Why use a laser weld seam tracking?
Pain Points:
- Incoming workpiece dimensional tolerances.
- Workman assembly clearance tolerances.
- Positioner accuracy tolerances.
- Thermal deformation during welding.
- Fixture wear.
Advantages:
- Reduced teaching time and lower labor costs.
- Enables high-speed welding and improves welding efficiency.
- Reduce material waste, improving production efficiency.
What is Laser Weld Tracking
- A laser weld seam tracker is an industrial automation device integrating laser technology, computer vision, and automatic control algorithms.
- The core function of laser weld seam tracking is to identify the position, shape, and dynamic offset of the weld seam in real time through non-contact optical detection, dynamically correcting the welding torch trajectory and welding parameters to ensure that the welding torch is always precisely aligned with the weld seam center.
- Laser weld seam tracking is a core piece of equipment that solves pain points in the welding process, such as “weld misalignment,” “thermal deformation,” and “assembly errors.”
- Laser weld seam tracking equips welding equipment (robots, welding machines, etc.) with an “intelligent vision system,” achieving high-precision automated welding through a closed-loop mechanism of “real-time detection – data processing – dynamic correction,” improving weld seam consistency, reducing defect rates, and increasing production efficiency.
Weld tracking uses characteristics：
- laser sensor technology and intelligent algorithms to achieve real-time monitoring and precise tracking of welds.
- High precision, measurement accuracy can reach ±0.01mm.
- Strong anti-interference ability, high-temperature resistance.
- Fast speed, high sampling frequency.
- Reduce labor and improve production efficiency.
- Ensure uniformity and consistency of welds.
components of a laser weld seam tracker
| SN | Name | Functions |
| 1 | Semiconductor lasers | It emits a laser beam that generates a specific lighting pattern in the weld area. |
| 2 | CCD cameras | It captures images in the laser-scanning area, providing raw information for data processing. |
| 3 | Laser protective lenses | It protects the laser and camera from spatter and high temperatures generated during welding. |
| 4 | Splash guards | It provides a physical barrier to further block welding spatter and protect the equipment. |
| 5 | Air cooling systems | It provides cooling for the laser and camera, maintaining stable operation of the equipment in high-temperature environments. |
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The working principle steps of a laser weld seam tracking sensor are as follows:
| SN | Device | Function | Description |
| 1 | Seam tracker | Laser Emission and Scanning | The sensor emits a linear laser beam, which illuminates the weld seam surface at a certain angle, forming a laser contour. |
| 2 | Seam tracker | Image Acquisition | The CCD or CMOS sensor captures the reflected image of the laser contour on the workpiece surface. |
| 3 | Computer | Image Processing and Analysis | The controller processes the acquired image, using algorithms to deduce the geometric parameters of the weld seam, such as position, width, and height. |
| 4 | Computer | Deviation Calculation | The system calculates the deviation between the welding torch and the actual weld seam position. |
| 5 | Robot | Real-Time Correction | The deviation data is sent to the motion actuator, which adjusts the welding torch trajectory in real time to ensure accurate tracking of the weld seam. |
Types of Weld Seam Tracker
Supports multiple welding types
Wide Range of Compatible Brands
Compatible with protocols for nearly 40 mainstream robot brands.
Including ABB, Borunte, Canopy, Yaskawa, Estun, EFORT, FANUC, GCU, Kawasaki, KUKA, OTC, Panasonic Qianjiang, Erbid, Siasun, etc.
Fewer Workers Needed
The combination of robotic laser welding machines and weld tracking technology can minimize the number of workers required, not only ensuring the accuracy and consistency of welding, but also effectively reducing enterprise costs.
Wide material adaptability
Laser weld tracking systems use optical sensors to detect weld positions.
Ideal for laser-reflective materials, they excel at welding ferrous/non-ferrous metals (carbon steel, low alloy steel, stainless steel, aluminum alloys) with high precision and real-time adjustments, solving common issues like material deformation and uneven seams.
Our Customer Application Case of Weld Tracking System
This robotic laser welding cell integrates a laser seam weld tracking system designed to monitor the weld seam in real time and make immediate adjustments to compensate for any deviations.
By continuously monitoring the weld joint in real time, the system assists the robot in maintaining precise alignment of the welding torch, thereby enhancing welding consistency and minimizing the need for rework caused by workpiece variations or thermal deformation.
This undoubtedly serves as a practical and viable solution for automated welding applications—such as sheet metal processing, structural component manufacturing, and various other scenarios—that demand exceptionally high standards of quality stability and production efficiency.
More about weld tracking
- Weld Tracking vs Traditional Welding Solutions
- seam weld example
- How weld tracking works
| Comparison Factor | Weld Tracking | Manual Welding | Mechanical Contact Tracking |
| Accuracy | ±0.01–0.1mm | ±0.5mm+ | ±0.1–0.3mm |
| Efficiency | High | Low | Medium |
| Workpiece Impact | Non-contact (no surface damage) | Risk of uneven seams/scratches | Contact-based (may scratch/indent) |
| Adaptability | Handles complex seams, thermal deformation, and positional errors | Only simple, low-volume welds | Limited by workpiece hardness/shape |
| Cost (Long-Term) | Lower | High | Medium |
| Ideal Use Case | High-precision, automated production | Small-batch, low-complexity welding | Basic industrial welding |
- Set up Teaching Point to get the best welding result.
- Record welding distance, posture, power, and Speed.
- Making the Tool TCP according to the best distance.
- Making Laser Sensor Calibration according to TCP.
- Making a verification program to test the Calibration.
- Making Component Saturion if the Calibration produces an error.
- Test Laser Scanner welding.
- Digitalization and integration
High integration with production systems, enabling data sharing and automated control.
- Compensation for various tolerances
By adjusting welding parameters in real time, the accuracy of the welding process is ensured, welding quality is steadily improved, and welding errors are reduced.
- Real-time communication with the system
Real-time exchange of data and instructions ensures information synchronization during the welding process.
- Achieve consistent and reproducible results
Achieve precise control of welding parameters to ensure consistency in the welding process.
- Simplify programming tasks
Automatic path planning and parameter setting improve efficiency and reduce manual intervention.
- Welding Quality Defects
- Weld Misalignment: Assembly errors and thermal deformation cause the welding torch to deviate from the joint, resulting in incomplete penetration/incomplete fusion.
- Defect Rate Soars
- Appearance Does Not Meet Standards
Do you face the following challenges in automated welding?
- Challenge 1: Deviations in workpiece cutting, assembly, and manual clamping? Deviations at each step lead to inaccurate dimensions, poor assembly, and affect overall process quality and progress, requiring strict fixture assistance.
- Challenge 2: Numerous weld seams and repeated modification points result in a large programming workload? Multiple and complex weld seams lead to complex, time-consuming, and labor-intensive programming, increasing manual workload and reducing work efficiency.
- Challenge 3: Inability to monitor production quality during the welding process? Quality problems arising during welding cannot be accurately controlled online in real time, easily leading to re-inspection.
Solution:
Our weld seam tracking product, based on embedded sensors and employing artificial intelligence algorithms, helps achieve intelligent and flexible welding. It not only solves the problem of difficult observation and monitoring during welding equipment operation but also improves the reliability of the welding system.
- Intelligent recognition technology;
- Dynamic parameter adjustment;
- Multisensor collaborative.
- Response speed；
- Tracking precision；
- Environmental adaptability.
- Sensor maintenance;
- Parameters calibration;
- System linkage debugging.