Welding Mask Long-Exposure Imaging for Flicker-Free Arc Video
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Solution Overview
Problem
Traditional welding helmets face challenges in capturing clear video feeds during welding processes due to stroboscopic aliasing and exposure time synchronization issues with the weld light intensity cycle.
Innovation Solution
A welding mask with a camera subsystem that captures images with exposure times longer than one-half of a weld light intensity cycle, combined with a darkening layer to attenuate light and an optical image stabilization system to reduce motion blur.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional short exposure times are used for video capture during welding, then motion blur is reduced, but stroboscopic aliasing occurs and frames are incorrectly exposed due to synchronization issues with weld light intensity cycle
Solution Approach 1:
The patent applies periodic action by synchronizing the camera exposure timing with the periodic weld light intensity cycle. The system captures images at specific phases of the welding cycle (e.g., during the arc off-period or at peak intensity moments) to ensure correct exposure while avoiding stroboscopic aliasing. This periodic synchronization allows long exposure times without capturing distorted intermediate states of the welding process.
Solution Approach 2:
The system performs preliminary action by pre-synchronizing the camera shutter with the weld cycle phase before actual image capture. The controller is configured to trigger the camera at predetermined timing relative to the welding arc cycle, ensuring that exposure occurs during appropriate phases (such as when the arc is off or at stable intensity), thereby preventing aliasing artifacts before they can occur.
2Reliability
If long exposure times longer than one-half of weld light intensity cycle are used, then stroboscopic aliasing is eliminated and frames are correctly exposed, but motion blur increases
Solution Approach 1:
By leveraging the periodic nature of the welding cycle, the system schedules long exposures to occur during specific phases (such as the arc off-period or at peak intensity) rather than continuously. This allows the camera to capture complete weld cycles or multiple cycles within a single exposure, ensuring correct exposure while the periodic structure prevents aliasing artifacts from appearing in the final image.
Solution Approach 2:
The system dynamically changes exposure parameters based on the weld cycle phase. During phases when the welding arc is off or at stable intensity, the camera uses longer exposure times to capture sufficient light without overexposure. The controller adjusts exposure duration, shutter timing, and gain settings in real-time according to the detected weld cycle phase, optimizing both exposure correctness and image clarity for each captured frame.
3Adaptability or versatility
If welding arc intensity varies during the cycle, then welding process is dynamic and realistic, but video frames become overexposed or underexposed without proper synchronization
Solution Approach 1:
The system employs feedback by continuously monitoring the weld light intensity cycle and using this information to control camera exposure timing. The controller detects the phase and intensity characteristics of the welding arc, then adjusts the camera shutter trigger timing and exposure duration accordingly. This closed-loop control ensures that each frame is captured at the optimal moment in the weld cycle, maintaining consistent exposure across all frames while preserving the dynamic nature of the welding process.
Solution Approach 2:
The system applies dynamics by making the camera exposure parameters adaptive rather than fixed. The exposure timing, duration, and gain settings are dynamically adjusted based on the real-time weld cycle phase and intensity variations. This allows the video capture system to respond to changing welding conditions, maintaining correct exposure consistency across frames while accurately representing the dynamic welding process with its varying arc intensity.
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 allows for improved video capture with correctly exposed frames, eliminating stroboscopic aliasing and providing a stable, clear video feed of the welding process.
Implementation Method 1
a darkening layer to attenuate light prior to image capture
Implementation Method 2
an optical image stabilization system to reduce or eliminate motion blur due to movement of the welding mask during the relatively long exposure time
Data Source
AI summary
Welding cameras, welding helmets, welding masks, and associated display systems are described herein that utilize darkening or attenuating filters in conjunction with long-exposure imaging to capture flicker-free video of a welding process. Example embodiments include one or more of a darkening filter, an image sensor to capture long-exposure images as frames of a video, an optical image stabilization subsystem, a data storage to store video, and an electronic display to display the video. For example, captured images may be displayed on an electronic display within the welding mask without risk of overexposure of ultraviolet radiation to the operator. In some examples, dual electronic displays are used to display different images to each eye of the operator to provide a stereoscopic video feed.