The evolution of the wind turbine to generate carbon-free renewable energy is rapidly growing. Thus, performing maintenance and inspection tasks in high altitude environments or difficult to access places, and even bad weather conditions, poses a problem for the periodic inspection process of the wind turbine industry. This paper describes the design and development of a scaled-down prototype climbing robot for wind turbine maintenance to perform critical tower operations. Thus, the unique feature of this maintenance robot is the winding mechanism, which uses a tension force to grip on the tower surface without falling to the ground either in static or dynamic situations, with the locomotion to perform a straight up–down motion in a circular truncated cone and the stability to work at significant heights. The robot computer-aided design (CAD) model of the mechanical mechanism, force and structural analysis, and the testing of the prototype model, are addressed in this paper. The key hardware developments that were utilized to build a low-cost, reliable and compact climbing robot are the embedded microprocessors, brushed DC motors, stepper motors and steel rope. This paper concludes with a successful preliminary experiment of a scaled down prototype proving the functionality of the concept. The potential applications for this robot are industrial maintenance, inspection and exploration, security and surveillance, cleaning, painting, and welding at extreme height conditions.

The emergence of renewable energy offers opportunities for academia and the industry to conduct scientific research and innovative technological developments on wind turbine climbing robots. These robots were developed to carry out specialized application tasks, such as in-situ inspection and maintenance of wind turbine physical structure. This paper presents a scaled-down prototype design of a climbing robot for wind turbine maintenance and its kinematic modeling. The winding mechanism is the key feature for providing enough adhesion force to support the climbing robot and needs to adapt to the different diameters of the wind turbine tower, as it climbs through a circular truncated cone shape. A climbing model is then considered, using four mecanum wheels for maneuverability of the different movement states up-down, rotation, and spiral as it climbs the wind turbine tower. The design of the wind turbine climbing robot was modeled in SketchUp and the motion states were implemented in MATLAB for the climbing performance capabilities of the driving wheels of the robot. Based on the theoretical results of motion characteristics, the scaled-down prototype design of a climbing robot possesses maneuverability of motion and is able to predict the robot’s performance. The contribution of this paper is intended to provide a basis for the new transformative climbing robot design and effectiveness of the mecanum wheel for robot motion.

The development of control technology on wind turbine application robots has played an integral role in facilitating the digitization of inspection and maintenance in the wind energy industry. This paper presents a wind-turbine-climbing robot that determines the service lifespan of the wind turbine components subject to its payload capacity. The model has four rubber wheels, as the driving mechanism for its locomotion is being supported by a Bowden cable as a winding mechanism for its adhesion. The design further incorporates an Arduino microcontroller, distance sensors, motors, and a step motor to form its electromechanical structure. The overall capability of the robot has been analyzed through its kinematics and dynamics. Practical indoor experiments using a wind turbine tower mockup have been conducted for the validation of the various speeds and payload capacity of the prototype. The results indicate the effectiveness of its driving and winding mechanism to climb at the various speeds and with or without a payload. The advantage of the operations of its mechanism conformed with the wind turbine application robots.