Laser Seam Tracking System for Automated Welding Project Description

Synapse is an ABB RobotStudio Add-In designed to simulate and validate Laser Seam Tracking (LST) for robotic welding. It provides a controlled virtual environment where engineers can evaluate seam-tracking performance before deployment on physical ABB industrial robots.

The system combines offline seam-data validation with virtual closed-loop simulation, enabling the complete LST workflow—from seam sensing and detection to path correction and robot motion—to be tested within RobotStudio. Synapse integrates virtual laser sensor modelling, seam detection and fitting algorithms, coordinate transformations, robot path correction, quantitative validation, and visualization.



Users can visually compare nominal, detected, estimated, and corrected paths while using quantitative metrics to evaluate seam detection accuracy, path deviation, and correction performance. The system also supports exporting validation reports, corrected path data, performance metrics, and ABB RAPID modules for further analysis and deployment.

Overall, Synapse aims to reduce commissioning risk and development time while improving confidence in LST algorithms through systematic virtual testing and validation before real-world implementation.