Wearable Welding Vision for Ergonomic Precision Workstations
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Solution Overview
Problem
Existing welding workstations for precision and microwelding operations are not ergonomically designed, leading to operator discomfort, muscle-skeletal disorders, eyestrain, and mental fatigue due to fixed postures and inadequate vision systems.
Innovation Solution
A welding workstation equipped with a wearable viewer device, such as augmented reality glasses, that provides a stereoscopic vision of the welding process, allowing operators to freely move and maintain an ergonomic posture while performing manual welding operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a microscope is used as the vision system, then the operator can observe the welding process in detail, but the operator must remain in a fixed position with eyes in contact with eyepieces, causing ergonomic discomfort and muscle-skeletal disorders
Solution Approach 1:
The patent replaces the traditional mechanical microscope system with a camera-based vision system that captures images and transmits them to a display device. This substitution allows the operator to view welding images without maintaining a fixed position or direct eye contact with optical components, thereby improving ergonomics while preserving detailed observation capability
Solution Approach 2:
The patent creates a visual copy of the welding process through a camera system that captures and transmits images to a display. This copy allows the operator to observe the welding operation in detail without being physically constrained to a fixed viewing position, resolving the contradiction between detailed observation and operator comfort
2Ease of operation
If a video camera with a fixed screen is used, then the operator can view the welding process, but the operator cannot freely rotate the head without losing visual contact with the screen, and artificial light causes reflections and glaring
Solution Approach 1:
The patent introduces a camera as an intermediary device that captures the welding process and transmits it to a display system. This intermediary allows the operator to view the welding process without direct exposure to the bright welding arc and surrounding artificial lights, eliminating reflections and glare while maintaining viewing freedom
Solution Approach 2:
The patent replaces the direct optical viewing path with an electronic image transmission system. By substituting the direct line-of-sight requirement with an electronic display interface, the operator gains freedom of head movement while the camera's ability to control lighting eliminates harmful reflections and glare
3Measurement precision
If the operator wears reading glasses, then the operator can see clearly, but the repeated taking off of reading glasses for microscope focusing causes further eyestrain
Solution Approach 1:
The patent creates a vision system that serves multiple functions: it provides detailed magnified views of the welding process like a microscope, while also being compatible with operators who wear reading glasses. The electronic display interface allows operators to maintain their reading glasses and adjust display settings rather than repeatedly removing and replacing glasses, eliminating the associated eyestrain
Data Source
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AI summary
The present application relates to a welding workstation (1) for carrying out manual welding operations comprising a welding device (2) adapted to provide the necessary heat and/or pressure for welding objects (10) and a vision system (4) configured to show the objects (10) during the welding operations to an operator; the vision system (4) comprising, in turn, image acquisition means (5) configured to capture images of the objects (10) during the welding operations; and viewer means (6) wearable by the operator and electrically connected to the image acquisition means (5); the viewer means (6) being configured to show the images captured by the image acquisition means (5) to the operator.