Keep every weld on target.
Not every part is perfect. Even with good fixtures, gaps and misalignment happen. That's where seam tracking comes in.
Our Through Arc Seam Tracking (TAST) feature automatically adjusts the weld path in real time, compensating for variation so you get consistent, high-quality welds without the extra rework.
Most shops won't need seam tracking for everyday jobs. But when you're working on parts with variable gaps, imperfect fit-up, or when consistency is absolutely critical, seam tracking is the tool that makes the difference.
This guide will walk you through how to use Seam Tracking in Beacon so your team can decide when—and how—it adds the most value in your operation.
Seam tracking isn't about adding complexity—it’s about giving you control when the work demands it.
Here’s what you’ll learn in this guide:
✅ How real-time arc feedback eliminates manual torch adjustments
✅ Why lateral and vertical tracking work together for optimal positioning
✅ Configuration options for sensitivity and tracking modes
✅ When to use seam tracking vs. traditional welding approaches
Ready to get started?
→ Subscribe to Beacon Seam Tracking ($100/month per robot) - How to subscribe
→ Enable tracking on your existing weave patterns
→ Monitor real-time feedback to optimize your settings
Let's get started
Before you begin
If you're new to Beacon welding, you'll need to complete these setup steps first:
Why seam tracking matters in real-world operations
Reduced Rework: Automatic correction reduces the need for manual adjustments. When your joint gaps vary or workpiece has height variations, Seam Tracking keeps the torch positioned correctly so you get consistent results.
Consistent Quality: Maintains optimal torch position throughout the weld. No more guessing if your setup will handle the variations along the weld path.
Faster Production: Less time spent on setup and correction means more time actually welding. The system handles corrections in real-time without interrupting your production flow.
Prerequisites
Seam Tracking add-on subscription required
Existing weld path with weave pattern configured
How Through Arc Seam Tracking (TAST) works
Through Arc Seam Tracking (TAST) automatically adjusts the torch position during welding to maintain optimal alignment with the seam, using real-time arc feedback to detect when the torch drifts from the ideal position and make automatic corrections.
Seam Tracking works in conjunction with your Hirebotics Cobot Welder's weave pattern, sampling arc data at specific points during each weave cycle.
The system samples current and voltage at precise moments:
Lateral Tracking: Samples current at the left and right peaks of the weave (90° and 270° positions)
Vertical Tracking: Samples voltage at the center positions of the weave (0°, 180°, 360°)
Two types of tracking
1. Lateral tracking (side-to-side)
Purpose: Keeps the torch centered on the seam width
Measurement: Compares current readings between left and right weave peaks
Correction: Adjusts the torch position left or right across the weld path
Sensitivity: Configurable from
0.0(least sensitive) to1.0(most sensitive)Why this matters: When joint gaps vary, the torch automatically stays centered instead of wandering toward one side of the joint.
2. Vertical tracking (up-down)
Purpose: Maintains optimal torch-to-work distance
Measurement: Compares voltage readings at center weave positions against target voltage
Correction: Adjusts the torch height up or down
Sensitivity: Configurable from
0.0(least sensitive) to1.0(most sensitive)Why this matters: As part height varies or gaps change depth, the torch maintains consistent arc length for optimal penetration.
Performance characteristics
Response time: Corrections are applied within
0.2mmincrements per weave cycleAccuracy: Sub-millimeter precision in both lateral and vertical directions
Stability: Advanced filtering prevents over-correction and oscillation
Your control: You determine sensitivity levels and which axes to track based on your application requirements.
Real-time feedback
The system provides comprehensive monitoring during welding:
Live statistics: Average offsets, maximum deviations, and sample counts
Performance metrics: Stability scores and correction frequency
Event logging: Detailed records of all corrections and measurements
Pro tip: Monitor these statistics during initial setup to optimize sensitivity settings for your specific application.
Configuration options
Sensitivity settings
High sensitivity (
1.0): More frequent corrections, ideal for precise work with tight tolerance requirementsLow sensitivity (
0.0): Fewer corrections, better for rough or variable surface conditionsCustom values: Fine-tune between
0.0and1.0for your specific applicationWhy this matters: Different materials and joint types require different responsiveness levels to achieve optimal results.
Tracking modes
Both Sides: Standard mode comparing left vs right peaks
Left Side Only: Track only the left side of the seam
Right Side Only: Track only the right side of the seam
Startup behavior
Initial delay: System skips the first 2 weave cycles to establish stable readings
Target calculation: For single-side tracking, builds a moving average over 3 cycles
How to use Through Arc Seam Tracking
Choose the start point you would like to enable seam on.
Enable the Seam Tracking toggle.
Note: Weave is automatically enabled when Seam Tracking is. You may not disable Weave, but you may modify the weave settings.
Modify any Seam Tracking related settings. (Optional)
Tap "Save".
Note: The Seam Tracking settings are also available in the Default Weld Settings screen. However, we recommend using it only as necessary for the points that require seam tracking.
When to use Through Arc Seam Tracking
Variable seam width: When the joint gap varies along the weld path
Uneven surfaces: When the workpiece has height variations
High-quality requirements: When consistent weld quality is critical
Automated production: When minimizing manual intervention is important
Setup recommendations
Test on scrap: Validate settings on similar material before production
Start with default settings: Begin with sensitivity at 1.0 for both lateral and vertical
Monitor performance: Watch the real-time statistics to understand correction patterns
Adjust gradually: If corrections are too frequent, reduce sensitivity
Troubleshooting
Excessive movement: Lower sensitivity values
Insufficient correction: Increase sensitivity values
Oscillation: Check for mechanical issues or reduce sensitivity
No corrections: Verify thresholds are appropriate for your welder type
Integration with existing workflows
Seam Tracking seamlessly integrates with your current welding setup:
No programming changes: Works with existing weld paths
Weave compatibility: Enhances any weave pattern
Real-time operation: No interruption to production flow
Backward compatibility: Can be disabled if needed
Bottom line: Your expertise + better tools
Beacon Seam Tracking doesn’t replace your expertise—it amplifies it.
Instead of stopping to make manual torch adjustments, you get real-time corrections that maintain optimal position automatically, while you stay in full control of your welding parameters.
More advanced features coming soon!
Seam Tracking is part of our growing suite of advanced welding capabilities. Our team is hard at work developing more innovative features to solve your toughest welding challenges. Bookmark this page — new advanced features are always in development.
Ready to try seam tracking in your shop? Here’s how to get started:
Pricing & availability
Access Seam Tracking through the Beacon App with the Seam Tracking add-on subscription. $100 / month per cobot
How do I subscribe?
Billing managers can subscribe directly within the Beacon application. Organization admins can designate one or more users to be a billing manager. We use Stripe to securely process your payment information.
As a Billing manager, navigate to the Subscription page from the left navigation bar. If on a mobile device swipe to the right from the left side or click the avatar icon at the top left to show the menu.
The Advanced Weld features will be displayed individually on the page.
How do I cancel?
Billing managers can cancel anytime within the Beacon application. Features remain active until the end of the billing cycle, so there’s no disruption mid-project.
Once the subscription has fully ended then the features will be disabled for your organization.