Welding Camera Unit With Adaptive Exposure and Light Blocking
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Solution Overview
Problem
Existing camera systems for welding operations struggle to provide accurate images due to the high variability in illuminance caused by welding lights, making it difficult for operators to accurately perform welding tasks.
Innovation Solution
A camera unit and welding information providing apparatus that adaptively change the operation mode and photographing conditions based on the intensity of light detected by an illuminance sensor, using a light blocking panel to shield a portion of the welding light and adjust the image capture settings accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If the camera captures images in the welding operation area, then the operator can check the welding environment, but the high intensity of welding light causes image overexposure and loss of detail
Solution Approach 1:
A light blocking panel is introduced as an intermediary component between the welding light source and the camera sensor. This panel selectively blocks excessive welding light while allowing sufficient light for image capture, preventing overexposure and preserving image detail without requiring post-processing
2Reliability
If the camera uses fixed photographing conditions, then the device complexity is reduced, but the image quality varies significantly under different lighting conditions
Solution Approach 1:
An illuminance sensor continuously monitors the light intensity in the welding operation area and provides feedback to the controller. Based on this feedback, the controller automatically adjusts photographing conditions (such as exposure time, gain, or light blocking panel transmission) to maintain consistent image quality across varying lighting conditions
Solution Approach 2:
The photographing conditions are made dynamic rather than fixed. The system can switch between different operation modes (e.g., welding mode and non-welding mode) with pre-set photographing parameters, allowing the camera to adapt to changing lighting conditions while keeping the adjustment mechanism relatively simple
3Speed
If the camera quickly switches between operation modes, then the response to lighting changes is improved, but the delay in mode switching may cause missed welding details
Solution Approach 1:
Multiple operation modes with pre-configured photographing conditions are prepared in advance (e.g., welding mode with higher exposure, non-welding mode with lower exposure). When the illuminance sensor detects a change in lighting conditions, the controller immediately switches to the appropriate pre-configured mode, eliminating the need for real-time parameter calculation and reducing switching delay
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
This solution enables the capture of clear and accurate images of welding operations, allowing operators to perform their tasks more accurately and safely by minimizing the impact of varying light conditions.
Implementation Method 1
an illuminance sensor configured to detect an intensity of light within the welding operation area
Implementation Method 2
a light blocking panel disposed in front of the camera module including the image sensor and configured to block a portion of light incident on the welding operation and transmit the remaining light to the image sensor
Data Source
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AI summary
Provided are a camera unit and a welding information providing apparatus including the same. The camera unit may include a camera module configured to obtain a welding image frame in a welding operation area according to photographing conditions, an illuminance sensor configured to detect an intensity of light within the welding operation area, and a controller configured to determine, based on the intensity of light detected by the illuminance sensor, an operation mode of the camera module to be one of a first mode and a second mode, and change photographing conditions of the camera module to preset photographing setting values according to the determined mode.