Sensor-Assisted Welding Headset With AR Guidance for Arc Visibility
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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, particularly in simulating or enhancing operator motor skills.
Innovation Solution
The implementation 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, incorporating holographic technology to enhance operator vision, provide real-time feedback, and simulate welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding helmets and dark filters are used to protect operators from arc light, then operator safety is improved, but vision clarity and visibility of welding details deteriorate
Solution Approach 1:
The patent introduces a head-mounted display system with optical sensors and transparent displays as an intermediary between the welding arc and the operator's eyes. The system captures the welding scene through sensors, processes it to enhance visibility, and presents it through transparent displays that allow operators to see welding details clearly while maintaining arc light protection.
Solution Approach 2:
The patent replaces the traditional mechanical dark filter system with an electronic imaging and display system. Instead of relying solely on passive dark filters that block all light, the system uses optical sensors to capture images, processes them electronically to enhance contrast and visibility, and displays them through transparent displays, substituting mechanical light blocking with electronic image processing.
2Manufacturing precision
If augmented reality displays are added to provide real-time guidance and feedback, then welding quality and operator assistance are improved, but device complexity increases
Solution Approach 1:
The patent implements a multi-functional head-mounted display system that combines multiple functions into a single device: optical sensing for scene capture, image processing for enhancement, augmented reality display for guidance, and communication capabilities for remote assistance. This universal system addresses multiple welding challenges simultaneously while managing complexity through integration.
Solution Approach 2:
The system incorporates automated image processing and analysis capabilities that work autonomously to enhance welding scene visibility, provide real-time feedback on welding quality, and guide operators without requiring constant external intervention. The processing unit automatically analyzes sensor data and adjusts display parameters to optimize visibility and provide actionable guidance.
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.