the user's eyes across different welding types and angles.
Implementation Method 1
a solar panel configured to generate electricity through ambient light, and generate a varying voltage signal as the second signal based on changes in the ambient light
Implementation Method 2
an optical sensor configured to detect an ambient light intensity signal
Implementation Method 3
a first operational amplifier configured to amplify the ambient light intensity signal as the first signal
Implementation Method 4
an infrared sensor configured to detect an infrared signal radiated by a welded object
Implementation Method 5
a second operational amplifier configured to amplify the infrared signal as the third signal
Data Source
AI summary
An automatic darkening filter with adaptive parameter adjustment includes: a welding arc intensity detection unit configured to provide a first signal for determining the welding arc intensity; a solar power supply module configured to provide electric energy for the welding arc intensity detection unit and provide a second signal for determining the ambient light intensity; and a CPU and a light valve, the CPU being configured to calculate a difference between the welding arc intensity and the ambient light intensity based on the first and second signals, and control the scale number of the light valve based on the difference. The automatic darkening filter can realize the automatic adjustment of the scale number, and in the adjustment process, the welding arc intensity signal can be revised based on the ambient light intensity, which can effectively ensure the accuracy of the final determination of the scale number.