Above: Trends in helmet design include weight reduction and streamlining.
High-end welding helmets offer advanced fit and function
February 2019 - Welders are demanding light, comfortable headgear that helps make them more productive, and newer designs for welding helmets are moving away from “big, square and bulky” to meet these needs, says Guy Shelverton, global product manager for equipment accessories and personal protective equipment (PPE) at ESAB Welding & Cutting Products.
“We see the main trends in weight reduction and streamlining the design itself,” Shelverton notes. “We are trying to save weight by using lighter materials where possible—without compromising performance.” And, he says, that although decals on helmets are still popular, “the sharp and tactical look seems to be growing in demand.”
Precision fit
ESAB’s Sentinel helmet reflects this trend. It has a sleek shell design that can account for a range of different head sizes and a flush exterior that minimizes extrusions so that the helmet won’t smack into surrounding objects when working in tight spaces, like between an industrial boiler and a wall.
The helmet’s trademarked ergonomic five-point Halo headgear “increases comfort by spreading the load over different pressure points on the head,” says Shelverton, and is adjustable for a custom fit.
Many welding helmets have only three points of contact: a headband with a ratchet mechanism to adjust the band diameter, padding for the forehead and the back of the head, and a band that goes over the top of the head. Combining all the possibilities for adjustment, helmets with three points of contact offer about 100,000 combinations. Next-generation helmets with the five-point headgear offer more than 500,000 possible options.
“A comfortable welder is a more productive welder,” Shelverton says. “The headgear has five harness straps to spread the weight evenly across the head, helping to reduce pressure points that can lead to headaches. It is also adjustable in multiple places—moreso than the average helmet—and this means that no matter the size of the head, the headgear can be made to fit.”
Minimize adjustments
Although welders want their fit to be highly adjustable, they don’t want to be constantly fiddling with their display. The Sentinel has a high-performance auto-darkening filter (ADF) with true color definition, giving workers better visibility in a variety of conditions. ADFs have sensors on the helmet that detect the welding arc and darken the lens automatically, eliminating the need to lift and lower the helmet to set up the weld. True color perception helps operators better “read” the weld puddle and the heat-affected zone. The shade also features a “grind mode,” which is activated by holding a button on the side of the helmet for two seconds; it fixes the shade of lens so that operators can grind without the sparks activating the sensors and causing the lens to darken to a welding shade.
“In the past, users regularly switching between welding and grinding would have had to switch between a welding helmet and grinding screen, or on some helmets, they would have had to take the helmet off to activate the grind mode. With the Sentinel, they can easily and quickly switch between the two, which ultimately increases productivity, saves time and reduces waste,” Shelverton says.
Finally, an upgrade to the standard analog buttons “offers a simple and intuitive operation” for Sentinel users. The helmet features a full-color LCD touchscreen panel, similar to the screen on a smartphone, and “the user manual should not be needed, unlike other complex ADF helmets on the market with clunky analog panels,” he says.
Making PPE easier to use is at the core of ESAB’s R&D efforts, Shelverton says. “All of our products are designed with the voice of the customer in mind: Every feature or functionality is there based on a want and need from the end users of the products.” That includes features to improve comfort or balance “to simple things like spare parts list in the inside of the shell.”
ESAB Welding & Cutting Products
Annapolis Junction, Maryland
800/372-2123
