Robot for performing non-destructive evaluation of a weld

A method of performing non-destructive evaluation of a weld of a component using a robot, the method comprising:

• sending and receiving, using a phased array ultrasonic probe, phased array ultrasonic signals;
• generating phased array ultrasonic images using the received phased array ultrasonic signals;
• and
• controlling, by a controller, an actuator to move the phased array ultrasonic probe based on a position of the weld in the generated phased array ultrasonic images to maintain a predetermined distance from the weld during the non-destructive evaluation.

A robot for performing non-destructive evaluation of a weld of a component, the robot comprising:

• a phased array ultrasonic probe for sending and receiving phased array ultrasonic signals;
• a processor configured to generate phased array ultrasonic images using the received phased array ultrasonic signals;
• an actuator for moving the phased array ultrasonic probe during the non-destructive evaluation;
• and
• a controller configured to control the actuator to move the phased array ultrasonic probe based on a position of the weld in the generated phased array ultrasonic images to maintain a predetermined distance between the phased array ultrasonic probe and the weld during the non-destructive evaluation;
• wherein the controller being configured to control the actuator to move the phased array ultrasonic probe based on a position of the weld in the generate image comprises the controller being configured to
• generate morphological images from the generated phased array ultrasonic images,
• compare the morphological images to a weld mask, wherein a weld mask is a binary image representing an ideal location of the weld to achieve full coverage of the weld, including an ideal weld position relative to the phased array ultrasonic probe, and
• control the actuator to move the phased array ultrasonic probe to reduce a displacement between a position of the phased array ultrasonic probe and an ideal position of the robot based on the comparison;
• and
• wherein the generating the morphological images comprises the controller being configured to
• normalise the phased array ultrasonic images to convert the phased array ultrasonic images into grayscale images,
• threshold, using a threshold value, the grayscale images to convert the grayscale images into binary images,
• apply morphological opening to the binary images,
• apply an erosion step to the morphologically opened binary images to form a single binary object,
• apply dilation to the single binary object until a number of pixels is constant, and
• multiply the dilated single binary object with the thresholded binary image.