Welding Camera Unit With Illuminance-Based Mode Switching
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Solution Overview
Problem
Welding operators face challenges in accurately monitoring welding operations due to intense light and high temperatures, which hinder their ability to recognize critical welding information without removing protective gear.
Innovation Solution
A camera unit integrated with an illuminance sensor and a controller, which adapts the camera's operation mode and photographing conditions based on light intensity, and a light blocking panel that adjusts its light blocking degree to provide clear images of the welding operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operator wears protective gear during welding, then safety is improved, but the ability to monitor welding operations and recognize critical information deteriorates
Solution Approach 1:
The patent uses a camera to capture images of the welding operation and transmits them to a display device, creating a visual copy of the welding process that the operator can view without removing protective gear. This allows the operator to monitor welding conditions while maintaining safety protection.
Solution Approach 2:
The patent introduces a camera and display system as an intermediary between the welding operation and the operator's vision. Instead of directly viewing the welding area through protective gear, the operator views the transmitted image on a display device, enabling information access while maintaining protection.
2Measurement precision
If the camera continuously adapts to light intensity changes, then image quality is improved, but the frequency of mode changes increases causing delay
Solution Approach 1:
The patent uses periodic sampling of light intensity changes and implements hysteresis thresholds to determine when to switch between photographing modes. This periodic adaptation with threshold filtering reduces unnecessary mode changes while maintaining image quality, balancing responsiveness with stability.
3Illumination intensity
If the camera captures images in high light intensity welding environments, then welding operation visibility is improved, but image quality deteriorates due to excessive light
Solution Approach 1:
The patent dynamically adjusts photographing conditions including shutter speed, aperture, and gain based on detected light intensity levels. The system switches between different photographing modes (first mode for high light, second mode for low light) to optimize image quality for each lighting condition, allowing the camera to adapt its parameters in real-time to maintain quality across varying illumination environments.
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 solution enables operators to obtain and view clear, high-definition images of the welding process without removing protective gear, enhancing their ability to accurately perform welding tasks and reducing eye strain from frequent mode changes.
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
AI summary
Proposed 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. The camera unit may also include an illuminance sensor configured to detect an intensity of light within the welding operation area. The camera unit may further include 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 or a second mode, and change photographing conditions of the camera module to preset photographing setting values according to the determined mode.