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<p>This study presents a wall-climbing robot designed to perform maintenance on high-altitude steel structures, where conventional methods pose safety risks and high labor costs. Existing climbing robots often suffer from low load capacity, poor obstacle-crossing performance, and limited mobility. The robot adopts a layout that separates permanent magnetic adsorption device from the tracked locomotion system. By integrating a triangular tracked locomotion system and a differential steering system, it achieves lightweight construction and high load capacity while ensuring adsorption stability. Static models were established for four working conditions: longitudinal movement, lateral movement, turning, and passive obstacle crossing. These models reveal the relationship between the critical adsorption force (with a longitudinal peak of 801.9 N) and obstacle-crossing height. Simulations and experiments demonstrate that the prototype, with a self-weight of 28.8&#xa0;kg, can safely carry a load of 14&#xa0;kg during obstacle crossing, yielding a load-to-weight ratio of 0.49. It is capable of passively crossing weld seam obstacles up to 6&#xa0;mm in height. Tests verify the robot’s high load capacity, agile steering, and stable obstacle-crossing ability on steel surfaces, offering a cost-effective and efficient solution for intelligent maintenance in high-risk environments.</p>

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Design and performance analysis of an obstacle-crossing tracked wall-climbing robot for steel facades

  • 期刊论文

  • 发表日期：

    2025年11月25日

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  • Jiasheng Zhu,
  • Zhengyao Yi,
  • Tianci Yang,
  • Mengshi Huang,
  • Zhaowen Shen,
  • Xiaoxiao Chen

摘要

This study presents a wall-climbing robot designed to perform maintenance on high-altitude steel structures, where conventional methods pose safety risks and high labor costs. Existing climbing robots often suffer from low load capacity, poor obstacle-crossing performance, and limited mobility. The robot adopts a layout that separates permanent magnetic adsorption device from the tracked locomotion system. By integrating a triangular tracked locomotion system and a differential steering system, it achieves lightweight construction and high load capacity while ensuring adsorption stability. Static models were established for four working conditions: longitudinal movement, lateral movement, turning, and passive obstacle crossing. These models reveal the relationship between the critical adsorption force (with a longitudinal peak of 801.9 N) and obstacle-crossing height. Simulations and experiments demonstrate that the prototype, with a self-weight of 28.8 kg, can safely carry a load of 14 kg during obstacle crossing, yielding a load-to-weight ratio of 0.49. It is capable of passively crossing weld seam obstacles up to 6 mm in height. Tests verify the robot’s high load capacity, agile steering, and stable obstacle-crossing ability on steel surfaces, offering a cost-effective and efficient solution for intelligent maintenance in high-risk environments.