Patent Abstract:
Provided for is a control system for a welding helmet comprising: an electronically controllable lens configured to be mounted in a welding helmet shell, a microphone configured to receive an audible input and to generate a signal in response to the audible input received and an electronic control module coupled to the lens and to the microphone and configured to control the electronically controllable lens based upon the signal. Also provided for is a welding helmet implementing a control system and a method of manufacturing a welding helmet including a control system.

Full Description:
BACKGROUND 
     The present invention relates generally to welding helmets and, more particularly, to the control methods by which the user adjusts settings of functions within a welding helmet. 
     Welding operations are generally performed with certain precautions due to the potential exposure of the welding operator to high heat, flames, weld spatter and ultraviolet light. For example, in arc welding, an arc may provide extremely bright emissions in the weld area that may lead to a condition known as “eye arc” in which ultraviolet light causes the inflammation of the cornea and can burn the retina of the eyes if they are unprotected. To prevent such a condition, goggles and helmets are worn by welders. These helmets generally include a face plate (or lens) that is darkened to prevent or limit exposure to the arc light. In some helmets, the lens is constantly dark with the user flipping down the helmet during welding. In other helmets, the lens may change from a clear state to a darkened state. For example, a user may “turn on” the lens to a constant darkened state, or the lens may automatically darken when it detects bright light that is in excess of a threshold value. Further, such welding helmets may provide for adjustment of the threshold value to trigger the lens change, as well as adjustment of a time delay for transitioning between darkened and clear states. For example, the user may remove the helmet and adjust a dial to provide for a threshold light limit, shade level, or delay from the time the arc is extinguished until the lens returns to a clear state. 
     In certain welding applications, it may be desirable for the welder to frequently change the state of the lens from a light state to a dark state or vice versa, or to adjust the settings of the helmet. For example, during welding, the welder may frequently need a clear state between welds to inspect the weld, or a welder may need to modify the settings to darken the helmet to avoid exposure to light generated by another nearby welder. In these instances, it may be time consuming and laborsome for the welder to manually adjust the settings of the lens. Accordingly, it may be desirable that a welding helmet include features that allow simpler and more flexible command of helmet settings and functions. 
     BRIEF DESCRIPTION 
     In accordance with one aspect of the present invention, a welding helmet includes a helmet shell; an electronically controllable lens mounted to the shell; a microphone configured to receive an audible input and to generate a signal in response to the audible input received. An electronic control module is coupled to the lens and to the microphone and configured to control the electronically controllable lens based upon the signal. 
     In accordance with another aspect of the present invention, a control system for a welding helmet includes an electronically controllable lens configured to be mounted in a welding helmet shell; a microphone configured to receive an audible input and to generate a signal in response to the audible input received. An electronic control module is again coupled to the lens and to the microphone and configured to control the electronically controllable lens based upon the signal. 
     A method is also provided for manufacturing a welding helmet. The method includes mounting an electronically controllable lens assembly in a helmet shell; and mounting a microphone in the helmet shell. The microphone is configured to receive an audible input and to generate a signal indicative of the audible input. A control module is mounted to the helmet shell, and is coupled to the electronically controllable lens and configured to control the electronically controllable lens based upon the signal. 
    
    
     
       DRAWINGS 
       These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein: 
         FIG. 1  is an illustration of an exemplary arc welding system including a welding helmet in accordance with aspects of the present technique; 
         FIG. 2  is an illustration of an exemplary embodiment of the welding helmet of  FIG. 1  including a microphone in accordance with aspects of the present technique; 
         FIG. 3  is a diagrammatical illustration of the exemplary embodiment of the welding helmet of  FIG. 2  in accordance with aspects of the present technique; 
         FIG. 4  is an illustration of an alternate exemplary embodiment of the welding helmet of  FIG. 1  including arc sensors in accordance with aspects of the present technique; 
         FIG. 5  is a diagrammatical illustration of the exemplary embodiment of the welding helmet of  FIG. 4  in accordance with aspects of the present technique; 
         FIG. 6  is an illustration of yet another exemplary embodiment of the welding helmet of  FIG. 1  including a manual input in accordance with aspects of the present technique; 
         FIG. 7  is an illustration of an exemplary embodiment of the welding helmet of claim  6  including a remote control manual input in accordance with aspects of the present technique; 
         FIG. 8  is a diagrammatical illustration of the exemplary embodiment of the welding helmet of  FIGS. 6 and 7  in accordance with aspects of the present technique; 
         FIG. 9  is an illustration of yet another alternate exemplary embodiment of the welding helmet of  FIG. 1  including a heads-up display in accordance with aspects of the present technique; 
         FIG. 10  is a diagrammatical illustration of the exemplary embodiment of the welding helmet of  FIG. 9  in accordance with aspects of the present technique; 
         FIG. 11  is an illustration of yet another alternate exemplary embodiment of the welding helmet of  FIG. 1  including a fan in accordance with aspects of the present technique; 
         FIG. 12  is a diagrammatical illustration of the exemplary embodiment of the welding helmet of  FIG. 11  in accordance with aspects of the present technique; 
         FIG. 13  is an illustration of yet another alternate exemplary embodiment of the welding helmet of  FIG. 1  including a secondary control module accordance with aspects of the present technique; 
         FIG. 14  is a diagrammatical illustration of the exemplary embodiment of the welding helmet of  FIG. 13  in accordance with aspects of the present technique; and 
         FIG. 15  is another diagrammatical illustration of the exemplary embodiment of the welding helmet of  FIG. 13  configured to provide a modular lens assembly in accordance with aspects of the present technique. 
     
    
    
     DETAILED DESCRIPTION 
     The present invention may have uses in a variety of welding applications. For example,  FIG. 1  illustrates an arc welding system  10 . As depicted, the arc welding system  10  may include a power supply  12  that generates and supplies a current to an electrode  16  via a conduit  14 . In the arc welding system  10 , a direct current (DC) or alternating current (AC) may be used along with a consumable or non-consumable electrode  16  to deliver the current to the point of welding. In such a welding system  10 , an operator  18  may control the location and operation of the electrode  16  by positioning the electrode  16  and triggering the starting and stopping of the current flow. 
     In welding operations employing welding system  10  depicted in  FIG. 1 , welding is generally performed with certain precautions due to the generation of heat, and bright light in visible and non-visible spectra. To avoid overexposure to such light, a helmet assembly  20  is worn by the welding operator  18 . The helmet assembly  20  includes a helmet shell  22  and a lens assembly  24  that may be darkened to prevent or limit exposure to the light generated by the welding arc, as discussed below. 
     When the operator  18  applies current from the power supply  12  to electrode, and begins the welding operation, an arc  26  is developed between the electrode and a work piece. The conduit  14  and the electrode  16  thus deliver current and voltage sufficient to create the electric arc  26  between the electrode  16  and the work piece. The arc  26  melts the metal (the base material and any filler material added) at the point of welding between electrode  16  and the work piece, thereby providing a joint when the metal cools. The welding systems  10  may be configured to form a weld joint by any known technique, including shielded metal arc welding (i.e., stick welding), metal inert gas welding (MIG), tungsten inert gas welding (TIG), gas welding (e.g., oxyacetylene welding), and/or resistance welding. 
     As described below, helmet assemblies in accordance with the present invention include a lens assembly that may include functionality to transition a lens  28  from a clear state to a darkened state. Generally, a lens assembly that transitions from a clear to darkened state may include a lens including a LCD layer that darkens when a voltage is applied across the layer. For example, a user may “turn on” the lens to provide a voltage across the lens and cause the lens to transition from a light or relatively clear state to a darkened state. 
     As described below, in particular embodiments, the lens assembly may include a lens  28  and associated electronic components to cause the lens to automatically darken when sensors detect bright light that is in excess of a threshold value, triggering circuitry of the lens assembly to provide a voltage across the lens. In addition to darkening the lens, helmets in accordance with the invention may provide for adjustment of the threshold value of sensed light that triggers the lens to transition between light and dark states. For example, the circuitry of the helmet assembly may include a circuit designed to allow for adjustment of the sensitivity of the helmet sensors and circuitry to light, and thereby set the level of external light that triggers the transition of the lens between states. Further, a time delay for transitioning between the darkened and clear states may be set by the user. Such a setting may govern the time delay between detecting that the arc is extinguished and transition of the state of the lens from its dark state to its clear state. 
     To simplify the use of welding helmet assembly  20 , the present invention allows for a voice control feature that may provide for audible selection and adjust of common features of the welding helmet assembly. Embodiments of this invention, including those discussed in detail below, may provide for adjusting settings in real-time while welding, and may also provide for adjusting settings without removing the helmet assembly  20 . For example, as depicted in  FIG. 2 , a welding helmet assembly  20  will include, in addition to a helmet shell  22  and lens assembly  24 , a microphone  30 , and a lens control module  32 . The microphone  30  may be incorporated into the lens control module  32 , or may be separate from it. 
     Certain of the settings of the welding helmet assembly  20  may be pre-set at the time of manufacture, and may be re-adjusted by the operator  18 . In particular, functions of the helmet assembly  20  may have adjustable settings controlled by manually adjusting analog or digital knobs, sliders, switches, buttons, and so forth. Accordingly, to make adjustments to the settings, an operator  18  may adjust the settings prior to welding, and/or re-adjust the settings once welding has begun. 
     As depicted by  FIG. 2 , the helmet shell  22  may constitute the general frame and support for the components of the welding helmet assembly. For example, the helmet shell  22  provides a partial enclosure about the face of the operator  18  and neck to shield the operator from exposure to the high heat and bright light produced during welding. In addition to providing general protection, the helmet shell  22  provide a location to mount a lens assembly  24  and any additional accessories or control circuitry discussed in more detail below (e.g., lens control module  32  or a secondary control module  40  of  FIG. 13 ). 
     The lens control module  32  may include circuitry configured to monitor and control the state of the lens  28 , as well as circuitry to control other functions of the helmet assembly  20 . In one embodiment, the lens control module  32  may be provided as component of the lens assembly  24 . For example, the lens assembly  24  may be mounted to the helmet shell  22  as a single unit. In another embodiment, the lens control module  32  may be a component that is separate from the lens assembly  24  and the lens  28 . For example, where the lens control module  32  is separate from the lens assembly  24 , it may be mounted remotely in the helmet shell  22  with a connection (e.g., via wire conductors) to the lens assembly  24  sufficient to transmit control signals. As will be discussed in further detail, the lens control module  32  may acquire various inputs (e.g., microphone  30  or manual inputs  36 ), process the inputs, compare the inputs to the values stored in a memory and carry out programmed functionality to provide corresponding outputs to accessories related to the welding helmet assembly  20 , particularly to lighten and darken the lens. 
     As an additional component of the welding helmet assembly, the microphone  30  may be configured to receive voice commands as an input to the lens control module  32 . In one embodiment, the microphone  30  may be mounted to the helmet shell  22  in a location convenient to receive voice commands from an operator  18 . For example, as depicted in  FIG. 2 , the microphone  30  may be located near the portion of the helmet shell  20  covering the mouth of the operator  18 . The proximity of the microphone  30  to the mouth of the user may provide for audible commands of the operator  18  to be sensed by the microphone  30 . As will be appreciated by those skilled in the art, the location of the microphone  30  may vary to meet requirements of specific applications. For example, the microphone  30  may be located remotely in the helmet shell  22 , within the lens control module  32 , or may be within additional circuitry of the helmet assembly  20 . 
     As depicted in the diagram of  FIG. 3 , the microphone  30  communicates with the lens control module  32  to facilitate audible control of the lens assembly  24 . In one embodiment, the microphone  30  may sense an audible command by the operator  18 , and output a signal indicative of the command sensed. For example, the microphone  30  may detect a command and output a raw or amplified analog waveform signal representative of the command detected. The signal may then be transmitted to the lens control module  32  for processing. The lens control module  32  may then process the signals from the microphone  30  and provide an output to the lens  28  based on the result of the processing and functions stored in memory. For example, the lens control module  32  may implement voice recognition processing to interpret a signal from the microphone  30  and determine that the audible command from the operator  18  was “dark.” Accordingly, the lens control module  32  may output a signal to the lens  28  which is configured to darken the lens. As an additional example, if the sensitivity of the lens  28  is too low such that the lens has not darkened, an operator  18  may issue an audible command (e.g., “dark”) to increase the sensitivity until the lens  28  darkens. The new sensitivity setting may remain as a setting even after the arc  26  is extinguished. As will be appreciated by those skilled in the art, other commands may be sensed and processed based on the functions and settings of the helmet assembly  20 . For example, the lens control module  32  may interpret the command “sensitivity” followed by the words “more” or “less” to make adjustment to sensitivity setting of an auto-darkening helmet assembly  20 . 
     Although some embodiments may include voice recognition processing in the lens control module  32 , the processing may be completed separate from the lens control module  32 . In one embodiment, the microphone  30  may include voice recognition processing to interpret the audible command and output a representative signal. For example, the microphone  30  may be configured to sense a command from a user, provide voice recognition processing and transmit a corresponding digital signal to the lens control module  32  for subsequent processing. As will be appreciated by those skilled in the art, various techniques and software for voice recognition currently exists, and may be implemented in any location and manner that provides for the processed voice command to control functions related to the welding helmet assembly  20 . 
     In addition to using an audible command to implement functions of the helmet assembly  20 , an auto-darkening welding helmet assembly  20  may include arc sensing circuitry that is responsive to the level of light created by the arc  26 . For example, as depicted in  FIG. 4 , the lens assembly  24  may include arc sensors  34  about the periphery of the lens  28 . In one embodiment, the arc sensors  34  may include photodetectors configured to sense the light of the arc  26 . In another embodiment, the arc sensors  34  may include electromagnetic sensors configured to detect the electromagnetic emissions of the arc  26 . The arc sensors  34  may determine the intensity of the light experienced at the lens  28 , and output a signal indicative of the light intensity to the lens control module  32 . Based on the signal provided by the sensors  34 , the lens control module  32  may output a signal to the lens  28  to change to a light or dark state. In one embodiment, the signals provided by the microphone  30  and the arc sensors  34  may be simultaneously monitored by the lens control module  32  (see  FIG. 5 ). For example, the lens control module  32  may command a dark lens  28  if either of the microphone  30  or arc sensors  34  provide a signal to that requires the lens to be darkened (e.g., an audible command or light above a threshold value). In another embodiment, the lens control module  32  may be configured to give priority to one input over another. For example, to ensure that the lens  28  is darkened when an arc  26  is present, the lens control module  32  may darken the lens even if the last audible command to the microphone  30  was for a clear lens  28 . In another embodiment, to prevent inadvertent clearing of the lens  28  during welding, the lens control module  32  may not respond to command signals to clear the lens  28  while the arc sensors  34  detect an arc. 
     Although measures such as auto-darkening may be beneficial, there may be times when the operator  18  needs to override the light or dark status of the lens  28  or commands from the control circuitry. In one embodiment, the operator  18  may be able to override the darkened state. For example, during the detection of an arc  26 , and darkened state of the lens  28 , the user may be able to command “override” and “clear” to return the lens  28  to a clear state. This may be useful when the sensitivity of the lens control module  32  has been set low, and the lens  28  darkens prematurely. As will be appreciated by those skilled in the art, the priority of each function may be manipulated to provide desired functionality of the helmet assembly  20 . 
     In addition to providing hands-free operation of the welding helmet assembly  20 , it may also be desirable that the helmet assembly  20  includes a manual input to select and fine tune functions or settings of the welding helmet assembly  20 . As depicted in the embodiment of  FIG. 6 , the manual input  36  may include a dial secured to the exterior of the helmet shell  22  that provides a signal when the dial is manipulated by the operator  18 . As will be appreciated by those skilled in the art, the manual input  36  may take any form which provides a corresponding signal in response to the input of the operator  18 . For example, the manual input  36  may include a digital encoder, a knob, a touch sensitive sensor and/or one or more buttons or keys. 
     In another embodiment, as depicted in  FIG. 7 , the manual input  36  may include a wired or wireless remote control  37  worn by the operator  18 . For example, the remote control  37  may include buttons to adjust a variety of settings and functions including those previously and subsequently discussed (e.g., shade, sensitivity, speed of an integrated fan—see  FIG. 11 , and other options). As depicted in the diagram of  FIG. 8 , the remote control  37  may transmit the inputs to the lens control module  32 , wherein the lens control module  32  is configured to receive and process the inputs, and output an appropriate signal to the lens  28 , a heads-up display (HUD)  38  (see  FIG. 9 ), or other helmet function  43 . In one embodiment, the remote control  37  may also receive and process signals from the lens control module  32 . For example, the lens control module  32  may output the status of helmet functions, and the remote control  37  may display the status of helmet functions (e.g., the status and settings of the lens  28 ). In yet another embodiment, a function of the remote control  37  may be provided independently or in coordination of a display on the HUD  38 . For example, a LED on the remote may indicate that the helmet assembly  20  is powered on, while a numerical indication of the current sensitivity setting is displayed via an LCD of the remote control  37  and the HUD  38 . 
     In operation, the manual input  36  may provide for inputs in conjunction with the microphone  30 . As depicted in the diagram of  FIG. 8 , the lens control module  32  may monitor inputs from both the microphone  30  and the manual input  36 , and output an appropriate signal to the lens  28 . In one embodiment, the operator  18  may speak a command into the microphone  30  to select the functionality of the manual input  36 , followed by the user adjusting the manual input  36 . For example, the operator may speak “shade” and then adjust the digital encoder knob to select the desired shade. As will be appreciated by those skilled in the art, the design of the manual input  36  may allow for increased flexibility in adjustment of the settings. For example, a high resolution encoder may provide for very fine adjustment of settings. 
     In a similar embodiment, the microphone  30  and manual input  36  may provide for simultaneous adjustment of functions and settings. For example, the operator  18  may command to adjust a particular function (e.g., shade), and subsequently adjust the setting for that function with audible commands through the microphone  30  or by manual input  36  (i.e., speak a command “dark” or “light”, or adjust the manual input until the desired shade is reached). In another embodiment, the manual input  36  may be used to select a particular function to adjust, and subsequently allow commands spoken into the microphone  30  to make the setting adjustments. For example, the operator may set the manual input  36  to a “shade” position and subsequently command “darker” or “lighter” to change the shade setting. As will be appreciated, the functionality of the microphone  30  and the manual input  36  may be varied in any combination to provide the desired functionality. 
     In addition to providing hands-free adjustments of the welding helmet functions and settings, it may be desirable for information to be readily available to the operator  18 . In one embodiment, the welding helmet assembly  20  may include a (HUD) that provides visual information in the line-of-sight (or peripheral vision) of the operator  18 . For example, as depicted in  FIG. 9 , the lens assembly  24  may include a HUD  38  on the lens  28  and in view of the operator  18 . In one embodiment, the HUD  38  may include a display of the present settings. For example, the HUD  38  may display the “shade” or “sensitivity” each followed by a corresponding number or symbol (e.g., “50%” or an icon) that indicates the present setting. In another embodiment, the HUD  38  may display the current selections of the operator  18 . For example, operator  18  may command “shade” followed by the HUD  38  displaying “shade” to indicate to the operator  18  that the manual input  36  and voice commands are now controlling the “shade” setting. As will be appreciated by those skilled in the art, the HUD  38  may also incorporate displaying information other than functions and settings of the welding helmet assembly  20 . For example, the HUD  38  may also display an indication of the status of the welding power supply  12 , a clock, the temperature, and so forth. Further, in an environment where a respirator is required, it may also be useful for the HUD  38  to display the surrounding air quality to inform the operator  18  when it may be safe to remove the respirator and welding helmet assembly  20 . 
     To provide for the display of information on the HUD  38 , the HUD  38  may be controlled by the lens control module  32 . In one embodiment, as depicted by the diagram of  FIG. 10 , the lens control module  32  may monitor inputs from the microphone  30 , the manual input  36 , the arc sensors  34 , and/or other inputs  39  and provide corresponding outputs to the lens  28  and HUD  38 . For example, the operator  18  may command “H-U-D shade” which is received by the lens control module  32  via the microphone  30 . The lens control module  32  may then process the input from the microphone  30  and send a corresponding signal to the HUD  38  to display the current shade setting. In another embodiment, the HUD  38  may activate when the operator  18  adjusts the manual input  36 . For example, the HUD  38  may be configured to display a blank screen until an input is received (e.g., a manual input). In such an embodiment, when the operator  18  turns the knob of the manual input  36 , the lens control module  32  may detect the input and provide a signal for the HUD  38  to display the current value of the setting and update the displayed value as the manual input  36  is manipulated. In yet another embodiment, the HUD  38  may be responsive to the arc sensors  34  as depicted in the diagram of  FIG. 10 . For example, in response to a signal from the arc sensor  34  indicating a light value above the a threshold limit, the lens control module  32  may provide an output to darken the lens  28  and may simultaneously output a signal for the HUD  38  to display an indication that the lens  28  has been auto-darkened (e.g., an icon representative of exceeding the threshold value). As will be appreciated by those skilled in the art, the lens control module  32  may control the lens  28  and HUD  38  based on signals from the microphone  30 , manual input  36 , arc sensors  34 , other inputs  39 , or any combination of the like. 
     Similar to the limitations of adjusting the lens assembly  24 , adjustment of additional helmet assembly functions may require removal of the helmet assembly  20 , which may decrease the efficiency of the operator  18 . Accordingly it may be desirable for the microphone  30  and lens control module  32  to control other functions of the welding helmet assembly  20 . In one embodiment, the helmet assembly  20  may include an additional helmet function that may be controlled by the lens control module  32 . For example, as depicted in  FIG. 11 , the welding helmet assembly  20  may include a fan  42  that may run at a variety of speeds. In one embodiment, the fan  42  may be controlled by an output of the lens control module  32  as depicted by the diagram of  FIG. 12 . The lens control module  32  may monitor inputs from the microphone  30 , manual input  36 , arc sensors  34 , or other inputs  39 , and send an appropriate control signal to the cooling fan  42  represented by the “other helmet functions” block  43  in the diagram of  FIG. 12 . For example, the operator  18  may speak the command “fan” and “up” into the microphone  30 , wherein the lens control module  32  responds by transmitting a signal to increase the speed of the fan  42 . As will be appreciated by a person of ordinary skill in the art, the control of other helmet functions  43  may include integration of all of the variations discussed previously, including the manipulation of the HUD  38  and the integration of the manual input  36 . For example, the manual input may be coordinated with audible inputs to control the fan  42 , all while the settings are updated on the HUD  38 . As will also be appreciated by those skilled in the art, the other helmet functions  43  may include any functions desirable to implement into that helmet assembly. For example, the lens control module may control radio communication, an audio system, a helmet security system, or a respirator connection. 
     Previously, the discussion has focused on control of the welding helmet assembly  20  by a single lens control module  32 . Although this configuration may prove beneficial, in some cases it may be desirable for additional control circuitry to be integrated into the helmet assembly  20 . In one embodiment, the helmet assembly  20  may include the lens control module  32  as well as a secondary control module  40 , as depicted in  FIG. 13 . For example, as depicted in the diagram of  FIG. 14 , the lens control module  32  and the secondary control module  40  may each receive inputs (e.g., microphone  30 , manual input  36 , arc sensors  34 , or other inputs  39 ), wherein the lens control module  32  outputs control signals to the lens  28 , the HUD  38 , and other outputs  44  (e.g., power supply  12 ), while the secondary control module  40  controls other helmet functions  43  (e.g., fan speed). For example, in an embodiment, a control signal may be output to the power supply  12  to control functions of the power supply  12 , including initiating welding in coordination with darkening the shade of the lens  28 . 
     A secondary control module may also provide for a modular helmet assembly wherein components such as the lens assembly  24  may be implemented as add-on features. In one embodiment, in contrast to the control system of  FIG. 14 , the lens control module  32  of  FIG. 15  may be limited to controlling the lens  28  and the HUD  38 , while the secondary control module is configured to control the other outputs  44  and the other helmet functions  43 . For example, as depicted in the diagram of  FIG. 15 , the lens control module  32  may be provided as part of the lens assembly  24 , and be configured to control functions of the lens  28  and arc sensors  34 , while a secondary control module  40  transmits and receives signals related to functions of the helmet not directly connected to the lens assembly  24 . In another embodiment, the lens control module  42  and the secondary control module  40  may share a signal to coordinate their responses. For example, the lens control module  42  may only receive inputs from the microphone  30  and arc sensors  34 , while the secondary control module  40  receives and processes signals from the additional inputs (microphone  30 , manual input  36 , and other inputs  39 ). The lens control module  32  and the secondary control module  40  may then be configured to coordinate the signals output to the lens  28 , HUD  38 , other helmet functions  43  and other outputs (e.g., power supply  12 ). For example, the operator  18  may command into the microphone  30  a particular shade for the lens which is interpreted by voice recognition processing in the secondary control module  40 . The secondary module may output the setting to an “other output” (e.g., remote control) and the lens control module  32 . In response the lens control module  32  may send a signal to the HUD  38  to display the current shade setting, and signal the lens to change to the darkened shade only when the arc sensor  34  detects light in excess of a threshold value. As will be appreciated by those skilled in the art, such a configuration may allow for a helmet design to modularize the lens assembly  24 . For example, an operator  18  may purchase a helmet assembly  20  with voice control of functions, and later add a lens assembly  24  that incorporates arc sensors  34  and a lens control module  32  to coordinate the HUD  38  and the lens  28  with the voice control processing. As will also be appreciated by those skilled in the art, the configuration of the helmet assembly  20  (inputs and outputs) may be modified and combined to provide the desired functionality and modularity within the welding system  10 . 
     Due to the demand for welding helmets, and the increased cost of helmets that include a range of features described above, it may also be desirable for the welding helmet assembly  20  to incorporate a security system into the control circuitry. In one embodiment, the helmet assembly  20  may include security via the voice recognition. For example, upon powering on of the helmet assembly  20 , the operator  18  may be required to speak a password to “unlock” the functionality of the helmet. The voice command sensed may then be compared to a previously recorded password, or stored audio data, to determine if the operator  18  is in fact an authorized operator  18  of the helmet assembly  20 . In another embodiment, the voice recognition software may also compare the vocal patterns to ensure that the password was spoken by the correct operator  18 . 
     To increase the level of flexibility for the helmet assembly  20 , it my also be desirable that the operator  18  be capable of customizing the interface. In one embodiment, an interface may be provided between the helmet assembly  20  and a processing computer (PC). For example, the helmet assembly  20  may include a standard connection (e.g., a USB cable connection) to a processing computer that allows the operator  18  to modify the commands available, the helmet assembly response to commands, and/or the menu structure. In another embodiment, this functionality may be contained within the helmet. For example, the HUD  38  in coordination with other inputs (e.g., microphone  30 , manual input  36 ) may be configured to provide for the operator  18  to modify the commands and menu structures. As would be appreciated by those skilled in the art, customizing the interface may take a multitude of forms, and include various implementations of functionality. 
     While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. 
     
       
         
               
             
               
               
             
           
               
                   
               
               
                 ELEMENT LIST 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 10 
                 Welding System 
               
               
                 12 
                 Power Supply 
               
               
                 14 
                 Conduit 
               
               
                 16 
                 Electrode 
               
               
                 18 
                 Operator 
               
               
                 20 
                 Helmet Assembly 
               
               
                 22 
                 Helmet Shell 
               
               
                 24 
                 Lens Assembly 
               
               
                 26 
                 Arc 
               
               
                 28 
                 Lens 
               
               
                 30 
                 Microphone 
               
               
                 32 
                 Lens Control Module 
               
               
                 34 
                 Arc Sensor 
               
               
                 36 
                 Manual Input 
               
               
                 37 
                 Remote Control 
               
               
                 38 
                 Heads Up Display 
               
               
                 39 
                 Other Inputs 
               
               
                 40 
                 Secondary Control Module 
               
               
                 42 
                 Fan 
               
               
                 43 
                 Other Helmet Functions 
               
               
                 44 
                 Other Outputs

Technology Classification (CPC): 8