Welder Protector With Virtual Image Overlay Through Darkening Filter
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Solution Overview
Problem
Welders face challenges in accessing critical information during welding operations while wearing protective gear, as they must remove the protector to visually check settings and conditions, compromising safety and efficiency.
Innovation Solution
A protective gear system for welders that includes a main body covering the face and eyes, a darkening filter, an image generator, an optical path bender, and a combiner, which projects virtual images of welding information onto the user's field of view, allowing for augmented reality mode operation and adjustable image placement and brightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the operator wears a protector to protect from light and heat, then eye protection and face protection are improved, but the ability to check welding information and settings is worsened
Solution Approach 1:
The patent introduces an intermediary optical system consisting of a combiner, optical path bender, and image generator that mediates between the darkening filter and the operator's eyes. This intermediary system allows welding information to be projected as a virtual image that can be viewed through the darkened protector without compromising eye protection.
Solution Approach 2:
The patent creates a virtual copy of welding information (settings, conditions, parameters) and projects it as a virtual image through the combiner. This optical copy allows the operator to view welding information without removing the protector or exposing eyes to harmful light.
2Loss of information
If the operator removes the protector to check welding settings, then visibility of information is improved, but safety protection is worsened
Solution Approach 1:
The combiner acts as an intermediary that superimposes welding information onto the visual field through the darkening filter. The optical path bender redirects light paths to enable this superposition, allowing information viewing while maintaining protective coverage.
Solution Approach 2:
The patent adds an additional optical dimension by projecting a virtual image layer onto the existing visual field. This creates a multi-layered visual experience where welding information appears as a virtual overlay on top of the actual welding scene, accessible through the protected interface.
3Object-affected harmful factors
If a darkening filter is used to protect eyes, then eye safety is improved, but brightness of displayed information is worsened
Solution Approach 1:
The patent employs parameter changes in the optical system, including adjustable darkening filter density and virtual image brightness. The controller adjusts these parameters dynamically to maintain optimal contrast between the virtual welding information and the background, ensuring readability while preserving eye protection.
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
Enables welders to view critical welding information, such as power usage and wire conditions, without removing the protector, enhancing safety and operational efficiency by providing a clear and adjustable virtual image overlay on the actual welding scene.
Implementation Method 1
The optical path bender may include at least one of a reflective mirror, a semi-transmissive mirror, and optical fiber
Implementation Method 2
The optical path bender may include at least one of a reflective mirror, a semi-transmissive mirror, and optical fiber
Implementation Method 3
The optical path bender may include at least one of a reflective mirror, a semi-transmissive mirror, and optical fiber
Implementation Method 4
a combiner configured to generate a virtual image on an outer portion of the main body by projecting the image light
Implementation Method 5
a darkening filter arranged in a front side of the main body and configured to protect the eyes of the operator
Data Source
AI summary
A protector for a welder includes a main body configured to cover a face and eyes of an operator; a darkening filter arranged in a front side of the main body and configured to protect the eyes of the operator; an image generator arranged in the main body and configured to generate image light; an optical path bender configured to change a proceeding path of the image light; and a combiner configured to generate a virtual image on an outer portion of the main body by projecting the image light, and arranged adjacent to the darkening filter.