|
Inconsistent fixturing or material edge variation can throw a MIG seamer off track, leading to incomplete fusion, rework, scrap, and inconsistent weld quality. Camera-based seam tracking gives manufacturers a way to monitor the weld joint in real time, keep the torch aligned, and reduce the need for operators to manually correct the process during an active weld.
The hidden cost of seam drift
Integrating a weld camera vision system with active seam tracking on a MIG seamer directly addresses one of the most persistent sources of process variability: joint deviation during continuous welding. When the arc drifts off the intended path, the result is often inconsistent bead geometry, less predictable penetration, and a tighter quality window that is harder to maintain over a full production run. For operations teams, that can mean more rework, more scrap, and more variation from one weld to the next.
Trying to spot and correct torch position while welding is difficult, especially when the process is moving continuously. It also keeps operators close to the arc zone, where they are exposed to spatter, UV radiation, and fume generation.
Seam tracking removes that burden by continuously monitoring the weld joint in real time, reducing the need for manual intervention while improving consistency.
A smarter way to track the seam using the Xiris NIR camera system and Xiris SeamMonitor
Xiris Seam Monitor software’s analytical approach to tools requires sufficient background information and contrast. While most offerings include supplementary lighting to assist the user with setup and alignment, this lighting provides no meaningful performance while welding due to arc intensity.
That is why the XVC-750T and XLP-850: Xiris NIR camera system is recommended for most Seam Monitor applications. The XLP-850 is a pulsed LED synchronized with the camera’s exposure and frame acquisition timing, which provides stable illumination from frame to frame.
This consistent illumination creates the contrast needed to clearly define key areas of the image, especially at the seam. During setup, the seam is clearly visible before arc ignition. During welding, synchronized LED pulsing helps maintain consistent image contrast, so the operator does not need to adjust tracking settings between phases.
Figure 1: XVC-750T camera view during setup mode scene illuminated by the XLP-850 pulsed LED, showing seam contrast before arc ignition.
|
 Figure 2: XVC-750T camera view during welding mode— arc intensity managed by XLP-850 synchronized LED pulsing, maintaining consistent image contrast. |
SeamMonitor software uses this contrast differential to automate seam tracking. The weld groove offers a natural advantage because the illumination creates a stable reference that helps the software detect and follow the seam accurately throughout the weld pass.
For pulsed applications and transfer methods such as single pulse, double pulse, spray transfer, and CMT, a Xiris Trigger Kit may be required to stabilize arc intensity in the image.
Figure 3: Seam Monitor real-time tracking overlay: Detection bounding boxes and seam centerline (blue) illustrate how the contrast differential at the weld groove is used to detect and follow the seam position throughout the weld pass.Control Options for Seam Tracking: Manual or Closed-Loop Feedback
The Seam Monitor software can support both manual adjustment and full closed-loop integration. For manual use, it provides a real-time operator dashboard that shows results during the weld.
Figure 4: Xiris Seam Monitor operator dashboard
For automated correction, Seam Monitor can be integrated into automated welding processes through the following communication protocols to help correct seam and torch misalignment:
- OPC-UA
- Modbus TCP/IP
- Beckhoff TwinCAT ADS
- Analog Output Module
More than one Application
Other than applying the SeamMonitor for longitudinal or straight MIG seamers, the same software and camera combination can also be used in broader welding applications. It can detect tungsten electrodes for TIG applications, and where analytical detectors are not effective, AI Key point models can detect weld head features such as MIG wire, tungsten electrodes, plasma shield cap or arc, and seam characteristics. That gives the system flexibility beyond one specific process or joint geometry.
The Result: More Consistent Welds
Camera-based seam tracking with the Xiris XVC-750T & XLP-850 and The SeamMonitor improves weld quality and operator safety on MIG seamer applications by maintaining consistent torch-to-seam alignment and reducing the need for manual intervention. Whether used for manual monitoring or fully integrated via closed-loop feedback, the system creates a more reliable foundation for process control. Its AI Key point capabilities also extend its usefulness across a wider range of processes and joint geometries.
Key Specifications of the Xiris NIR camera:
|
|
If seam drift, rework, or operator exposure are challenges in your MIG seamer process, contact Xiris to discuss whether Xiris Seam Monitor is the right fit for your application.
|
