Automatic Filtering Goggle for Welding is Protective Goggle, Which Can

8/14/2019 Automatic Filtering Goggle for Welding is Protective Goggle, Which Can

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Abstract

Automatic filtering goggle for welding is protective goggle, which can be used to

protect eyes of welder from sharp light rays while welding specially in electrical arc

welding. This goggle becomes black when actual welding procedure takes place and

as soon as welding is stopped it gets transparent. It is a original design through

operator can see the job directly without removing goggle. The arcs associated with

arc welding emit high levels of ultraviolet radiation (UVR), and this often causes

acute injuries in the workplace, particularly photo era to conjunctivitis. It is important

to know the level of UVR emitted by arc welding under various conditions, as this

information will help in evaluating potential UVR hazards in welding workplaces and

taking protective measures against it. In this study, the ACGIH effective irradiance

for UVR was measured experimentally for CO2 arc welding in order to evaluate its

UVR hazards. A welding robot was used in the experiment in order to realize

reproducible and consistent welding operations. The UVR from CO2 arc welding is

actually hazardous for the eye and skin. It was found that the effective irradiance is

inversely proportional to the square of the distance from the arc is strongly dependent

on the direction of emission from the arc with a maximum at 5060 from the plate

surface, and tends to increase with welding current.

SCOE, Mechanical Engineering 2009-10- 1 -


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1. Introduction

In practices two type of concepts generation research occurs. First is termed as need

research. In need research emphasis is upon identifying sufficed needs that exist in

market. Second is termed concept identification ion is to be carried

Automatic filtering goggle for welding can be termed as needs research. In industries,

worker has to remove goggles when inspection is to be carried out after welding has

taken place. It introduces fatigue both in hands and eyes. Also nonproductive time (like

removing goggles) increases, which reduces profit of industry. Thus need is to reduce

fatigue and minimization of non-productive time.

Skin cancer is linked to excessive exposure to ultraviolet radiation(UVR). It is the

most common cancer, and the World Health Organization has reported that excessive

solar UVR exposure results in 60,000 premature deaths per year worldwide.

Exposure to solar ultraviolet radiation (UVR) is an occupational health and safety issue

for outdoor workers since excessive exposure is associated with negative health

outcomes, including eye conditions and skin cancers

The term filter usually refers to glasses used in optical systems, to either

transistor prevent transmission of specific wavelengths. The term absorber is usually

reserved for glasses which are used for controlling light to provide protection fromdamage to humans, for example, for eye protection, as in sunglasses, or welder and laser

goggles, or to materials exposed to light.

In welding practice, welding goggles is essential from safety point of view.

Operators need to be protected from hazardous rays, spatters, hot slag particles. Also he

should protect himself from falling when welding at a height from ground. Also these

goggles increase the fatigue because operator has to remove goggles to inspect the job

after taking small cuts. This wearing and removing activities increases fatigue and non-

productive time, which is considerable, point for profit orientated industries.

1.1 Existing arc welding equipments:-



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Arc welding power source i.e. AC & DC., Welding cable, Electrode holder Ground

clamp, Welding electrode ,Welding helmet, hand shield, Hand gloves.

Hand shield and helmets are protecting devices used in arc welding for shielding and

protecting the face and neck of the operator .A hand shield or helmet consist of Face

shield: which is made up of fiber and is formed in a shape of cover front half of head. An

opening at the level of eyes. To provide visibility. It contents three components The first

is expensive good grade of colored are welding filter lens that removes 99.5% of infrared

rays and 99.75% ultraviolet rays. Next to welding lens is another lance of double strength

glass and is used to protect the inner welding lens from metal spatter.

A clear lens is put on the face side of the helmet to protect welding lens.

1.2 About new product development:

Survival for fittest is now become important for organization. After carefully regimenting

the market, choosing target customers, identifying their needs and determining market

positioning, companies go for product development.

Generally new product is categorized into four categories.

New to the world products: These are new product, which create entirely new

market

New product lines: These are new product, which allowed company to hit anestablished market for first time.

Addition to existing product lines: These products are added to list of already

existing products.

Improvement and revision of exiting product performance: These are instrument

in providing an improved product performance.

1.3 Towards product development:

Idea generation:



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Searching for ideas is first step in the new product development process.

Customers scientists, competitors employees, channel members and top

management are the sources for new product ideas. According to traditional

marketing concepts customers are best choice to start the ideas search.

Idea screening:

Ideas are generally divided into three categories i.e. promising ideas, marginal

ideas and rejects. Among this marginal once are sent for full-scale screening. The

main objective of screening is to drop poor ideas as soon as possible.

Concept development:

A product idea can be defined as a possible product, which the company might

thin of the market. A product concept is an extended version of the ideas

expressed in meaningful consumer terms. Consumers do not by product ideas but

they only buy product concepts. An idea can be termed into several concepts.

Marketers need to know who end user of the product is. What value addition does

the product provide?

Concept testing

In this stage concept is presented to the relevant customers and their feedbacks is

sought. The closer the actual product is to the tested concepts, the more realistic

will be the feedback.

Development to Commercialization

After clearing the development stages company requires huge financial

investment for making the product. At this stage company has fair idea regarding

commercial feasibility of the product. Quality function deployment methods are

necessary to translate target customer requirement into a working prototype it is

useful to covert desired customer attributes into engineering attributes

2. MARKET SURVEY



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Generally market research has following objectives.

It tells the future of existing products and the products yet to be introduced in to

the market.

It studied market potential and market shear.

It explores new market and help developing new product.

It analysis user characteristics, attitudes and opinions with particular emphasis on

any shift in market composition or personal preferences.

It provides technical information about its functional characteristics.

Market survey is the systematic design, collection and analysis and reporting of

data and finding that are relevant to different marketing situations. During new

product development process, a concept is formed but it cannot be developed fully

into a product. At this stage marketing survey is helpful to provide guidance. So as to

how concept might be improved and refine. The bead geometry that characterizes the

quality of the weld is dependent on a number of input process parameters. These

parameters are closely coupled in such a way that it is difficult to identify the extent

of contribution of these factors toward the desired output. An expert welder from his

experience of trial and error selects a set of parameters that may yield fairly good

results. However, the obtained result may not be the optimal one. The trial and error

of the welder can be avoided, if a suitable mathematical model can be developed,

which could forecast the output from a set of desired parameters or vice-versa.[2].


Define problems and

research objective


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Fig.1 Steps for Market Survey And Analysis

Need of Analysis:

Defining the problem and the research objective

It is first step toward finding a solution or launching a research study. Which focuses on

understanding the nature and limits of a question? The research objective is useful to state

what information is needed to solve the problem. To move to next step of designing the

research refinement of a board indefinite problem into a precise, researchable statement is

essential.

Developing the research plan:

Once a problem is identified and research objective is clearly stated, next step is to

prepare a plan for getting the information needed for research. Research technique is a

reliable one if it produces almost identical result in successive repeated tricks. It is valid


Develop the research

plan

Collection the

information

Analyze the

information

Present the

information


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3 Need Analysis: Safety Goggles of Welding

Problem Definition:

In welding practice, welding goggles is essential from safety point of view. Operators

need to be protected from hazardous rays, spatters, hot slag particles. Also he should

protect himself from falling when welding at a height from ground. Also these goggles

increase the fatigue because operator has to remove goggle to inspect the job after taking

small cuts. This wearing and removing activities increases fatigue and non-productive

time, which is considerable, point for profit-oriented industries. Hence the basic problem

is to minimize the fatigue and to increase productivity of operator.

.Development of plan:

After determining the research objective, brainstorming was carried out to develop the

research plan. During brainstorming session various aspects of welding were listed down.

In which various hazards faced by operator, variety of products, expected advancements

in product, economy of product were focused.

.Data collection

To collect the data related to welding goggles, various survey were carried for

multivariable analysis. As questionnaire is the most commonly used tool to collect

primary data, also it is simple and flexible. So it was used to collect the data.

Questionnaires:

To collect the data related to welding goggles various questionnaire were prepared. In

questionnaires for pre-design users study, various observations like workers standard

practices, any vision aspect due to welding, efficient use of welding equipments etc. were

studies.

Fact finding:

After collecting information with the help of suitable questionnaires following facts



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are found.



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Fig-6 Market Shear Of Different Types Of Goggle

Fig.7 Hazards Faced By Operator

Type 1: Full Dark Type 3 : White Glass

Type 2: Medium Dark Type 4 : Screen.

Fig. 8



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Summery :

After analyzing various facts and recording information following results concluded.

In section is done by frequently removing goggles.

Most of the operator use type 3 goggles, as they are low in cost.

Through type 3 goggles are not safe it covers major shares of market.

Also new product has grater market potential, as it reduces fatigue level of operator.

4 Automatic Filtering Safety Goggles

4.1 Electrode Holder:

It is used to hold the electrode and direct it for welding in a few designed electrode holder

one adaptive pressure switch is installed to control the action of LCD glass in goggle. The

switch is mounted on the holder in lower side related to position of four fingers. It will

operate with nominal pressure of finger.

Fig. 9 Electrode Holder



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4.2 Adaptive Pressure Switch

Adaptive Pressure Switch is mounted on electrode holder considering ergonomics. These

switches are used while welding to control just the on and off function of Goggle LCD.

The fig shows adaptive pressure switch.

Fig. 10 Adaptive Pressure Switch

Feature of Adaptive Pressure switch: Accommodate wide range of action and can be categorized to the physical action

required to activate to activate them.

Responsive across their entire surface.

They provide clear tactile.

Available in various sizes.



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4.3 LCD Glass:

This is filtering glass when we supply electronic signal (3v) then liquid molecules in

glass are arranged in such a way that they can make resistance for light passing through

it. When electric current is disconnected the liquid molecules in glass again comes to

original position and light can pass through it duty i.e. glass become transparent.

Single-domain Nematic liquid crystal (LC) devices based on either the

polarization-rotation or the bi re fringent effect or both are investigated for reflective

spatial light modulators (SLMs). We evaluate each LC mode in terms of its contrast ratio,

optical efficiency, operating voltage and its tolerance in cell-gap. We study the hybrid-

aligned, the 0-, 45- and 63.6-twisted Nematic LC modes which can be operated in either

normally white (NW) or normally black (NB) mode. We also include the mixed twisted

Nematic and self-compensated Twist Nematic modes for NW and the tilted home tropic

mode for NB. Two-dimensional simulations have been carried out to compare with

experimental observation for one of the NB modes implemented in active matrix

reflective SLMs to elucidate the effect of fringe-fields. To improve the optical efficiency,

we also study polarization-independent LC phase gratings using patterned alignment for

reflective SLMs. The basic equations for the diffracted and non-diffracted intensities for

both the reverse-twist and orthogonal-twist two-domain LC phase gratings have beenderived. The device parameters, the operating voltage and the optical diffraction

efficiency are given for various cases with a twist angle equal to or less than 90 0.



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FIG.11 Operation of LCD 900 twisted

FIG.12 L.C. Aligns with Electric Field

Basic of LCD Operation:

LCDs use a type of liquid called Twisted Nematic (TN). Super Twisted

Nematic(STN)Liquid Crystal material offers a highest twist angle (>=2000 vs

900 ) that provide higher contrast and a better viewing angle. The most recent advance has

been the introduction of Film to compensated Super Twisted Nematic(FSTN) displays.

This adds a relation film to the STN display that compensates for color added by the

birefringence effect. This allows a black and white display to be produced.

See fig . Below to see a visual of the molecules alignment

Fig.13 Liquid Crystal Molecules



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4.4 RECHARAGEBLE BATTERY:

LITHIUM Manganese Lithium Rechargeable

These super compact lithium secondary batteries feature a new configuration in which a

manganese compound oxide is used for the positive electrode, and a lithium/ aluminum

alloy for the electrode. (MT Type).

Fig. 14 Rechargeable Battery

Technical data table:

Technical data Type 1- Manganese Lithium Rechargeable (ML)

Modal No.

Nominal

Voltage

(V)

Nominal

Capacity

(mAh)

Dimension

(mm)

External Height

Diameter

Basic

Battery

Weight

(g)

Continuous

Drain

(Ma)

ML2020 3 200.0 20.2 2.0 2.2. 0.10

* Nominal capacity shown is based on standard drain and cut off voltage drawn to 2.0V

at 200C



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Features of battery:

Charge at voltages even under 3v

Larger capacity for hour- after-hour back up

Excellent withstand voltage, overcharge and over discharge withstanding

characteristics.

4.5 WORKING OF PRODUCT

While welding operator will hold electrode holder with his four fingers on adaptive

pressure switch. As soon as he start welding he will grip firmly and exert a little pressure

on switch and the switch will close the circuit and LCD become black, filtering the light

rays emitted from the arc. When operator stops welding and want to inspect the job he

will release his four finger and switch will get off. As current in circuit is off LCD glass

become transparent and operator can inspect the job through LCD glass. For welding he

will grip the electrode holder against and LCD glass will get black. In this way operator

can inspect the job without removing goggle. Following figure illustrate the above



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procedure.

Fig. 15 Before Welding Process



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Fig.16 After Welding Process

5. Conclusion:

This concept tell about need of analysis technique, to find out problem and line of

operation using proper technique. Problems of welding goggles, i.e. what are the different

problems during welding? Accordingly developing their plan from collected data. Which

is flexible using different component like Electrode Holder, Adaptive Pressure Switch,

LCD Glasses etc.

which gives :-

It reduces the fatigue of operator up to very high extend and provide comfort and safety.

It will reduce the non productive time of operator hence increases the speed of welding

procedure. As it reduces fatigue of operator productivity of operator will increase. It will

helpful to weld in night by adjusting darkness of goggle.

References:



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1.Gunaraj and Murugan, 2000b V. Gunaraj and N. Murugan, Prediction and

optimization of weld bead volume for the submerged arc processPart 2,Welding

Journal78 (2000),pp.331s338s.(2)

2.Ignacio Moreno, Noureddine Bennis, Jeffrey A. Davis, Carlos Ferreira Twist angle

determination in liquid crystal displays by location of local adiabatic pointsOptics

Communications Volume 158, Issues 1-6, 15 December 1998,Pages 231-238 (4.3)

3. Forrest, K.Y., Cali, J.M., Cavill WJ, 2008. Use of protective eyewear inU.S. adults:

results from the 2002 national health interview survey. Ophthalmic. Epidemiol. 15.

3741.

4. Fea, A., Bosone, A., Rolle, T., Grignolo, F.M., 2008. Eye injuries in an Italian

urban population: report of 10620 cases admitted to an eye emergency

department in Torino. 1. Graefes Arch. Clin. Exp. Ophthalmol. 246.

5.World Health Organization. Ultraviolet radiation: global solar UV index. An

educational tool to reduce risks of skin cancer and cataract. Fact sheet # 271.

Geneva: World Health Organization; 2002.

6.Statistics New Zealand. New Zealand population clock. Available from: www.

stats.govt.nz/people/population/default.htm. Gawkrodger DJ. Occupational skin cancers.

Occup Med 2004;54:45863.

7.Agrawal GP (2002) Fiber Optic Communication Systems,3rd edn. New York: John

Wiley & Sons Inc.

8.Basch B, Gringeri S, Goudreault R and Ravinkumar S (2002) Evolution of the

photonic core within metropolitan and regional networks. NFOEC. Technical

Proceedings. Green PE (1993) Fiber Optic Networks. Upper Saddle River, NJ: Prentice

Hall.

9.Ramaswami R and Sivarajan KN (2002) Optical Networks: A Practical Perspective,

2nd edn. San Francisco, CA: Morgan Kaufmann Publishers

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Annex -I

GOGGLE MODEL



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Annex-II

Annex-III



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PRE-DESIGN----USERS STUDY

Name of operator : __________________________________________________

Location of W/S : ___________________________________________________

Experience : ___________________________________________________

Types of worker

Average Slow Fast Qualified

Is he following standard practices?

Yes No

Is he using safety equipment effectively & adequately?

No If Yes Occasionally Regularly

Is he experiencing some strain on eyes welding?

No Yes If Yes Severe Sometimes Very little

Any eye problem or vision defect due to occupation of welding?

Is he uses any Eye-Drop or Medicine?

No YesHand movement observed:________________________________________________

How he is gripping welding electrode holder:_________________________________

Length of Welding:______________________________________________________

Length of pause : ________________________________________________________

Date

Place Signature

Annex-IV



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PRODUCT SURVEY

Name of shop/ firm:___________________________________________________

Address:____________________________________________________________

Contents Type 1 Type 2 Type 3 Type 4

Specification

Color

Quality

Durability

LifeSafety

Standards

Who buy

Cost

Aesthetic

Degreeof

comfort

Manufacturer

More salable

Your

recommendation

Any more

reason

SCOE, Mechanical Engineering 2009-1024

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Automatic Filtering Goggle for Welding is Protective Goggle, Which Can