The Problem of Adhesion Methods and Locomotion Mechanism Development for Wall-Climbing Robots

This review considers a problem in the development of mobile robot adhesion methods with vertical surfaces and the appropriate locomotion mechanism design. The evolution of adhesion methods for wall-climbing robots (based on friction, magnetic forces, air pressure, electrostatic adhesion, molecular forces, rheological properties of fluids and their combinations) and their locomotion principles (wheeled, tracked, walking, sliding framed and hybrid) is studied. Wall-climbing robots are classified according to the applications, adhesion methods and locomotion mechanisms. The advantages and disadvantages of various adhesion methods and locomotion mechanisms are analyzed in terms of mobility, noiselessness, autonomy and energy efficiency. Focus is placed on the physical and technical aspects of the adhesion methods and the possibility of combining adhesion and locomotion methods

Climbing Robot for Steel Bridge Inspection: Design Challenges

Inspection of bridges often requires high risk operations such as working at heights, in confined spaces, in hazardous environments; or sites inaccessible by humans. There is significant motivation for robotic solutions which can carry out these inspection tasks. When inspection robots are deployed in real world inspection scenarios, it is inevitable that unforeseen challenges will be encountered. Since 2011, the New South Wales Roads & Maritime Services and the Centre of Excellence for Autonomous Systems at the University of Technology, Sydney, have been working together to develop an innovative climbing robot to inspect high risk locations on the Sydney Harbour Bridge. Many engineering challenges have been faced throughout the development of several prototype climbing robots, and through field trials in the archways of the Sydney Harbour Bridge. This paper will highlight some of the key challenges faced in designing a climbing robot for inspection, and then present an inchworm inspired robot which addresses many of these challenges

Investigations on the effect of wall thickness on magnetic adhesion for wall climbing robots

The focus of this work is to investigate the adhesion characteristics of a permanent magnet arrangement over ferromagnetic surfaces for wall climbing robot applications. The changes in wall thickness affect the adhesion characteristics of the robot, this in turn influences the payload and alters the operating conditions. The effect of varying the wall thickness on the adhesion strength of a wall-climbing robot is an area barely investigated and this is being explored in this work. A two-dimensional model of the adhesion mechanism and the ferromagnetic surface is developed and simulated in this study. The adhesion characteristics are studied for different thicknesses of the ferromagnetic surface with different grades of the magnet. Two different standoff distances which comprise the gap between the magnet and the surface to be inspected are investigated therein. Experimental studies are also carried out to measure the performance, and the results show a strong correlation with the simulation results. Simulation with experimental validation of magnetic adhesion presented will provide better insights into magnetic wall climbing systems

Design and development of a pole climbing surveillance robot

The cost of installing, monitoring and servicing a fixed camera system can be high and not all areas are in need of constant surveying. The increase in crime in urban areas emphasizes the need for a more effective and efficient surveillance system, as a result could lead to fewer crimes. A temporary surveillance unit which is able to climb to gain an elevated view has great potential for both military and civilian application. This paper highlights how the patent pending climbing robotic system (PC-101) was developed to be used by London’s Metropolitan Police Forensic Department for analysing outdoor crime scenes especially that related to car accidents. When cars are involved in accidents in the Metropolitan area, depending on the scale of the incident, the road generally has to be shut off to traffic if there are serious casualties. Elevated images are required for cases which may be taken to court, which then the images are then used as evidence, therefore regulations on the quality and perspectives of the image have to be met. By climbing a range of existing street furniture such as street lamp post, a temporary platform eliminates the use of larger special vehicle which struggles to get to the crime scene as well as cuts down the duration of the road closure. 98% of London street lamps in the Metropolitan area are constructed out of steel structures which make the use of magnetic wheels for locomotion an ideal solution to the climbing problem. Once remote controlled to the top of the lamp post, the PC-101 makes use of its actuated camera arm/gimbal to take the required shot, which can be seen on the ground control unit. A surveillance tool of this sort can be used for many applications which include crowd/riot control, crime scene investigations, monitoring hostile environments and even the monitoring of nature within urban environment

Magnetic Adhesion in Wall Climbing Robots using varied Electromagnet Arrangements

The improvements and innovations in the field of robotics have given a great opportunity to perform tasks that are hazardous for humans to perform. For example, robots can be used for working on high-storied buildings, inspection on ferromagnetic surfaces, painting and maintenance of buildings, surveillance purposes, etc., at the outset, to carry out any operation on vertical surfaces, which may be quite hazardous and time-consuming as well, wall climbing robots (WCRs) can be deployed. The method of adhesion determines the stability of the robot on the wall, be it smooth or coarse. Using magnets to bring about magnetic adhesion would be advantageous when the robot is maneuvered over iron or steel surfaces, typically, to clean boilers, etc., This paper presents the different ways of placements of the magnets, both permanent and electromagnets, in order to introduce adequate magnetic adhesion that would cease the robot from toppling down while encountering an obstacle. This work proposes two methods of arrangement of magnets: square and diamond. Four electromagnets when arranged in array formation with 5000 windings of thin copper coil, generated a magnetic field force of approximately 150 N when 50 A of current is passed. By and large, around 35 N to 40 N is the suction force that would be sufficient to stick the WCR of 2kg on the wall, while using a suction chamber instead of electromagnets. Other methods of placing the magnets such as square and diamond are studied and compared as well using FEMM. Hence arranging the 4 electromagnets in array formation gives an adhesion pressure sufficient to hold and move the WCR, over the vertical wall against gravity

A Survey of Technologies and Applications for Climbing Robots Locomotion and Adhesion

The interest in the development of climbing robots has grown rapidly in the last years. Climbing robots are useful devices that can be adopted in a variety of applications, such as maintenance and inspection in the process and construction industries. These systems are mainly adopted in places where direct access by a human operator is very expensive, because of the need for scaffolding, or very dangerous, due to the presence of an hostile environment. The main motivations are to increase the operation efficiency, by eliminating the costly assembly of scaffolding, or to protect human health and safety in hazardous tasks. Several climbing robots have already been developed, and other are under development, for applications ranging from cleaning to inspection of difficult to reach constructions. A wall climbing robot should not only be light, but also have large payload, so that it may reduce excessive adhesion forces and carry instrumentations during navigation. These machines should be capable of travelling over different types of surfaces, with different inclinations, such as floors, walls, or ceilings, and to walk between such surfaces (Elliot et al. (2006); Sattar et al. (2002)). Furthermore, they should be able of adapting and reconfiguring for various environment conditions and to be self-contained. Up to now, considerable research was devoted to these machines and various types of experimental models were already proposed (according to Chen et al. (2006), over 200 prototypes aimed at such applications had been developed in the world by the year 2006). However, we have to notice that the application of climbing robots is still limited. Apart from a couple successful industrialized products, most are only prototypes and few of them can be found in common use due to unsatisfactory performance in on-site tests (regarding aspects such as their speed, cost and reliability). Chen et al. (2006) present the main design problems affecting the system performance of climbing robots and also suggest solutions to these problems. The major two issues in the design of wall climbing robots are their locomotion and adhesion methods. With respect to the locomotion type, four types are often considered: the crawler, the wheeled, the legged and the propulsion robots. Although the crawler type is able to move relatively faster, it is not adequate to be applied in rough environments. On the other hand, the legged type easily copes with obstacles found in the environment, whereas generally its speed is lower and requires complex control systems. Regarding the adhesion to the surface, the robots should be able to produce a secure gripping force using a light-weight mechanism. The adhesion method is generally classified into four groups: suction force, magnetic, gripping to the surface and thrust force type. Nevertheless, recently new methods for assuring the adhesion, based in biological findings, were proposed. The vacuum type principle is light and easy to control though it presents the problem of supplying compressed air. An alternative, with costs in terms of weight, is the adoption of a vacuum pump. The magnetic type principle implies heavy actuators and is used only for ferromagnetic surfaces. The thrust force type robots make use of the forces developed by thrusters to adhere to the surfaces, but are used in very restricted and specific applications. Bearing these facts in mind, this chapter presents a survey of different applications and technologies adopted for the implementation of climbing robots locomotion and adhesion to surfaces, focusing on the new technologies that are recently being developed to fulfill these objectives. The chapter is organized as follows. Section two presents several applications of climbing robots. Sections three and four present the main locomotion principles, and the main "conventional" technologies for adhering to surfaces, respectively. Section five describes recent biological inspired technologies for robot adhesion to surfaces. Section six introduces several new architectures for climbing robots. Finally, section seven outlines the main conclusions

Design and Development of a Mobile Climbing Robot for Wind Turbine Inspection

Wind turbines (WT) have become an essential renewable energy source as the contribution of WT farms has reached megawatts scale. However, wind turbine blades (WTB) are subjected to failure due to many loading effects such as aerodynamic, gravity and centrifugal loads and operation in harsh environments such as ultraviolet (UV) radiation, ice, hail, temperature variation, dirt, and salt. As a result, the blades suffer different types of damage. Consequently, a periodic inspection process is required to detect and repair defects before a catastrophic failure happens. This thesis presents a literature review of wall climbing robots to identify the most appropriate locomotion and adhesion method to use for a WT climbing machine that can take a large payload of non-destructive testing (NDT) sensors up to a blade and deploy them with scanning arms. A review of wind turbine blade construction, various loading effects on blades and types of damage in blades is followed by a review of the NDT techniques used for inspecting WTB. The above review determines the design requirements to achieve the aim of the current research which is to design a low-cost and reliable mobile robot which will be able to climb the WT tower and subsequently scan the blade surface to perform the inspection using various sensors to identify and classify damages. This robot system should be able to access all the critical areas of the blade structure in a stable and secure way. It should be stable enough to allow the various test sensors to scan the blade structure in the shortest possible time. The thesis describes the development of a tower climbing robot that uses magnetic adhesion to adhere to the WT. As a preliminary study, a simulation model is developed using COMSOL Multiphysics to simulate the magnetic adhesion force while climbing the tower. A test rig is designed and fabricated to measure the magnetic adhesion force experimentally to validate the simulation model. The response surface methodology (RSM) using Box-Behnken design (BBD) is used to design and perform experiments to optimise different independent variables i.e. air gap, the distance between magnets in an array and backplate (yoke) thickness that affect the magnetic adhesion force. A scaled-down prototype magnetic adhesion climbing robot has been designed and constructed for wind turbine blade inspection. The robot is 0.29 m long with two 1.0 m long arms, weighs 10.0 kg and can carry a maximum 2.0 kg payload of NDT sensors. Optimum design of a magnetic adhesion mechanism has been developed for the climbing robot prototype that maximises the magnetic adhesion force. The robot is equipped with two arms that can be extended by one meter to come close to the blade for inspection. Each arm is equipped with a gripper that can hold an inspection tool of weight up to one kilogram. A scaled-down wind turbine has been modelled using SolidWorks and a portion of it constructed to experimentally test the scaled-down climbing robot. To scale up the robot prototype for operation on a normal sized wind turbine, a 100 m tall wind turbine with three 76 m long blades has been modelled and the prototype robot scaled up based on these dimensions. The scaled-up robot is 3.0 m long, weighs 1135 kg and has two 10 m long arms. Static stress analysis and flow simulation have been carried out to check the durability of the scaled-up robot while climbing the wind turbine tower. The procedure for scaling up the adhesion mechanism to achieve equilibrium of the robot has been introduced based on the reaction force concluded from the static stress and flow simulation study. As a result, the maximum payload that each arm can carry has been calculated for both the scaled-down prototype (1 kg) and the scaled-up design (50 kg). This concludes the utility and robustness of the wall climbing robot as a robotic solution for wind turbine blade inspection

Design and Development of Climbing Robotic Systems for Automated Inspection of Steel Structures and Bridges

Steel structures are indispensable parts of modern civilization, with typical civil infrastructures including bridges, wind turbines, electric towers, oil rigs, ships, and submarines, all made of steel. These structures require frequent maintenance to ensure safety and longevity. Steel bridges are the most challenging architectures due totheir complexity and height. Most inspections are conducted manually by professional human inspectors with special devices to inspect visible damages and defects on or inside these structures. However, this procedure is usually highly time-consuming, costly, and risky. Automated solutions are desired to address this problem. However, arduous engineering is delaying progress. A complete system needs to deal with three main problems: (1) locomotive performance for the high complexity of steel bridges, including differential curvatures, transitions between beams, and obstacles; (2) data collection capability, inclusive of visible and invisible damages, in-depth information such as vibration, coat, and material thickness, etc.; and (3) working conditions made up of gust winds. To achieve such a complete system, this dissertation presents novel developments of inspection-climbing robots. Five different robot versions are designed to find the simplest and most effective configuration as well as control manner. Our approach started with (1) a transformable tank-like robot integrated with a haptic device and ii two natural-inspired locomotion, (2) a roller chain-like robot, (3) a hybrid worming mobile robot, (4) a multi-directional bicycle robot, and (5) an omni-directional climbing Robot, identified as the most potential solution for automated steel bridge inspection. For each robotic development, detailed mechanical analysis frameworks are presented. Both lab tests and field deployments of these robotic systems have been conducted to validate the proposed designs

Design, Build, and Control of a Climbing Robot for Irregular Surface Geometry

Climbing robots are ideal for situations were maintenance and inspection tasks can cause people to be in dangerous situations or require them to be present for extended periods of time. Applications include inspection, testing, civil construction, cleaning, transport and security. The focus of this thesis was on robots that used pneumatic means to attain adhesion and wheels for locomotion. Research objectives include designing or utilizing a pneumatic based adhesion method to allow the robot to stick to concrete, brick, glass, or other such surfaces; climb on a surface with the lowest possible coefficient of friction between it and the robot; have the ability to overcome a step-like obstacle while climbing; use a single body to passively transition through sharp surface changes while climbing; have the ability to traverse over a gap-type obstacle while climbing without loss of adhesion or mobility. To complete the objectives, a test rig was created that comprised of three surfaces that were hinged together and could be locked into place using aluminum struts at the hinge joint. Different material pallets were created and adhered to plywood that was then mounted to the test rig with screws. The robot was designed and built around laser cut and 3D printed parts. From the experiments it was found that the robot could adhere to a glass surface with a coefficient of friction of 0.43 between it and the glass. Furthermore it was able to overcome a 15mm tall speedbump while climbing without loss of adhesion as well as being able to passively transition between surfaces that had an acute angle of 80° between them and do wall to ceiling transitions. Finally the robot was able to pass over a 55mm gap that was 23mm deep while climbing on a concrete surface. It was concluded that by using thrust based adhesion the robot could handle a diverse array of surfaces and even gain greater ability to overcome obstacles while climbing. Future directions would improve on the robot by adding treads or multiple bodies to improve its base abilities