Power Saving Welding Helmet Dual LCD Phase Shift
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional welding helmets with automatic light transmittance adjustment consume excessive power due to high-frequency AC signals, leading to frequent battery replacement and inconvenience for welders.
Innovation Solution
A power-saving welding helmet design featuring a lens device with two liquid crystal display (LCD) panels controlled by different AC signals with phase shifts, reducing power consumption by lowering the frequency of control signals to less than 1 Hz, allowing welders to see surroundings without removing the helmet and providing consistent darkness during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-frequency AC signals are used to control the viewing lens for automatic light transmittance adjustment, then the welding helmet can provide consistent darkness and eye protection, but power consumption increases and battery needs frequent replacement
Solution Approach 1:
The patent divides the single viewing lens into two separate LCD panels (first LCD panel and second LCD panel) that are controlled by AC signals with different phase shifts. This segmentation allows each panel to be independently controlled, reducing the overall power consumption while maintaining consistent darkness through the combined effect of both panels.
Solution Approach 2:
The patent employs AC signals with frequencies below 1 Hz to control the LCD panels, creating a periodic action that is too slow to be perceived by the human eye. This periodic control at low frequency significantly reduces power consumption compared to high-frequency control, while the phase-shifted dual-panel configuration ensures consistent darkness is maintained throughout each cycle.
2Reliability
If the viewing lens is kept dark to protect eyes during welding, then eye protection is provided, but the welder cannot see the surroundings when not working
Solution Approach 1:
The patent uses dynamically controllable LCD panels that can adjust their light transmittance properties in real-time. When welding occurs, the panels darken to protect the eyes; when welding stops, the panels become transparent allowing the welder to see the surroundings. This dynamic adjustment is controlled by detecting welding arc presence and applying appropriate AC signals to the panels.
3Reliability
If AC signal frequency is increased to prevent persistence of vision effects, then consistent darkness is achieved, but power consumption increases
Solution Approach 1:
The patent uses periodic AC signals with frequencies below 1 Hz to control the LCD panels. This low-frequency periodic action is combined with phase-shifting between two panels to achieve consistent darkness without requiring high frequencies that would increase power consumption. The human eye's persistence of vision naturally fills in the gaps between cycles, maintaining the appearance of consistent darkness.
Solution Approach 2:
The patent introduces asymmetry by applying phase shifts between the AC signals controlling the first and second LCD panels. This asymmetric phase relationship ensures that when one panel is transitioning, the other is at a different state, maintaining consistent overall darkness while allowing each panel to operate at low frequency with reduced power consumption.
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 significantly reduces power consumption, extending battery life and enhancing user convenience by minimizing the frequency of control signals, preventing persistence of vision and maintaining consistent darkness for eye protection.
Implementation Method 1
The magnetic sensor is mounted on the outer surface of the lens device, and generates and transmits magnetic signals to the filter control unit
Implementation Method 2
The first LCD panel is electrically connected to the control logic module through the phase shift module to receive the control signals shifted by the phase shift module. The second LCD panel is directly electrically connected to the control logic module to receive the control signals generated by the control logic module
Data Source
AI summary
A power saving welding helmet includes a helmet shell and a lens device. The helmet shell includes a mounting hole to contain the lens device. The lens device has an inner surface and an outer surface, and includes a magnetic sensor, a filter control unit, and a filter lens. The control logic module controls the filter lens according to magnetic signals generated by the magnetic sensor. The filter lens includes a first LCD panel and a second LCD panel respectively controlled by different control signals. Therefore, a refresh time of the first LCD panel and a refresh time of the second LCD panel do not synchronize. A welder does not feel the first LCD panel or the second LCD panel flashing, and the welding experiences this as consistent darkness.