Journal of Intelligent & Robotic Systems

, Volume 59, Issue 3–4, pp 283–298 | Cite as

Real-Time Seam Tracking Technology of Welding Robot with Visual Sensing



A seam tracking system with visual sensing free from calibration was developed for the robot applied in gas tungsten arc welding. A visual sensor with double-layer filter system was researched for the different levels of the welding current. An image processing in C+ + language was developed to extract the seam trajectory and the offset of the torch to the seam in the welding images of aluminum alloys plates with grooves. The rectifying rule of the robot used in this paper was found based on the experimental data, and the seam tracking controller was also analyzed and constructed. The experimental results on straight line seam and curve seam demonstrated the efficiency of the proposal seam tracking system.


Visual sensing Real time Seam tracking Welding robot 


Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.


  1. 1.
    Yu, J-Y., Na, S-J.: A study on vision sensors for seam tracking of height-varying weldment, part 1: mathematical model. Mechatronics 7(7), 599–612 (1997)CrossRefGoogle Scholar
  2. 2.
    Yu, J-Y., Na, S-J.: A study on vision sensors for seam tracking of height-varying weldment, part 2: applications. Mechatronics 8(1), 21–36 (1998)CrossRefGoogle Scholar
  3. 3.
    Bauchspiess, A., Absi Alfaro, S.C., Dobrzanski, L.A.: Predictive sensor guided robotic manipulators in automated welding cells. J. Mater. Process. Technol. 109, 13–19 (2001)CrossRefGoogle Scholar
  4. 4.
    Smith, J.S., Balfour, C.: Real-time top-face vision based control of weld pool size. Ind. Rob. 32(4), 334–340 (2005)CrossRefGoogle Scholar
  5. 5.
    Zhou, L., Lin, T., Chen, S.B.: Autonomous acquisition of seam coordinates for arc welding robot based on visual servoing. J. Intell. Robot. Syst. 47, 239–255 (2006)CrossRefGoogle Scholar
  6. 6.
  7. 7.
    Lee, S.K., Na, S.J.: A study on automatic seam tracking in pulsed laser edge welding by using a vision sensor without an auxiliary light source. J. Manuf. Syst. 21(4), 302–315 (2002)CrossRefGoogle Scholar
  8. 8.
    Kim, J.S., Son, Y.T., Cho, H.S., Koh, K.I.: A robust method for vision-based seam tracking in robotic arc welding. Mechatronics 6(2), 141–163 (1996)CrossRefGoogle Scholar
  9. 9.
    Kuo, H-C., Wu, L-J.: An image tracking system for welded seams using fuzzy logic. J. Mater. Process. Technol. 120(1), 169–185 (2000)CrossRefGoogle Scholar
  10. 10.
    Bae, K.Y., Lee, T.H., Ahn, K.C.: An optical sensing system for seam tracking and weld pool control in gas metal arc welding of steel pipe. J. Mater. Process. Technol. 120(2), 458–465 (2002)CrossRefGoogle Scholar
  11. 11.
    Ge, J., Zhu, Z., He, D., Chen, L.: A vision-based algorithm for seam detection in a PAW process for large-diameter stainless steel pipes. Int. J. Adv. Manuf. Technol. 26(10), 1006–1011 (2005)CrossRefGoogle Scholar
  12. 12.
  13. 13.
    Yamane, S., Kaneko, Y., Kitahara, N., Ohshima, K., Yamamoto, M.: Neural network and fuzzy control of weld pool with welding robot. In: Ind. Appl. Soc. Annu. Meet. Conf. Rec. 1993, IEEE, vol. 3, pp. 2175–2180 (1993)Google Scholar
  14. 14.
    Zhao, D.B., Chen, S.B., Wu, L., Dai, M., Chen, Q.: Intelligent control for the shape of the weld pool in pulsed GTAW with filler metal. Weld. J. 80(11), 253–260 (2001)Google Scholar
  15. 15.
    Smith, J.S., Lucas, J.: Vision-based seam tracker for butt-plate TIG welding. J. Phys., E Sci. Instrum. 22(9), 739–744 (1989)CrossRefGoogle Scholar
  16. 16.
    Luo, H.: Robotic welding, intelligence and automation, laser visual sensing and process control in robotic arc welding of titanium alloys. LNCIS 299, 110–122 (2004)Google Scholar
  17. 17.
  18. 18.
    Lee, S.K., Chang, W.S., Yoo, W.S., Na, S.J.: A study on a vision sensor based laser welding system for bellows. J. Manuf. Syst. 19(4), 249–255 (2007)CrossRefGoogle Scholar
  19. 19.
  20. 20.
  21. 21.

Copyright information

© Springer Science+Business Media B.V. 2010

Authors and Affiliations

  • Hongyuan Shen
    • 1
  • Tao Lin
    • 1
  • Shanben Chen
    • 1
  • Laiping Li
    • 2
  1. 1.Institute of Welding EngineeringShanghai Jiao Tong UniversityShanghaiPeople’s Republic of China
  2. 2.Shanghai Spaceflight Precision Machinery Research InstituteShanghaiPeople’s Republic of China

Personalised recommendations