KR20190013601A - Welding helmet configuration providing real-time fume exposure warning capability - Google Patents

Abstract

The present invention relates to welding helmets, systems and kits capable of monitoring and warning fume exposure in real time during arc welding. A welding helmet constituted to protect a head of a user in welding comprises an intelligent warning device, and an air sampling pickup and output port. The air sampling pickup and output port is connected to an adjacent end part of the air sampling tube which makes sampling of respirable air within the welding helmet and the remote end part of the air sampling tube is connected to an air sampling inlet port of an external aerosol monitoring device. The intelligent warning device receives air sample output data from the aerosol monitoring device in order to generate warning data and/or warning signals based on predetermined exposure level limit and/or operation modes of exposure warning, and communicates with the aerosol monitoring device to process the air sample output data.

Description

[0001] WELDING HELMET CONFIGURATION PROVIDING REAL-TIME FUME EXPOSURE WARNING CAPABILITY [0002]

Cross-reference to related application

This application is a continuation-in-part of U.S. Patent Application Serial No. 15 / 281,784 filed on September 30, 2016, which is a continuation-in-part of U.S. Patent Application Serial No. 13 / 106,525, filed May 12, The disclosures of which are incorporated herein by reference.

Technical field

Certain embodiments relate to the monitoring of fumes during the welding process. More particularly, certain embodiments relate to a welding helmet, method and kit that provide real-time fume exposure monitoring and alerting capabilities.

During the welding process (e.g., an arc welding process), when drilled by a welder, contaminants such as fumes, which can be harmful to the welder, can be generated. In many welding situations (especially indoor situations), ventilation equipment is used to draw and eject fumes. However, from time to time, ventilation equipment may be unsuitable for a particular welding process or scenario, or the ventilation equipment may not be properly set by the welder or properly used. Since safety and health regulations tend to be performance based, compliance with industrial hygiene standards depends on having actual workplace exposure decisions made by qualified industrial hygienists. Current practice is to perform a full shift duty monitoring where the sampling device is placed on the operator to filter and collect representative samples of contaminants present in the operator's respiratory tract. The goal is then to obtain a time weighted average concentration of 8 hours that can be compared to an acceptable level in the regulation. However, as it is often necessary to send samples to an approved laboratory for analysis several times, results can not be obtained until several weeks after the sampling event.

Additional limitations and disadvantages of the conventional, conventional and proposed approaches will be apparent to those skilled in the art from a comparison of such approaches with embodiments of the present invention presented in the remainder of the present application with reference to the drawings.

Welding helmets, systems and kits that provide real-time fume exposure monitoring and warning capabilities during an arc welding process are disclosed herein. A welding helmet configured to protect a user's head during the welding process is configured to have an intelligent warning device and an air sampling pickup and output port. The air sampling pick-up and output port is connected to the proximal end of the air sampling tube sampling breathable air in the welding helmet and the distal end of the air sampling tube is connected to the air sampling inlet port of the external aerosol monitoring device. The intelligent alarm device receives air sample output data from an aerosol monitoring device to generate alert data and / or alert signals based on preset exposure level settings and / or exposure alert operating modes, and processes air sample output data To communicate with the aerosol monitoring device. As a result, the welder and / or supervisor of the welder, for example, can easily be informed of any unacceptable exposure to the welder during the welding process, before any significant damage can occur to the welder. Such helmets, systems and kits can be used as powerful everyday tools for both managing workplace exposure and better understanding.

These and other features of the claimed invention as well as details of the illustrated embodiments of the claimed invention will be more fully understood from the following description and drawings.

Figure 1 is an illustration of a first exemplary embodiment of a welding helmet that provides real-time fume exposure warning capability during the welding process.
Figure 2 is an illustration of a second exemplary embodiment of a welding helmet that provides real-time fume exposure warning capability during the welding process.
3 is an illustration of a first embodiment of a system for providing real-time fume exposure monitoring and alerting capability using the welding helmet of FIG. 1 (or alternatively, the welding helmet of FIG. 2) during the welding process.
4 is a functional block diagram of the system of FIG. 3 showing the functional elements of a first embodiment of the intelligent warning device IWA of the welding helmet of FIG. 1 (or the welding helmet 200 of FIG. 2).
5 is an illustration of a second embodiment of a system for providing real-time fume exposure monitoring and warning capability using a slightly modified embodiment of a welding helmet during a welding process.
Figure 6 is a functional block diagram of the system of Figure 5 showing the functional elements of the IWA of the welding helmet of Figure 5;

Embodiments of the present invention are directed to welding helmets, systems and kits that provide real-time fume exposure monitoring and warning capabilities during an arc welding process. According to certain embodiments of the present invention, such capability is provided at least partially in a welding helmet that is worn by a user performing a welding process.

As used herein, the term " integrated " refers to being located on, being physically integral, or being attached (with or without the ability to be unattached). As used herein, the term " real time " means that a welder and / or a supervisor of a welder, for example, can easily and unambiguously expose any unacceptable exposure to a welder during the welding process before any significant damage can occur to the welder Communication, and processing of air sample output data during the welding process so as to be notified. As used herein, the term " aerosol " means a system of particles dispersed in a gas (e.g., solid fumes or smoke particles dispersed in air).

Details of various embodiments of the present invention are described herein below with respect to Figures 1-6. FIG. 1 is an illustration of a first exemplary embodiment of a welding helmet 100 that provides real-time fume exposure warning capability during the welding process. The welding helmet 100 includes a welding head gear 110 configured to be worn on the head of the welder to protect the welder during the welding process. The welding helmet 100 also includes an intelligent warning device (IWA) 120 that is integrated with the welding head gear 110. The IWA 120 is configured to communicatively interface with the EAM device to receive air sample output data from an external aerosol monitoring (EAM) device. IWA 120 generates alert information and other environmental status information in response to receiving air sample output data from the EAM device. Details of the interaction of the IWA 120 and the EAM device are described herein below.

In the embodiment of FIG. 1, the IWA 120 is located on the exterior of the helmet 100. According to certain embodiments of the present invention, the IWA 120 may be fixed on the welding head gear 110, or may be attachable to and detachable from the welding head gear 110. The IWA 120 includes a user interface 121, a communications input port 122 (e.g., a USB port), a radio frequency (RF) antenna 123, and an alarm or alert device 124. These elements of the IWA 120 are described in more detail below. In accordance with an alternative embodiment of the present invention, the alert device 124 may be separate from the IWA 120 and may be integrated elsewhere within or on the helmet 100. In such an alternative embodiment, IWA 120 may activate alerting device 124 in a wired or wireless manner.

The welding helmet 100 further includes an air sampling pick-up and output port (ASPOP) 130 that is integrated with the welding head gear 110. The ASPOP 130 is configured to be connected to the proximal end of the air sampling tube for sampling or collecting breathable air within the welding head gear 110 and for funneling the sampled air away from the head gear 110 . The distal end of the air sampling tube is attached to the EAM device as discussed herein below. As used herein, the term " breathable air " refers to a sample of air that represents the air being breathed by a welder while wearing the helmet 100. Although the ASPOP 130 is shown near the front end of the welding head gear 110 in Figure 1, the ASPOP 130 can be positioned almost anywhere on the welding head gear 110 (e.g., toward the rear end of the welding head gear 110) ).

2 is an illustration of a second exemplary embodiment of a welding helmet 200 that provides real-time fume exposure warning capability during the welding process. The welding helmet 200 of FIG. 2 is similar to the welding helmet 100 of FIG. However, the welding helmet 200 includes an IWA 120 that is substantially integrated on the interior of the welding head gear 110, as shown by the dashed lines of the IWA 120 in FIG. However, the user interface 121, the communication input port 122 and the RF antenna 123 are still accessible from the outside of the welding head gear 110. The alarm or warning alert device 124 is on the inside of the welding head gear 110. In the embodiment of FIG. 2, most of the IWA 120 is protected by being integrated within the weld headgear 110.

3 illustrates a first embodiment of a system 300 that provides real-time fume exposure monitoring and alerting capabilities using the welding helmet 100 of FIG. 1 (or alternatively, the welding helmet 200 of FIG. 2) It is an example. In addition to the welding helmet 100, the system 300 includes an external aerosol monitoring (EAM) device 310 external to the helmet 100. The EAM device 310 is configured to determine the concentration of one or more contaminants in the sampled respirable air and to generate associated air sample output data. For example, the EAM device 310 may be a laser photometric device. Examples of such laser photometer devices are SIDEPAK (TM) devices manufactured by TSI, Inc. The system 300 may further include a belt or harness (not shown) to hold the EAM device 310 while the belt or harness is worn by the user.

The system 300 also includes a communications cable 320 (e.g., a USB cable) that connects the communications input port 122 of the IWA 120 with the data output port 311 of the EAM device 310. During operation, the EAM device 310 transmits air sample output data to the IWA 120 via the communication cable 320. Both EAM device 310 and IWA 120 may be powered by, for example, a battery or a rechargeable power source enclosure. Alternatively, the EAM device 310 and / or the IWA 120 may be powered by, for example, an AC adapter plugged into a power outlet, or an auxiliary power source of a welding power supply or wire feeder.

The system 300 further includes an air sampling tube 330. The air sampling tube 330 may be a durable, heat-resistant, flexible plastic tube, according to one embodiment of the present invention. One end of the tube 330 is connected to the ASPOP 130 on the helmet 100. The other end of the tube 330 is connected to an air sampling inlet port 312 on the EAM device 310. The EAM device 310 can send respirable air to the EAM device 310 for analysis via the helmet 100, through the ASPOP 130, through the tube 330, through the air sampling inlet port 312, And a pump (not shown) for generating a vacuum to be drawn out. According to one embodiment of the present invention, the communication cable 320 and the air sampling tube 330 work together as a harness to provide a " clear " design implementation. In such an embodiment, the air sampling inlet port 312 and the data output port 311 may be relatively close together on the EAM device 310. Likewise, the communication input port 122 and the ASPOP 130 may be relatively close together on the headgear 110.

During operation of the system 300, as the EAM device 310 draws breathable air from the helmet 100, the EAM device 310 may determine the particle mass (e. G., Through aerosol counting) in the sampled air Analyze the sampled breathable air to determine the concentration. According to one embodiment of the present invention, the EAM device 310 is a laser photometric device capable of determining a real-time aerosol mass concentration and a time weighted average (TWA) aerosol mass concentration over longer periods, Can be distinguished.

Mass concentrations determined by EAM device 310 are transmitted to IWA 120 via communication cable 320 as air sample output data for processing and analysis. Other types or types of air sample output data may also be generated by the EAM 310 and transmitted to the IWA 120 in accordance with various embodiments of the present invention. For example, EAM device 310 may generate and record historical exposure data over time or even through multiple welding process periods.

The various elements of the system 300 of FIG. 3 (welding helmet, EAM device, IWA, air sampling tube, telecommunication cable and harness) are assembled by the user for ease and ease of use, As shown in FIG.

4 is a functional block diagram of the system 300 of FIG. 3 showing the functional elements of the first embodiment of the IWA 120 of the welding helmet 100 (or the welding helmet 200 of FIG. 2) of FIG. As can be seen in FIG. 4, the IWA 120 includes an RF transmitter 126 connected to the processor 125 and the RF antenna 123. The processor 125 is operatively connected to an RF transmitter 126, a user interface 121, and an alarm or alerting device 124. According to various embodiments of the present invention, the processor 125 may be a software-programmable microprocessor, a digital signal processor, a microcontroller, or a processor 125 that may be configured or programmed to provide the processing functionality described herein for the processor 125 Or any other processing device or chip. The processor 125 also operatively interfaces to the EAM device 310 via the communication cable 320 to receive air sample output data.

Processor 125 processes the air sample output data and generates exposure alert data and information. Exposure warning data and information may include boundary alert data indicating when certain predetermined exposure level limits are being exceeded, as well as other data and information including, for example, pollutant concentration level history and run time averaging data .

The user interface 121 may be, for example, a touch sensitive display, or a combination of switches and / or buttons. Other types of user interfaces are also possible. In one embodiment, the user interface is used by a welder to set one or more exposure level settings. The exposure level setpoint is a value that is compared by the processor 125 to the air sample output data (or the processed version of the air sample output data). The air sample output data represents the concentration of one or more contaminants in the sampled respirable air. The user may, for example, rely on the standard maximum fume exposure guidelines (MFEG) to determine appropriate exposure level settings for a particular welding procedure.

If the processor 125 determines that the concentration of the contaminant has been exceeded (i.e., determines that a warning condition has occurred), then the processor 125 may then send an alert signal 124 to activate the alert device 124 to alert the user Lt; / RTI > The alert device 124 may be an audible alarm device, a visual alert device, or a combination of the two, according to various embodiments of the present invention. Other types of alert devices are also possible, such as, for example, a vibration alert device. According to an alternative embodiment of the present invention, the alert device 124 may be separate from the helmet 100 and activated wirelessly by the IWA 120 of the helmet 100. Moreover, if the welding helmet is of a type having an internal display that can be seen by the welder, the warning information from the IWA 120 can be displayed on the internal display.

In another embodiment, the user interface is used by a welder to select a predefined warning operating mode. The predetermined warning mode of operation is the mode of operation of the system 300 that is programmed or configured with the processor 125 to correlate with a particular welding process and contaminants that may be generated as part of that particular welding process. Certain predetermined warning operating modes include preset exposure level settings, and possibly other parameters and / or actuating algorithms corresponding to a particular welding procedure. The predefined warning mode of operation is designed to keep the welder informed and safe for contaminant exposure during such a particular welding process (e.g., through boundary alerts).

According to one embodiment of the present invention, RF transmitter 126 receives alert data and information from processor 125 and sends alert data and information to an external alert station (not shown). The external warning station may be, for example, a personal computer running an exposure software application in an office immediately outside the factory work environment. The external alerting station may be staffed by the weld supervisor to track the exposure levels of one or more welders currently working in the welding environment.

In accordance with another embodiment of the present invention, the RF transmitter 126 may be operatively coupled to the processor 125 to turn off or shut down the welding power source, for example, when the processor determines that the pollutant levels are approaching dangerous or dangerous levels And transmits the associated command messages or signals to the welding power source 376 that is currently being operated on by the user of the system 300. [ Likewise, the RF transmitter 126 may be operable to vent the ventilation system to change the operating state of the ventilation system (e.g., to increase the fan speed of the ventilation system) if the processor determines that the pollutant levels are approaching dangerous or dangerous levels And send associated command messages or signals to the system.

The ventilation system may be for the entire work environment (e.g., a room in a factory or a factory) or may be specific to an individual welder (e.g., a PAPR attached to a welding helmet 100 ) 360). For illustrative purposes, a circuit connection PAPR system 360 is schematically illustrated in Fig. As shown, the PAPR system 360 includes a controller 362, a fan 364, and a battery 366. Such a fan 364 draws air through the inlet 368 and discharges air through a hose 370 that is connected to the helmet 100. The controller 362 is operatively connected to the fan 364 to control the operation (e.g., speed) of the fan 364 based on the received input. In the embodiment of FIG. 4, the input is received from a circuit connection connection from processor 125 of IWA 120. Battery 366 provides power to fan 364 and controller 362.

For large ventilation systems, the RF transmitter 126 may send command messages or signals to the controller such that the ventilation system automatically changes the fan speed or other characteristics of the ventilation system. Likewise, the RF transmitter 126 may send command messages or signals to the controller 362 to cause the PAPR system 360 to automatically change the fan speed or other characteristics of the PAPR system 360. In the case of PAPR systems 360 located on or near a user and / or connected to a welding helmet 100, the PAPR system 360 is in communication with a PAPR system 360 (RF receiver / transceiver of a PAPR system 360 not shown) The use of the RF transmitter 126 may be replaced by a circuit connection connection as shown in FIG.

For large ventilation or PAPR systems 360, the fan 364 may operate at multiple speeds. For example, a high rate can be used when the pollutant exposure is above the threshold, and a low rate can be used when the pollutant exposure is below the threshold. Thus, based on the exposure information generated by the processor 125 of the IWA 120, the processor 125 determines whether to transmit a signal to transmit or decrease the signal to increase the fan speed to an appropriate level for the determined exposure Can be determined. The threshold used to determine the fan speed may be different from the threshold used to determine the alarm condition and the processor may utilize a different threshold for each of the different types of airborne contaminants. The thresholds may be set in the user interface 121 of the IWA 120. The user interface 121 of the IWA 120 may serve as a user interface of the ventilation system to enable direct control of the fan or other characteristics of the system from the IWA 120. [

In the case of PAPR systems 360, the fan 364 is often powered by a battery 366 or other limited power source. Thus, controlling the fan speed to an appropriate level based on the determined exposure results in more efficient power consumption. For example, when the exposure is low, the fan does not need to operate at a high speed, and therefore power consumption can be reduced by keeping the fan at a low speed.

While the state of the ventilation or PAPR systems may be altered by changing the fan speed, any other characteristic of the systems may be altered in a similar manner to increase the efficiency of the system.

The PAPR fan 364 may be manually activated, for example, by a switch on the PAPR system 360. The PAPR system 360 may be configured to automatically activate the fan 364. [ For example, the PAPR fan 364 can be automatically activated when the welding helmet 100 or headgear is moved to a lowered position for protection during welding at an elevated position (where the helmet does not cover the user's face) . The PAPR fan 364 may be automatically deactivated when the helmet 100 or the headgear is moved from the lowered position to the raised position. The welding helmet 100 may include a position switch 372 or other sensor for determining movements of the helmet between the raised position and the lowered position. The position switch 372 is coupled to the processor 125 or to the IWA 120 in the IWA 120 communicatively coupled to the controller 362 at the PAPR system 360 to notify the PAPR system of the current position of the welding helmet 100. [ And may provide signals to other processors in the helmet 100. Based on the current position of the welding helmet 100, the controller 362 in the PAPR system 360 can automatically activate or deactivate the fan 364 to activate the fan when needed.

Like the position switch 372, the welding helmet 100 may include an arc sensor 374 that activates the PAPR fan 364. When an arc welding operation is initiated and an arc is to occur between the welding torch and the workpiece, the arc sensor 374 will generate a signal that can be communicated to the controller 362 in the PAPR system 360. When an arc is detected, the controller 362 can automatically activate the PAPR fan 364 if the PAPR fan 364 is not yet operating. The PAPR fan 364 may be deactivated when the arc is no longer sensed by the arc sensor 374 or the fan may remain in operation until the welding helmet 100 is raised or manually switched off .

At least one of the welding helmet 100, the IWA 120, the EAM 310 and the PAPR system 360 may be communicatively interfaced with the welding power source 376 and / or the wire feeder 378. The welding power supply 376 generates welding waveforms for performing the welding operation and the wire feeder 378 supplies the welding electrodes of the consumables to a welding torch (not shown) used to perform the welding operation. The welding power source 376 or the wire feeder 378 may communicate with the PAPR system 360 (or with the PAPR system such as the IWA 120) that the torch trigger signal has been received from the welding torch by the welding power source Device). Similar to fan operations based on the arc sensor 374, the PAPR system 360 can automatically activate the fan 364 when the torch trigger signal is received by the welding power source.

The wire feeder 378 will typically be located near the operator, and thus also close to the PAPR system 360. [ In certain embodiments, the PAPR system 360 may be operatively connected to the wire feeder 378 to charge the PAPR battery 366 by a wire feeder. Wire feeder 378 may include a charging output that provides charging power to PAPR system 360 and provides a suitable electrical connection.

The welding helmet 100 may include a camera 380 that captures images of the welding environment. In certain embodiments, the camera 380 may be part of an augmented reality welding system constructed with a welding helmet 100. The processor 125 at the IWA 120 or another processor at the welding helmet 100 may receive images captured by the camera 380 and analyze the images to determine the presence or absence of fumes during the welding operation have. Based on the presence, quantity, or other characteristics of the fumes in the captured images, the PAPR system 360 may be signaled to increase or decrease the fan speed to an appropriate level.

The operations of the welding power source 376 may be controlled based on the presence of air samples output data from the EAM 310 or fumes in images captured by the camera 380. For example, the welding power (e.g., current or voltage) may be reduced based on the fume or contaminant level, or a command may be issued to cause the welding power source 376 to stop the welding operation. The operations of the welding power supply 376 may be controlled based on the charge level of the battery 366 in the PAPR system 360. [ For example, the welding power source 376 may be commanded to interrupt the welding operation when the charge level of the battery 366 drops below a predetermined level. The abort command may originate directly from another device, such as the PAPR system 360 or IWA 120, or the battery charge level may be communicated to the welding power source 376 for comparison to a predetermined level by the welding power source .

In accordance with other embodiments of the present invention, the RF transmitter 126 may be replaced by some other type of wireless communication device, such as, for example, an infrared transmitter or a sound wave transmitter. Other types of wireless communication devices may also be possible. Thus, the external warning station, the welding power source, and the ventilation system will be configured to communicate with such alternative wireless communication devices.

5 is an illustration of a second embodiment of a system 500 that provides real-time fume exposure monitoring and alerting capabilities using a slightly modified embodiment of the welding helmet 510 during the welding process. In the system 500 of FIG. 5, the communication between the second embodiment of the EAM device and the second embodiment of the IWA is performed via radio means. The EAM device 530 of Figure 5 does not have a data output port 311 and instead has an RF antenna 531 that transmits air sample output data to the IWA 520 of Figure 5. Similarly, the IWA 520 of FIG. 5 does not have a communication input port 122 and instead has an RF antenna 123 that receives air sample output data from the EAM device 530. According to alternative embodiments of the present invention, other radio means for communicating air sample output data from the EAM device to the IWA may comprise infrared means, sound wave means or some other radio means.

FIG. 6 is a functional block diagram of the system 500 of FIG. 5 illustrating the functional components of the IWA 520 of the welding helmet 510 of FIG. The EAM device 530 includes an RF transmitter 620 operatively connected to an RF antenna 531. The RF transmitter 620 functions to transmit air sample output data to the IWA 520 via the RF antenna 531. The IWA 520 may include an RF transceiver 126 that is operative to receive air sample output data via the RF antenna 123 and to send air sample output data to the processor 125 for processing and analysis, (610).

The RF transceiver 610 also receives alert data and information from the processor 125 and functions to send alert data and information to an external alert station (not shown). The external alerting station may be, for example, a mobile device executing an exposure software application. The external warning station may be worn by an industrial hygienist who checks the welding work environment at the factory to determine whether the exposure levels experienced by one or more welders currently working in the welding work environment meet current industry standards .

Furthermore, the RF transceiver 610 may receive warning data (e. G., Data) from the processor 125 to turn off or shut down the welding power source, for example, when the processor 125 determines that the pollutant levels are approaching dangerous or dangerous levels And to transmit the associated command messages or signals to a welding power source (not shown) that is currently operating by a user of the system 500. Likewise, if the RF transceiver 610 determines that the processor 125 is approaching dangerous or dangerous levels of pollutant levels, the RF transceiver 610 may be configured to control the ventilation (e.g., to increase the fan speed of the ventilation system) May transmit associated command messages or signals to a ventilation system (not shown) to change the operating state of the system. According to other embodiments of the present invention, the RF transceiver 610 may be replaced by some other type of wireless communication device, such as, for example, an infrared transceiver or a sonic transceiver. Other types of wireless communication devices may also be possible. Thus, the external warning station, the welding power source, and the ventilation system will be configured to communicate with such alternative wireless communication devices.

According to one embodiment of the present invention, the IWA is configured to generate and / or analyze hysteresis data. For example, the IWA may receive historical exposure data in the form of air sample output data from the EAM device and process and analyze the hysteresis exposure data to generate statistical exposure parameters for the IWA 520. The IWA 520 may include an RF transceiver 126 that is operative to receive air sample output data via the RF antenna 123 and to send air sample output data to the processor 125 for processing and analysis, (610).

The RF transceiver 610 also receives alert data and information from the processor 125 and functions to send alert data and information to an external alert station (not shown). The external alerting station may be, for example, a mobile device executing an exposure software application. The external warning station may be worn by an industrial hygienist who checks the welding work environment at the factory to determine whether the exposure levels experienced by one or more welders currently working in the welding work environment meet current industry standards .

Furthermore, the RF transceiver 610 may receive warning data (e. G., Data) from the processor 125 to turn off or shut down the welding power source, for example, when the processor 125 determines that the pollutant levels are approaching dangerous or dangerous levels And to transmit the associated command messages or signals to a welding power source (not shown) that is currently operating by a user of the system 500. Likewise, if the RF transceiver 610 determines that the processor 125 is approaching dangerous or dangerous levels of pollutant levels (e.g., to increase the fan speed of the ventilation system) And transmit associated command messages or signals to a ventilation system (not shown)

According to other embodiments of the present invention, the RF transceiver 610 may be replaced by some other type of wireless communication device, such as, for example, an infrared transceiver or a sonic transceiver. Other types of wireless communication devices may also be possible. Thus, the external warning station, the welding power source, and the ventilation system will be configured to communicate with such alternative wireless communication devices.

According to one embodiment of the present invention, the IWA is configured to generate and / or analyze hysteresis data. For example, the IWA receives historical exposure data from the EAM device in the form of air sample output data and processes the hysteresis exposure data to generate statistical exposure parameters and trend data in the form of exposure alert data and information Can be analyzed. Such statistical exposure parameters and trend data can provide great insight to the industrial hygienist for environmental operations of the plant or plant (e.g., through a full eight-hour shift, or through a whole week).

In short, an embodiment of the present invention includes a welding helmet that provides real-time fume exposure alert capability. The welding helmet includes a welding head gear configured to be worn on the user's head to protect the user during the welding process. The welding helmet further includes an intelligent warning device that is integrated with the welding head gear and is configured to communicatively interface with an external aerosol monitoring device to receive air sample output data from an external aerosol monitoring device. The welding helmet also includes an air sampling pick-up and output port that is integrated with the welding head gear and is configured to be connected to the proximal end of the air sampling tube sampling the breathable air in the welding head gear. The distal end of the air sampling tube is configured to be connected to an air sampling inlet port of an external aerosol monitoring device. The intelligent alarm device includes a processor configured to process air sample output data received from an external aerosol monitoring device to generate at least alert data. The intelligent alarm device may also include a user interface operatively connected to the processor and configured to enable the user to set at least one exposure level setting and / or to select an alert operating mode from a plurality of predefined alert operating modes have. The intelligent alarm device may further include a wireless communication device operatively connected to the processor and configured to at least receive alert data from the processor and wirelessly transmit alert data to the external alert station at least. The intelligent alarm device may include a wireless communication device operatively connected to the processor and configured to wirelessly receive air sample output data from an external aerosol monitoring device and may include a wireless communication device configured to operatively shut down the welding power in response to alert data, As shown in FIG. The intelligent alarm device may further include an alert device or alert device operatively connected to the processor and configured to issue an alert upon receipt of an alert signal from the processor. According to an alternative embodiment of the present invention, the alert or boundary alert device is not part of the intelligent alert device and instead operatively interfaces the intelligent alert device to receive an activation alert signal from the intelligent alert device.

Another embodiment of the present invention includes a kit that provides real-time weld fume exposure monitoring and alerting capabilities. The kit includes a welding helmet having an air sampling pick-up and output port integrated with the welding helmet. The helmet is configured to be worn on the head of the user of the kit to protect the user during the welding process. The kit further includes an aerosol monitoring device configured to have air sampling inlet ports and to generate air sample output data. The kit also includes an intelligent alarm device configured to communicate with the aerosol monitoring device in a communicative manner and to generate at least warning data in response to the air sample output data. The intelligent warning device may be physically integrated with the welding helmet, or it may be possible to attach to and separate from the welding helmet. The kit further includes an air sampling tube having a proximal end and a distal end. The air sampling tube is configured to operatively match the air sampling pick-up and output port of the welding helmet at the proximal end of the air sampling tube and is operatively associated with the air sampling inlet port of the aerosol monitoring device at the distal end of the air sampling tube . The kit may further comprise a communication cable having a proximal end and a distal end. The communication cable is configured to operatively match the communication input port of the intelligent alarm device at the proximal end of the communication cable. The communication cable is also configured to operatively match the data output port of the aerosol monitoring device at the distal end of the communication cable. Alternatively, the communication cable facilitates wired communication from the aerosol monitoring device to the intelligent alarm device. The intelligent alarm device and the aerosol monitoring device can be configured to communicate with each other wirelessly. The intelligent alert device may include wireless communication capabilities configured to send alert information generated by the intelligent alert device to an external alert station. The intelligent alarm device may be configured to communicatively interface with the external ventilation system to effect a change in the operating state of the external ventilation system in response to the alert data. The intelligent warning device may be configured to communicatively interface with the welding power source to operatively shut down the welding power source in response to the warning data. The intelligent alarm device may include a user interface configured to enable a user to set at least one exposure level setting and / or to select a warning operation mode from a plurality of predefined alert operation modes. The intelligent alarm device may include an alert device or a border alert device configured to be activated when the alert condition is determined by the intelligent alarm device. According to an alternative embodiment of the present invention, the alarm or boundary alarm device is not part of the intelligent alarm device, but instead operatively interfaces the intelligent alarm device to receive an activation alert condition signal from the intelligent alarm device. The kit may further include a harness or belt to hold the aerosol monitoring device while the harness or belt is worn by the user.

A further embodiment of the present invention includes a system for providing real-time fume exposure monitoring and alerting capabilities. The system includes means for protecting the user's head during the welding process, means for monitoring breathable air samples originating from means for protecting to generate air sample output data, and means for monitoring the air sample output data And processing means. The system further includes means for communicating air sample output data from the means for monitoring to the means for processing. The system may include means for generating a boundary alarm or an alarm in response to the warning data. The system may further comprise means for the user to set at least one exposure level setting and means for the user to select an alert operating mode from a plurality of predetermined alert operating modes. The system may include means for communicating alert data to an external alert station, and means for bringing about a change in the operating state of the external ventilation system in response to the alert data. The system may further comprise means for shutting down the welding power supply in response to the warning data, and means for maintaining means for monitoring on the user.

Although the claimed subject matter of the present application has been described with reference to specific embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the claimed subject matter. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the claimed subject matter without departing from the scope of the claimed subject matter. It is, therefore, intended that the claimed subject matter is not limited to the specific embodiments disclosed, but that the claimed subject matter will include all embodiments falling within the scope of the appended claims.

Claims (20)

A welding head gear configured to be worn on a user's head to protect a user during a welding process; And
An intelligent warning device integrated with the welding head gear, the intelligent warning device being configured to communicatively interface with an external aerosol monitoring device to receive air sample output data from an external aerosol monitoring device,
Wherein the intelligent warning device comprises a user interface operatively connected to the processor and configured to enable the user to select an alert operating mode from a plurality of predetermined alert operating modes, Wherein the helmet system correlates each of the specific welding processes by including parameter values specific to the particular welding processes. The method according to claim 1,
(PAPR) comprising an air hose connected to the welding head gear and a fan for transferring air to the welding head gear through the air hose. 3. The method of claim 2,
Wherein the intelligent alarm device is configured to communicate with the PAPR and to control the fan operating speed of the fan. 3. The method of claim 2,
The fan automatically activates when the welding head gear is moved from the raised position to the lowered position. 3. The method of claim 2,
Wherein the fan automatically deactivates when the welding head gear is moved from a lowered position to an elevated position. 3. The method of claim 2,
Said welding head gear comprising an arc sensor, said fan automatically activating when an arc is detected by said arc sensor. 3. The method of claim 2,
Wherein the PAPR comprises a battery supplying power to the fan and the PAPR is operatively connected to a wire feeder to charge the battery by a wire feeder. 3. The method of claim 2,
Wherein the helmet system is configured to communicatively interface with a welding power source. 9. The method of claim 8,
Wherein the PAPR comprises a battery that powers the fan and wherein the helmet system is configured to send a weld stop command to the welding power source based on a charge level of the battery. 9. The method of claim 8,
Wherein the PAPR comprises a battery that powers the fan and the helmet system is configured to transmit battery charge level information to the welding power source. 9. The method of claim 8,
Wherein the helmet system is configured to transmit a power output adjustment command to the welding power source. 9. The method of claim 8,
Wherein the fan automatically activates based on a torch trigger signal received by the welding power source. A helmet configured to be worn on the user's head to protect the user;
An external aerosol monitoring device operatively coupled to the helmet; And
And an intelligent alarm device configured to communicatively interface with the external aerosol monitoring device to receive air sample output data from the external aerosol monitoring device,
Wherein the intelligent alert device comprises a user interface operatively connected to the processor and configured to enable the user to select an alert operating mode from a plurality of predetermined alert operating modes, Each correlating to specific welding processes by including parameter values specific to particular welding processes. 14. The method of claim 13,
(PAPR) comprising an air hose connected to the helmet and a fan for delivering air to the helmet through the air hose. 15. The method of claim 14,
Wherein the intelligent alarm device is configured to communicate with the PAPR and to control the fan operating speed of the fan. 15. The method of claim 14,
The fan automatically activates when the helmet is moved from the raised position to the lowered position. 15. The method of claim 14,
Wherein the fan automatically deactivates when the helmet is moved from a lowered position to an elevated position. 15. The method of claim 14,
Wherein the helmet comprises an arc sensor and the fan automatically activates when an arc is detected by the arc sensor. 15. The method of claim 14,
Further comprising a wire feeder, wherein the PAPR includes a battery that powers the fan, and wherein the PAPR is operatively connected to the wire feeder to charge the battery by the wire feeder. 15. The method of claim 14,
Further comprising a welding power source, wherein at least one of the helmet, the external aerosol monitoring device, the intelligent warning device, and the PAPR communicates with the welding power source.

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