Wireless Projector Auto-Darkening Welding Helmet
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Solution Overview
Problem
Welding operators face discomfort and reduced efficiency due to the need to repeatedly adjust operating parameters on auto-darkening helmets and navigate cables, leading to eye strain and potential damage, especially in harsh welding environments.
Innovation Solution
A wireless projector-type auto-darkening welding helmet with a micro-projector that allows operators to adjust and view operating parameters without removing the helmet, using a wireless communication module to connect with the welding machine, enabling real-time parameter adjustments and eliminating cable constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the operator adjusts operating parameters by repeatedly taking off and wearing the helmet, then the parameters can be set correctly, but the operator's energy is consumed and eye damage risk increases
Solution Approach 1:
The patent introduces a wireless communication module as an intermediary between the welding helmet and the welding machine. This module enables parameter adjustment through wireless transmission, eliminating the need for the operator to repeatedly remove and wear the helmet. The wireless module receives control signals and transmits parameter data, serving as a mediator that resolves the contradiction between accurate parameter setting and operator safety.
Solution Approach 2:
The patent replaces the mechanical interaction system (physical connection between helmet and machine for parameter adjustment) with a wireless communication system. Instead of mechanically removing the helmet to access controls, the operator can adjust parameters wirelessly while wearing the helmet, substituting mechanical operations with electromagnetic communication to eliminate harmful exposure.
2Reliability
If a cable connects the welding machine and welding helmet, then signal transmission is enabled, but the operator is constrained by cable length and may be stumbled
Solution Approach 1:
The patent extracts the physical cable from the system by introducing a wireless communication module. This module enables signal transmission between the welding machine and helmet without requiring a physical connection. The wireless module transmits control signals and parameter data through electromagnetic waves, completely removing the cable that constrained operator mobility while maintaining reliable signal connection.
Solution Approach 2:
The patent replaces the mechanical cable connection system with a wireless communication system. The physical cable that limited operator movement is substituted with wireless electromagnetic communication, allowing the operator to move freely within the wireless communication range while maintaining reliable signal transmission for parameter control and display.
3Loss of information
If the operator views parameter display on the welding machine panel, then parameters are visible, but the operator must stop welding to check and adjust
Solution Approach 1:
The patent merges the parameter display function into the welding helmet itself through a micro-projector and display module. Instead of separating the display on the welding machine panel, the system combines the display capability with the helmet, allowing parameters to be projected directly into the operator's field of view. This integration enables continuous monitoring and adjustment without interrupting the welding process, resolving the contradiction between information visibility and work efficiency.
Solution Approach 2:
The patent transitions the parameter display from a two-dimensional panel on the welding machine to a projected display within the operator's three-dimensional visual field. The micro-projector projects parameter information directly into the helmet's viewing area, allowing the operator to see and adjust parameters in the same spatial dimension where they are working, eliminating the need to shift attention to a separate display location and maintaining continuous productivity.
Data Source
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AI summary
The present application discloses a wireless projector-type auto-darkening welding helmet comprising: a helmet housing; a headband structure for securing the helmet housing; an auto-darkening filter secured on the helmet housing; a wireless communication module; and a micro-projector which is data-connected to the auto-darkening filter and the wireless communication module, wherein when the auto-darkening filter is in a transparent state, the micro-projector is adaptable to project operating parameters of the auto-darkening filter and/or data received by the wireless communication module, as images, onto a plane in front of the welding helmet such that they can be watched by an operator who wears the welding helmet on his/her head. The present application also discloses a welding apparatus equipped with said wireless projector-type auto-darkening welding helmet.