Patent Description:
Welding is a process that has increasingly become utilized in various industries and applications. Such processes may be automated in certain contexts, although a large number of applications continue to exist for manual welding operations. In both cases, such welding operations rely on a variety of types of equipment to ensure the supply of welding consumables (e.g., wire feed, shielding gas, etc.) is provided to the weld in appropriate amounts at the desired time.

Welding operations are performed on a variety of different materials using various techniques. For example, a workpiece may be formed from a carbon steel, a corrosion resistant alloy, such as stainless steel, an aluminum, and so on. Certain workpieces may thus benefit from different welding techniques and monitoring. Accordingly, a quality of a weld on a workpiece may depend on more closely monitoring the welding operation. It would be beneficial to improve monitoring capabilities via welding helmet systems.

The document <CIT> relates to a system for use with an electrically controllable light-producing activity. The light is modulated to affect an imaging function, as a secondary effect, without substantially affecting a primary or main purpose of the light-producing activity.

The document <CIT> relates to a connecting structure of an LCD shielding screen for a welding mask, in which the LCD shielding screen for protecting user's eyes from harmful rays generated during welding operation is connected to a welding plane having a transparent window formed through the front surface thereof for covering a user's whole face.

The document <CIT> relates to an electric arc welder including a helmet, a welding current generator, a welding torch and a reel of fuse wire.

The document <CIT> relates to an apparatus for monitoring manual arc welding procedures for providing to the welder real-time monitoring of the welding characteristics to achieve optimum welds.

The document <CIT> relates to arc welding simulations that provide simulation of virtual destructive and non-destructive testing and inspection of virtual weldments for training purposes.

The document <CIT> relates to a welding helmet for detecting arc data. The welding helmet includes an arc detection system configured to detect one or more welding arcs that occur during one or more welding operations.

The document <CIT> relates to a retainer lens of shape and dimensions configured to be releasably secured in the front opening of a face plate or helmet. The retainer lens has a window opening configured for positioning in front of the eyes of a wearer of the face plate or helmet.

The document <CIT> relates to a system to aid a welder. The system provides a real-world arc welding system or a virtual reality arc welding system along with a computerized eyewear device having a head-up display.

The present invention relates to a welding helmet system according to independent claim <NUM>, wherein further developments of the inventive welding helmet system are provided in the sub-claims <NUM> to <NUM>.

In one embodiment, a welding helmet system is provided. The welding helmet system includes a protective shell and a welding display system. The welding helmet system includes a protective shell and a welding display system. The welding display system is configured to be removably coupled to the protective shell. The welding display system is configured to receive data from a sensor, and to display a welding metric derived from the sensor via the image generation system.

In another embodiment (not part of the claimed invention), a welding helmet system includes a protective shell, and a first welding display system configured to be removably coupled to the protective shell. The first welding system is configured to receive data from a sensor.

The first welding system is additionally configured to display a welding metric, wherein the welding metric is derived from the data, and to communicate with a second welding display system, with an external system, or a combination thereof.

In a further embodiment (not part of the claimed invention), a welding display system is provided. The welding display system includes an image generation system and an attachment system configured to attach and to detach the welding display system to a welding helmet, to a protective face shield, or a combination thereof. The welding display system includes a processor configured to receive data from a sensor, and to display the welding metric via the image generation system, wherein the welding metric is derived from the data.

Embodiments of the present disclosure may be used in any application where it may be desired to more closely monitor welding operations, for example, via enhancements throughout a reality-virtuality continuum of welding and/or training operations. That is, the techniques described herein may be applicable at a reality-only first end of the continuum, where the real environment is presented to a welding operator and/or trainer unmodified, such as through a transparent or semi-transparent screen. The techniques described herein may be further applicable to improve welding operations and/or training by augmenting reality via additional features (e.g., augmented reality features) such as text, graphics, and/or audio superimposed onto the real environment. The techniques described herein may additionally improve welding operations and/or training via a mediated reality, further along the reality-virtuality continuum, where reality may be mediated, for example, by viewing the real world via one or more cameras. Further, the techniques described herein may improve welding operations and/or training via presentation of a full virtual welding environment at an opposite end of the reality-virtuality continuum, where viewable and audio constructs may all be computer generated. By operating throughout the entirety of the reality-virtuality continuum, the improvements disclosed herein may enhance and improve welding operations and welding training.

Advantageously, the techniques described herein include removable, replaceable, and upgradeable inserts and eyeglasses that may be used in conjunction with welding helmets to provide for enhanced visualizations and audible features. The inserts and eyeglasses described herein may be communicatively coupled to a variety of sensors, welding power supplies, and external systems (e.g., cloud-based systems) to provide for visualizations and audio useful in monitoring, for example, a quality of welding operations and/or training. The inserts and eyeglasses may be communicatively coupled to each other to deliver, for example, visual and audio data to other interested parties, such as a supervisor or trainer. Indeed, a variety of welding metrics, user biometrics, and/or environmental metrics may be derived and delivered via the inserts and eyeglasses described herein. It is to be understood that the term welding metric, as described herein, includes images and videos taken by a camera sensor. By providing for a variety of reality-virtuality continuum inserts and eyeglasses, the techniques described herein provide for enhanced welding helmets suitable for more efficiently monitoring welding operations.

Turning now to the figures, <FIG> illustrates an embodiment of an arc welding system <NUM>. As depicted, the arc welding system <NUM> may include a power supply <NUM> that generates and supplies welding power to an electrode <NUM> via a conduit <NUM>. In the arc welding system <NUM>, a direct current (DC) or alternating current (AC) may be used along with a consumable or non-consumable electrode <NUM> to deliver current to the point of welding. In such a welding system <NUM>, an operator <NUM> may control the location and operation of the electrode <NUM> by positioning the electrode <NUM> and triggering the starting and stopping of the current flow. As illustrated, a helmet system <NUM> is worn by the welding operator <NUM>. The helmet system <NUM> includes a helmet shell <NUM> and, in certain embodiments, a lens assembly that may be darkened to prevent or limit exposure to the light generated by a welding arc <NUM>. The helmet system <NUM> may be coupled to a variety of eyeglasses and inserts, as described in more detail below, to provide for enhanced visuals and audio that work throughout the reality-virtuality continuum. The helmet shell <NUM> and other protective shells described herein may be made of a variety of materials, including carbon fiber, plastics, leather, fabric materials, or a combination thereof. The protective shells may protect against heat, sparks, light, or a combination thereof.

When the operator <NUM> begins the welding operation (or other operation such as plasma cutting) by applying power from the power supply <NUM> to the electrode <NUM>, the welding arc <NUM> is developed between the electrode <NUM> and a workpiece <NUM>, such as the illustrated pipe. The workpiece <NUM> may be formed from a carbon steel or a corrosion resistant alloy, such as stainless steel, or other metals and alloys (e.g., aluminum, titanium, zirconium, niobium, tantalum, nickel alloys). Non-metal (e.g., plastic, polymeric, rubber) workpieces <NUM> may also be welded or otherwise joined, for example, by stir welding.

Generally, the techniques described herein enable certain operations (e.g., welding, cutting, grinding, induction heating, testing) to be performed on the workpiece <NUM> by applying power supplied by the power supply <NUM>. The workpiece <NUM> may be disposed in an industrial facility (e.g., industrial plant, shipyard) but may also be disposed in a residential facility, such as a garage or a home. The workpiece <NUM> may include tubular pieces (e.g., pipe), flat sheeting (e.g., metal or plastic sheets and plates), angled workpieces <NUM> (e.g., angle iron) or any other piece that may be welded, cut, ground, induction heated, or tested, for example, by using power delivered via the power supply <NUM>.

The electrode <NUM> and the conduit <NUM> thus deliver current and voltage sufficient to create the welding arc <NUM> between the electrode <NUM> and the workpiece <NUM>. The welding arc <NUM> melts the metal (the base material and any filler material added) at the point of welding between the electrode <NUM> and the workpiece <NUM>, thereby providing a joint when the metal cools. The welding system <NUM> may be configured to form a weld joint by any suitable technique, including shielded metal arc welding (SMAW) (i.e., stick welding), gas tungsten arc welding (GTAW), gas metal arc welding (GMAW), flux-cored arc welding (FCAW), metal inert gas welding (MIG), tungsten inert gas welding (TIG), gas welding (e.g., oxyacetylene welding), sub-arc welding (SAW), and/or resistance welding. As may be appreciated, shielding gas may be used in certain applications, such as GTAW, GMAW, and FCAW, for example. Waveforms used during welding may include regulated metal deposition (RMD) type waveforms, among others, surface tension transfer (STT), cold metal transfer (CMT).

As mentioned above, the helmet system <NUM> may include a variety of inserts and eyeglasses that provide for enhanced visualizations and audio during welding operations and welding training. For example, <FIG> illustrates an embodiment of the helmet system <NUM> including detachable augmented reality (AR) safety eyeglasses <NUM> (e.g., welding display system). The AR eyeglasses <NUM> may be securely coupled to a headgear assembly <NUM> via an eyeglass fastener <NUM> of the headgear assembly <NUM>. The headgear assembly <NUM> may be adjustable to fit a variety of head <NUM> sizes and may be coupled to a protective welding helmet shell <NUM>. For example, the headgear assembly <NUM> (e.g., helmet shell suspension system) may attach to the helmet shell <NUM> via one or more attachment techniques (e.g., snap fasteners, rotating fasteners, screws, and the like).

In use, the welding operator <NUM> may attach the AR eyeglasses <NUM> to the headgear assembly <NUM> via the eyeglass fastener <NUM>, and then "flip down" the welding helmet shell <NUM> during welding (or training) activities. A filter screen <NUM> on the welding helmet shell <NUM> may attenuate or otherwise filter light from, for example, the welding arc <NUM>, to enable a more suitable view during the welding activities. The AR eyeglasses <NUM> may include an image generation system <NUM> suitable for displaying images viewable by the operator <NUM>, and/or a trainer, for example, as an overlay over real world images viewable through the filter screen <NUM>. More specifically, the image generation system <NUM> may include processors, light projector systems, prisms, and so on, useful in delivering images viewable by the human eye. Accordingly, the real environment (e.g., viewable through the filter screen <NUM>) may be augmented via a variety of useful displays. For example, welding metrics, user biometrics, and/or environmental metrics may be provided as described in more detail below. By deriving and displaying a variety of welding metrics, user biometrics, and/or environmental metrics, welding operations and training may be improved.

Sensors <NUM> may be communicatively coupled to the AR eyeglasses <NUM>, directly or indirectly via another system (e.g., sensor data transmitted via power supply <NUM>), for example, through wireless protocols (e.g., Bluetooth, IEEE <NUM>. 11x [e.g., WiFi], Zigbee, HART, LTE, Z-Wave, WirelessHD, WiGig). The sensors <NUM> may include sensors <NUM> disposed on the power supply <NUM> (e.g., current and voltage sensors), on or about the workpiece <NUM> (e.g., temperature sensors, optical sensors, x-ray sensors), on the welding helmet shell <NUM>, or on the AR eyeglasses <NUM> themselves (for example to monitor the operator <NUM>). When disposed on the AR eyeglasses <NUM> and/or on (e.g., worn by) the operator <NUM>, the sensors <NUM> may include biometric sensors suitable for deriving user biometrics, for example, heat stress, heart rate (e.g., via pulse oximetry and the like), and other biometric readings of the operator <NUM>. Accordingly, the operator <NUM> may be monitored, and data relayed to the operator <NUM> (and third parties) relating to heat stress, heart rate, and the like. Sensors <NUM> may additionally provide for derivations of environmental metrics, such as surrounding temperature, humidity, ambient pressure, altitude, light levels, gases (e.g., air quality gases), and the like. Indeed, the sensors <NUM> may include temperature sensors, voltage sensors, current sensors, optical sensors, x-ray sensors, capacitance sensors, inductive sensors, air quality sensors, and the like.

In certain embodiments, the AR eyeglasses <NUM> may include a camera <NUM> (e.g., charge coupled device [CCD] sensor) and one or more speakers <NUM>, as shown in <FIG>. More specifically, <FIG> shows a perspective view of the AR eyeglasses <NUM> having a single camera <NUM> disposed between lenses <NUM>. It is to be noted that, in other embodiments, one or more cameras <NUM> may be used, and the cameras <NUM> may be disposed at various locations, including a right temple <NUM> and/or a left temple <NUM> location. It is also to be noted that the lenses <NUM> may include prescription lenses suitable for adjusting or otherwise correcting vision, and the lenses <NUM> may be safety lenses suitable for use in industrial environments. Generally, the camera(s) <NUM> capture the same view as that of the operator <NUM>. The speakers <NUM> may include bone conduction speakers suitable for conducting sound through bones in the human skull, in-ear speakers disposed inside the ear, over-ear speakers disposed on the ear, or a combination thereof.

In use, the camera(s) <NUM> may capture images and/or video of welding operations and/or training activities. The captured images and/or video (and all data captured, including sensor <NUM> data) may then be used, for example, as logging data suitable for certifying a weld quality, and for further analysis. For example, a wired and/or wireless communications system <NUM> may be used to transmit data to and receive data from external systems (e.g., power supply <NUM>, cloud-based systems, local area network [LAN] workstations/servers, wide area network [WAN] workstation/servers, and so forth). The communications system <NUM> may include wireless systems such as <NUM>. 11x (e.g., WiFi), Zigbee, Z-wave, Bluetooth, cell phone communications systems (e.g., LTE, <NUM>, CDMA, GSM), and the like. The communications system <NUM> may also include wired systems such as Ethernet based systems, two-wire systems (e.g., I2C), PCI, <NUM>-wire systems, and the like.

The data transmitted from the AR eyeglasses <NUM> may include camera <NUM> data, as well as data from other sensors <NUM> used to sense welding operations or training. Other sensor data may include temperature data of the workpiece <NUM>, power supply <NUM> data (e.g., voltage and current used), workorder data (e.g., type of workpiece to be welded, type of weld to be applied, welding supplies to be used), and so on. The data (e.g., camera <NUM> data and/or sensor <NUM> data) may be additionally or alternatively processed via processing circuitry <NUM>. Attachment points <NUM> may be used to attach the AR eyeglasses <NUM> to the eyeglass fastener <NUM>, and may additionally provide for electrically conductive attachments to provide power to charge batteries <NUM> that may power the AR eyeglasses <NUM>. For example, power may be provided via an external power supply and/or via other batteries disposed on the welding helmet shell <NUM>, and the attachment points <NUM> may facilitate power being transferred from such power sources to the AR eyeglasses <NUM>. A user input system <NUM> may be used by the operator <NUM> to provide a variety of inputs, such as via head nods, eye winks, touch gestures (e.g., swipes of certain portions the temples <NUM>, <NUM>) and/or voice commands (e.g., via microphone). In one example, voice annotations during welding, as well as voice commands to change voltage and/or current delivered via the power supply <NUM> may be provided via the input system <NUM>.

Camera <NUM> data (observing the weld torch <NUM>) and/or sensors <NUM> may be processed to determine, for example, a welding speed, an angle at which the operator <NUM> holds the weld torch <NUM>, as well as various weld observations, which, depending on a type of weld (e.g., fillet weld, groove weld, lap weld, plug and slot weld) may include concavity/convexity metrics, cross sectional weld area, leg size, toe angle, undercut metrics, weld face metrics, weld throat metrics, mismatch metrics, bead width metrics, reinforcement height metrics, porosity metrics, and so on, which may be displayed via the image generation system <NUM> in real-time during welding.

For example, weld speed may be determined by accelerometers on the weld torch <NUM> and/or via camera <NUM>/sensor <NUM> observations that identify the weld torch <NUM> moving with respect to the workpiece <NUM> or other object. Weld angle may be determined by similar visual observations via camera <NUM>/sensor <NUM> as well as via one or more gyroscopes disposed in the weld torch <NUM>. Visual observations via camera <NUM>/sensor <NUM> may also observe if a weld is concave or convex, and measure concavity/convexity thickness, as well as the cross section of a weld area. Likewise, leg size, toe angle, undercut size/shape, weld face metrics, weld throat metrics, mismatch metrics, reinforcement height (e.g., height of bead reinforcement), and/or bead width may be observed and measured, for example, by applying trigonometric calculations. The cameras <NUM>, <NUM> and/or sensors <NUM> described herein may include a variety of sensor embodiments, including infrared sensors, x-rays, ultrasound, and the like. Porosity, for example, may be measured via radiology and/or ultrasound.

The camera <NUM> data processing (e.g., via external systems and/or via the circuitry <NUM> of the AR eyeglasses <NUM>) may include real-time processing suitable for guiding the operator <NUM> during welding activities. For example, if the operator <NUM> is moving the electrode <NUM> too slowly or too quickly, the AR eyeglasses <NUM> may then display, via the image generation system <NUM>, certain animations, icons, warnings, text, and so on, notifying the operator <NUM> of the issue and/or corrective actions to take (e.g., slow down, speed up). The image generation system <NUM> may additionally display workorder information (e.g., type of workpiece <NUM>, welding supplies to use, and so forth), further instructions, notes, and so on. Likewise, the speakers <NUM> may be used to provide audio indications, text-to-speech, and other audio suitable for improving welding operations, such as alarms, alerts, voice guidance, and the like.

In one example, the operator <NUM> may scan a workorder (e.g., workorder barcode) by using the camera(s) <NUM> and/or by using the input system <NUM>. The AR eyeglasses <NUM> may then load certain parameters based on the workorder, such as welding supplies to be used, type of weld to be performed, and/or weld parameters (e.g., concavity/convexity metrics, cross sectional weld area, leg size, toe angle, undercut metrics, weld face metrics, weld throat metrics, mismatch metrics, bead width metrics, reinforcement height metrics, porosity metrics, and so forth). The operator <NUM> may then proceed with the welding operation, with the camera(s) <NUM> capturing image data. The AR eyeglasses <NUM> may then use the internal circuitry <NUM> and/or external systems to derive, via the image data and/or sensor data, a quality of welding. The AR eyeglasses <NUM> may then inform the operator <NUM> of the welding operation quality during and/or after the welding operation. Data captured, such as image data, may be stored in a memory medium of the AR eyeglasses <NUM> and/or external systems (e.g., cloud storage), for example, to certify the weld or for additional data analysis.

The AR eyeglasses <NUM> may be communicatively coupled to a second pair of AR eyeglasses <NUM> worn by a supervisor or trainer. Accordingly, the supervisor or trainer may don the second pair of AR eyeglasses <NUM> and observe the welding or training activities in real-time. Pairing between two or more AR eyeglasses <NUM> may be initiated by the third-party observer (e.g., supervisor), by the welding operator <NUM>, and/or by the "cloud. " For example, the supervisor may don a pair of AR eyeglasses <NUM> and may then request a list of other AR eyeglasses <NUM> that are online. In one embodiment, the list is filtered to only include AR eyeglasses <NUM> located in a given facility or geographic area. The list may additionally be filtered to include only AR eyeglasses <NUM> that the supervisor (or other entity) has access to. The supervisor may then select a desired pair of AR eyeglass <NUM> from the list. In one embodiment, the supervisor may then enter additional security information, such as login information, to complete the pairing and to begin viewing data remotely. To unpair AR eyeglasses <NUM>, either one of the supervisor or operator <NUM> may request to unpair and disconnect via the input system <NUM>, such as through voice command, menus, touches, gestures, and the like.

Voice and/or text feedback may be captured on the supervisor's input system <NUM> and transmitted to the operator <NUM> (and vice versa). Likewise, the AR eyeglasses <NUM> may be communicatively coupled to an external system, such as a cell phone, tablet, computer, notebook, website, cloud-based system, and the like, which may be used by a third party to provide feedback to the operator <NUM> when wearing the AR eyeglasses <NUM>. Further, the AR eyeglasses <NUM> may display, via the image generation system <NUM>, welding manuals, training videos, notes, and so on, useful to operate and/or train on the welding system <NUM>. Additionally, the AR eyeglasses <NUM> may be communicatively coupled to other removable and replaceable AR and/or mediated reality (MR) systems, as described in the more detail below.

<FIG> depicts an embodiment of the helmet system <NUM> having MR eyeglasses <NUM> coupled to a protective welding shell <NUM>. In the depicted embodiment, the MR eyeglasses <NUM> are coupled to the shell <NUM> via headgear assembly <NUM> and eyeglass fastener <NUM>. Unlike the AR eyeglasses <NUM> that may include transparent or semi-transparent lenses, the MR eyeglasses <NUM> view data from an external camera(s) <NUM> mounted on an exterior face of the shell <NUM>, and present the data to the operator <NUM> and/or other users (e.g., supervisors, trainers). Accordingly, the MR eyeglasses <NUM> can present data along the mediated portion of the reality-virtuality continuum because the MR eyeglasses <NUM> may mediate the real environment via the camera(s) <NUM>. For example, when the camera <NUM> is in use, the MR eyeglasses <NUM> may display imaging data (e.g., images, video) transmitted from the camera <NUM> representative of the real world, thus providing for a mediated reality-based imaging. Additionally, the camera <NUM> data may be further processed, for example, by overlaying data (images, text, icons, and the like) on top of the camera <NUM> images to further mediate reality, providing for a mediated or mixed reality view.

Further, the MR eyeglasses <NUM> may provide for an immersive virtual environment, where no camera <NUM> images are presented and instead, all images are computer-generated in real-time. This virtual reality mode of operations may be particularly useful in training situations. For example, a virtual reality "world" may be presented, including virtual representations of the workpiece <NUM>, the power supply <NUM>, the electrode <NUM>, and other components of the system <NUM>. The operator <NUM> may then virtually weld the virtual workpiece <NUM> and receive feedback via the MR eyeglasses <NUM> representative of weld quality during and/or after the virtual welding operation. For example, the MR eyeglasses <NUM> may instruct the operator <NUM> to reposition the electrode <NUM>, to change an angle of the electrode <NUM>, to move the electrode <NUM> faster or slower, to change power supply parameters (e.g., applying more or less current/voltage, and so on. Likewise, alerts, alarms, and other welding parameters may be displayed. Additionally, third party users may provide feedback (voice, text) while viewing the operator's performance during the virtual welding, for example, through external systems such as cell phones, tablets, computers, notebooks, websites, cloud-based systems, through other AR eyeglasses <NUM>, other MR eyeglasses <NUM>, and the like.

In one embodiment, the virtual world may be created based on a scan of a workorder, or via some other input. The virtual world may include a virtual representation of the type of material to be worked on, the welding supplies to be used, the welding equipment (e.g., system <NUM>) to be used, and/or the work environment (e.g., upside down weld, flat weld, and so on). Accordingly, the operator <NUM> may train on a virtual world representative of the system <NUM> and workpiece <NUM> until a desired weld quality is achieved. The operator <NUM> may then switch to an augmented-reality mode, a mediated-reality mode and/or a reality-only mode, and proceed with performing the physical weld. In this manner, a more focused and efficient training environment may be provided, better representing the work about to be performed.

<FIG> additionally shows further details of a portion <NUM> of the shell <NUM> showing an attachment assembly <NUM> of the shell <NUM> suitable for attaching the MR eyeglasses <NUM> when disposed inside of the shell <NUM>. In the depicted embodiment, the MR eyeglasses <NUM> may include a frame <NUM> that may be "slid" or otherwise disposed inside of the attachment assembly <NUM>. An interference fit or force, a magnetic force, a spring-bias force, or a combination thereof, may then provide for a secure attachment between the MR eyeglasses <NUM> and the shell <NUM> via the attachment assembly <NUM>. Accordingly, movements of the head <NUM> may then correspondingly move the shell <NUM>, cameras <NUM>, and MR eyeglasses <NUM> together, thus increasing view fidelity and minimizing view latency. It is to be noted that, in other embodiments, the MR eyeglasses <NUM> may be used with shells <NUM> lacking the attachment assembly <NUM>. It is also to be noted that the attachment assembly <NUM> may be used with the AR eyeglasses <NUM> above as part of the shell <NUM>, to more securely hold the AR eyeglasses <NUM> in place when coupled to the shell <NUM>.

<FIG> shows a perspective view of an embodiment of the MR eyeglasses <NUM>, showing certain features in more detail. Because <FIG> includes like elements to the figures above, the like elements are shown with like element numbers. It is also to be noted that elements of both the AR eyeglasses <NUM> and the MR eyeglasses <NUM> may be used in the other eyeglasses, such as input systems <NUM>, <NUM>, processing systems <NUM>, <NUM>, and the like. In the depicted embodiment, the MR eyeglasses <NUM> include two displays <NUM>. The displays <NUM> may include light emitting diode (LED) displays, organic LED (OLED) displays, liquid-crystal display (LCD) displays, or a combination thereof, suitable for displaying images and/or video. For example, the displays <NUM> may provide for a field of vision (FOV) between <NUM> and <NUM> degrees horizontal at resolutions between <NUM> to <NUM> horizontal and <NUM> to <NUM> vertical at desired aspect ratios (e.g., <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, and so on). Accordingly, an image generation system <NUM> may include circuitry suitable for driving the displays <NUM>. In one example, a processing circuitry <NUM>, for example, in combination with the image generation system <NUM>, may drive images via the displays <NUM> to achieve a latency (e.g., time between head movements and corresponding movement of virtual embodiments displayed) of between <NUM> and <NUM>.

Indeed, an input system <NUM> may track head movement to derive a desired viewing orientation, and thus change the data (e.g., virtual world) on the displays <NUM> accordingly to match the viewing orientation. In this manner, the operator <NUM> may more naturally move the head <NUM> with a correlative change in the view presented by the displays <NUM>. Also shown is a light blockage housing <NUM> suitable for minimizing or eliminating external light sources impinging upon the displays <NUM>, thus presenting more generated light to the operator <NUM>. It is to be noted that the eyeglasses <NUM> and <NUM> may be communicatively coupled to each other. Accordingly, the screens <NUM> may view imaging data (or other data) captured via the AR eyeglasses <NUM>, and the AR eyeglasses <NUM> may display imaging data (or other data) captured via the MR eyeglasses <NUM>.

As mentioned earlier, the cameras <NUM> may capture imaging data for presentation via the displays <NUM> and/or for transmission (e.g., via communications system <NUM>) to external systems for data capture and further analysis, similar to the data capture and analysis described above with respect to the AR eyeglasses <NUM>. Indeed, similar to the AR eyeglasses <NUM>, the camera <NUM> data may be processed to determine, for example, a weld speed, an angle at which the operator <NUM> holds the electrode <NUM>, as well as various weld observations, which, depending on a type of weld (e.g., fillet weld, groove weld, lap weld, plug and slot weld) may include concavity/convexity metrics, cross sectional weld area, leg size, toe angle, undercut metrics, weld face metrics, weld throat metrics, mismatch metrics, bead width metrics, reinforcement height metrics, porosity metrics, and so on, which may be displayed via the image generation system <NUM> in real-time (and transmitted to external systems via system <NUM>). The camera data processing (e.g., via external systems and/or via the internal circuitry <NUM>) may include real-time processing suitable for guiding the operator <NUM> during welding activities. For example, if the operator <NUM> is moving the electrode <NUM> too slowly or too quickly, the MR eyeglasses <NUM> may derive or may receive derivations from external systems, to display, via the image generation system <NUM> certain animations, icons, warnings, text, and so on, notifying the operator <NUM> of the issue and/or corrective actions to take (e.g., slow down, speed up). Likewise, the speakers <NUM> may be used to provide audio indications suitable for improving welding operations, such as alarms, alerts, voice guidance, and the like.

Sensors <NUM> shown in <FIG> and <FIG> may be communicatively coupled to the MR eyeglasses <NUM>, directly or indirectly via another system (e.g., sensor data transmitted via power supply <NUM>) for example, through wireless protocols (e.g., Bluetooth, IEEE <NUM>. 11x [e.g., WiFi], Zigbee, HART, LTE, Z-Wave, WirelessHD, WiGig). As mentioned above, the sensors <NUM> may include sensors <NUM> disposed on the power supply <NUM> (e.g., current and voltage sensors), on or about the workpiece <NUM> (e.g., temperature sensors, optical sensors, x-ray sensors), on the welding helmet shell <NUM>, and on the MR eyeglasses <NUM> themselves (for example to monitor the operator <NUM>). When disposed on the MR eyeglasses <NUM> and/or on (e.g., worn by) the operator <NUM>, the sensors <NUM> may include biometric sensors suitable for detecting, for example, heat stress, heart rate (e.g., via pulse oximetry and the like), and other biometric readings of the operator <NUM>. Accordingly, the operator <NUM> may be monitored, and data relayed to the operator <NUM> (and third parties) relating to heat stress, heart rate, and the like.

As shown in <FIG> in a front view embodiment, the cameras <NUM> may be used in lieu of a filter screen, such as the filter screen <NUM>. The cameras <NUM> may communicate with the MR eyeglasses <NUM>, for example, via wired conduits (e.g., High-Definition Multimedia Interface [HDMI], S-video, video graphics array [VGA], and so on), via wireless protocols, such as Wireless Display (WiDi), Wireless Home Digital Interface (WHDI), Bluetooth, IEEE <NUM>. 11x (e.g., WiFi), and so on). In certain embodiments, the cameras <NUM> may be affixed to the shell <NUM> via external threads disposed on a camera housing and corresponding internal threads disposed on the shell <NUM>, or via other mechanical fastening techniques. In another embodiment, the cameras <NUM> may be magnetically attached to the shell <NUM>. Regardless of the fastening technique used, the cameras <NUM> may be replaceable. Accordingly, the operator <NUM> may select cameras <NUM> for specific operations. For example, higher magnification cameras (e.g., <NUM>-20x magnification) may be selected to view smaller welds. Likewise, cameras having other optical characteristics, such as infrared or near infrared cameras may be used, which may additionally provide temperature data. In certain embodiments, the camera <NUM> types may be mixed. That is, one camera <NUM> may be a standard optical camera while a second camera <NUM> may be an infrared camera.

It is also to be noted that the AR eyeglasses <NUM> and the MR eyeglasses <NUM> may automatically switch into various operation modes (e.g., change functionality) based on, for example, where the eyeglasses <NUM> and <NUM> are disposed. In one example, if the eyeglasses <NUM>, <NUM> are disposed inside of the shells <NUM>, <NUM>, then certain user biometric derivations may be computed, while eyeglasses <NUM>, <NUM>, not disposed in the shells <NUM>, <NUM>, may not derive the user biometrics unless specifically enabled by the user. Likewise, the AR eyeglasses <NUM> and/or the MR eyeglasses <NUM> may enable or disable certain functions based on the type of shells <NUM>, <NUM> that they may be disposed inside of. For example, the shell <NUM> enables light to flow through screen <NUM>, and thus, the AR eyeglasses <NUM> and/or MR eyeglasses <NUM> may enable modes that superimpose data over certain images (e.g., images incoming through screen <NUM>), while when disposed on the shell <NUM>, the AR eyeglasses <NUM> and/or MR eyeglasses <NUM> may enable modes that display data over a larger portion or all of the lenses <NUM> and/or displays <NUM>. Accordingly, the AR eyeglasses <NUM> and the MR eyeglasses <NUM> may automatically adapt to their surroundings.

<FIG> is a perspective view showing an embodiment of the helmet system <NUM> including an AR welding helmet <NUM>, a detachable AR welding shield <NUM> (e.g. welding display system), and a detachable MR welding shield <NUM>. In use, the welding shield <NUM> or <NUM> may be coupled to the helmet <NUM>, for example, to cover an integrated grind shield <NUM> and to provide for AR and/or MR features similar to those provided by the AR and MR eyeglasses <NUM>, <NUM>. For example, in one AR embodiment, the detachable welding shield <NUM> may include the image generation system <NUM> suitable for displaying images viewable by the operator <NUM> and/or a trainer, as an overlay over real world images incoming through a filter screen <NUM>. More specifically, the image generation system <NUM> may include projector systems, prisms, and so on, useful in delivering images viewable by the human eye through the filter screen <NUM>.

In certain embodiments the image generation system <NUM> may additionally or alternatively be disposed in a shell <NUM>. Accordingly, the grind shield <NUM> may display the same or similar data as the AR eyeglasses <NUM> and/or detachable AR welding shield <NUM>. It is to be noted that all of the AR/MR systems <NUM>, <NUM>, <NUM>, <NUM>, <NUM> described herein may be user-configurable. For example, the operator <NUM> may set up the AR/MR systems <NUM>, <NUM>, <NUM>, <NUM>, <NUM> to show only certain types of data (e.g., welding metrics, user biometrics, environmental metrics) and/or alerts and alarms. Accordingly, the AR helmet system <NUM> may be set up by the user to only show data useful during grinding activities, while the AR/MR systems <NUM>, <NUM>, <NUM>, <NUM> may be set up to show welding-related data.

The detachable AR welding shield <NUM> may include one or more cameras <NUM> and the detachable MR welding shield <NUM> may include one or more cameras <NUM>. Likewise, the AR helmet <NUM> may include one or more cameras <NUM> disposed at various locations on the shell <NUM> and/or the grind shield <NUM>. The cameras <NUM>, <NUM>, may be of the same type and may operate in similar fashion as when mounted on the AR eyeglasses <NUM> and the MR eyeglasses <NUM>, respectively. That is, the cameras <NUM>, <NUM> may capture images and/or video of welding operations and/or training activities. The cameras <NUM>, <NUM> (HD camera, SD camera, thermal camera, eddy current camera) The captured images and/or video may then be used, for example, as logging data suitable for certifying a weld quality, and for further analysis. The cameras <NUM> (and <NUM>), may be removable and repositionable on a shield surface <NUM> (e.g., via screw housings, magnetic housings, and the like), and may be communicatively coupled with the processing circuitry <NUM> and image generation system <NUM> via wired or wireless conduits (e.g., High-Definition Multimedia Interface [HDMI], S-video, video graphics array [VGA], and so on), via wireless protocols, such as Wireless Display (WiDi), Wireless Home Digital Interface (WHDI), Bluetooth, IEEE <NUM>. 11x (e.g., WiFi), and so on).

As mentioned earlier, the cameras <NUM> may capture imaging data for transmission to external systems (e.g., via communications system <NUM>) for data capture and further analysis, similar to (or the same as) the data capture and analysis described above with respect to the AR eyeglasses <NUM>. Likewise, the cameras <NUM> may be used for presentation of imaging data via the display(s) <NUM> and/or may capture imaging data for transmission to external systems (e.g., to other users), similar to the data capture and analysis described above with respect to the MR eyeglasses <NUM>. Indeed, similar to the eyeglasses <NUM>, <NUM>, data from the cameras <NUM>, <NUM> may be processed by the processing circuitry <NUM> and <NUM>, respectively, or by external systems (e.g., power supply <NUM>, cloud-based systems, local area network [LAN] workstations/servers, wide area network [WAN] workstation/servers) to determine, for example, a weld speed, an angle at which the operator <NUM> holds the electrode <NUM>, as well as various weld observations, which, depending on a type of weld (e.g., fillet weld, groove weld, lap weld, plug and slot weld) may include concavity/convexity metrics, cross sectional weld area, leg size, toe angle, undercut metrics, weld face metrics, weld throat metrics, mismatch metrics, bead width metrics, reinforcement height metrics, porosity metrics, and so on, which may be displayed in real-time.

The camera data processing (e.g., via external systems and/or via internal systems <NUM>, <NUM>) may include real-time processing suitable for guiding the operator <NUM> during welding activities. For example, if the operator <NUM> is moving the electrode <NUM> too slowly or too quickly, the systems <NUM>, <NUM>, <NUM> may derive or may receive derivations from external systems to display, via circuitry <NUM> certain animations, icons, warnings, text, and so on, notifying the operator <NUM> of the issue and/or corrective actions to take (e.g., slow down, speed up). Likewise, the speakers <NUM> may be used to provide audio indications suitable for improving welding operations, such as alarms, alerts, voice guidance, and the like.

The sensors <NUM> may be communicatively coupled to the systems <NUM>, <NUM>, <NUM>, directly or indirectly via another system (e.g., sensor data transmitted via power supply <NUM>) for example, through wireless protocols (e.g., Bluetooth, IEEE <NUM>. 11x [e.g., WiFi], Zigbee, HART, LTE, Z-Wave, WirelessHD, WiGig). As mentioned above, the sensors <NUM> may include sensors <NUM> disposed on the power supply <NUM> (e.g., current and voltage sensors), on or about the workpiece <NUM> (e.g., temperature sensors, optical sensors, x-ray sensors), on the systems <NUM>, <NUM>, <NUM>, themselves (for example to monitor the operator <NUM>). When disposed on the systems <NUM>, <NUM>, <NUM>, and/or on (e.g., worn by) the operator <NUM>, the sensors <NUM> may include biometric sensors suitable for detecting, for example, heat stress, heart rate (e.g., via pulse oximetry and the like), and other biometric readings of the operator <NUM>. Accordingly, the operator <NUM> may be monitored, and data relayed to the operator <NUM> (and third parties) relating to heat stress, heart rate, and the like.

Embodiments of the AR safety eyeglasses <NUM> and/or the MR safety eyeglasses <NUM> (e.g., welding display systems <NUM>, <NUM>) may securely coupled to a variety of protective equipment, including a protective face shield <NUM> (e.g., protective shell <NUM>), shown in one embodiment in <FIG>. Indeed, when the protective face shield <NUM> is selected, the user may then select the AR safety eyeglasses <NUM>, the MR safety eyeglasses <NUM>, or other safety glasses, and position the selected eyeglasses over the opening <NUM> to add enhanced protection. Various fastening techniques may be used to fasten the AR safety eyeglasses <NUM> and the MR safety eyeglasses <NUM> to the protective face shield <NUM>. For example, an interference or friction fit between portions of the AR safety eyeglasses <NUM> (or portions of the MR safety eyeglasses <NUM>) and the protective face shield <NUM> may securely couple the eyeglasses <NUM>, <NUM> to the protective face shield <NUM>. Additionally or alternatively, latches, Velcro™, clips, and so on, may be used to secure the AR safety eyeglasses <NUM> and the MR safety eyeglasses <NUM> to the protective face shield <NUM>.

It is to be noted that the protective face shield <NUM> may, in certain embodiments, include extra batteries <NUM> useful for providing additional power to the AR safety eyeglasses <NUM> and the MR safety eyeglasses <NUM>. Indeed, the protective face shield <NUM> may be operatively coupled to the AR safety eyeglasses <NUM> and the MR safety eyeglasses <NUM> to provide either extra electrical power via batteries <NUM> and/or extra processing power via one or more processors <NUM>. Accordingly, detachable electrical connectors, such as magnetic connectors, pin-based connectors, and so on, may be used to electrically couple the protective face shield <NUM> to the AR safety eyeglasses <NUM> and the MR safety eyeglasses <NUM>.

Claim 1:
A welding helmet system (<NUM>), comprising:
- a protective shell (<NUM>, <NUM>, <NUM>); and
- a welding display system configured to be coupled to the protective shell (<NUM>, <NUM>, <NUM>), wherein the welding display system is configured to:
- receive data from a sensor (<NUM>); and
- display a welding metric derived from the sensor (<NUM>),
characterized in that
the welding display system is configured to be removably positioned on an interior portion (<NUM>) of the protective shell (<NUM>, <NUM>) or inside the protective shell (<NUM>, <NUM>, <NUM>), and wherein the welding display system comprises augmented reality eyeglasses (<NUM>) or mediated reality eyeglasses (<NUM>) which automatically switch into various operation modes based on where the eyeglasses (<NUM>, <NUM>) are disposed.