New mechanism to pass obstacles for magnetic climbing robots with high payload, using only one motor for force‐changing and wheel‐lifting

Purpose – The purpose of this paper is to describe a new solution for wheel‐robot's adhesion and passing‐obstacles mechanism and the optimal design of magnetic adhesion unit with finite element methods. The new mechanism makes the robot have a simpler structure, finer passing obstacles and larger payload capabilities. Design/methodology/approach – After researching literature and analyzing in detail the disadvantages and advantages of magnetic wheel and structure magnet mounted under the chassis of a robot, the structure magnet is selected as the robot's adhesion style. Then the paper introduces the robot's structure and locomotion mechanism, the design of the new mechanism and the optimization of structure parameters for magnetic adhesion unit are described in detail in this paper. The new design can lift the robot's wheel unit and change adhesion force using only a motor. Findings – A prototype of robot has been developed and successful test results prove that the proposed technology is feasible. The climbing robot can overcome 70‐mm high obstacles and has a large enough payload capability while climbing on vertical surfaces. Research limitations/implications – The new design reduces the number of actuators used in the robot and increases the magnetic adhesion force. Practical implications – Thanks to the excellent passing‐obstacles and payload capabilities, the climbing robot with the new mechanism has a widely applying prospect in the field of welding and inspecting large equipment. Originality/value – The lifting mechanism can lift the wheel unit and change magnetic adhesion force using only one motor. This makes the robot have a simple structure as well as the large payload capability.