Welding Head-Mounted Display for Arc-Safe Augmented Vision
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Solution Overview
Problem
Weld operators face obscured vision in harsh arc welding environments due to intense light contrast, and the industry lacks effective training methods for skilled operators, leading to difficulties in producing high-quality welds.
Innovation Solution
The development of a mediated reality welding user interface using augmented or mixed reality with see-through displays that blend computer-generated graphics with the real welding scene, enhancing operator vision and providing real-time guidance and training through holographic projections on a head-mounted display.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional welding helmets and dark lenses are used to protect operators from arc light, then operator safety is improved, but vision clarity and ability to see weld details deteriorate
Solution Approach 1:
The patent introduces a head-mounted display system with optical waveguides as an intermediary between the welding arc and the operator's eyes. The waveguides capture arc light and guide it to edge-emitting points around the periphery of the user's field of view, while the central field remains darkened for protection. This mediator allows simultaneous arc light utilization and eye protection without direct exposure.
Solution Approach 2:
The patent moves the arc light visualization from the central viewing dimension to the peripheral dimension. By projecting arc images to the edges of the field of view through optical waveguides, the system preserves central darkness for protection while providing arc information in the peripheral visual dimension, resolving the contradiction between protection and visibility.
2Reliability
If dark lenses are used to block intense arc light, then operator eye safety is improved, but the ability to see seam, electrode placement, and weld puddle details deteriorates
Solution Approach 1:
The optical waveguide system acts as an intermediary that captures arc light through the darkened lens area and redirects it to peripheral display points. This allows the dark lens to maintain its protective function while the waveguide mediator provides visual information about weld details without compromising eye safety.
Solution Approach 2:
The patent segments the visual information display from the protective function. The dark lens handles protection while the optical waveguide system handles information display, separating these two functions into distinct optical paths that work simultaneously without interfering with each other.
3Ease of operation
If see-through displays are used to provide real-time welding information, then operator guidance and training capability are improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical display systems with optical waveguide technology. Instead of using bulky mirrors, lenses, or liquid crystal displays that require complex alignment and control mechanisms, the system uses thin optical waveguides that passively guide light through total internal reflection, dramatically simplifying the mechanical complexity while maintaining see-through functionality.
Solution Approach 2:
The optical waveguides are implemented as thin film structures that can be integrated into the helmet without adding significant bulk or complexity. These thin optical films provide the display functionality through their optical properties rather than mechanical complexity, reducing overall device complexity while enabling real-time guidance.
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
Improves weld operator vision by overlaying virtual objects onto the real scene, enhancing clarity and providing real-time feedback and training, enabling less skilled operators to produce high-quality welds that pass quality inspection.
Implementation Method 1
optical waveguide displays that guide light from an observed scene to display points around a periphery of a user's field of view
Implementation Method 2
augmented reality or mixed reality with see-through or transparent displays that blend computer generated graphics with real welding scene observed directly by human eyes
Data Source
AI summary
Sensor assisted head mounted displays for welding are disclosed. Disclosed example head mounted devices include an optical sensor, an augmented reality controller, a graphics processing unit, and a semi-transparent display. The optical sensor collects an image of a weld environment. The augmented reality controller determines a simulated object to be presented in a field of view, a position in the field of view, and a perspective of the simulated object in the field of view. The graphics processing unit renders the simulated object based on the perspective to represent the simulated object being present in the field of view and in the weld environment. The display presents the rendered simulated object within the field of view based on the position. At least a portion of the weld environment is observable through the display and the lens when the display is presenting the rendered simulated object.