Design and Optimization of a Non-Contact Magnetic Adhesion Module for Wall-Climbing Robots in Boiler Environments

To address the challenges of adhesion and locomotion on irregular boiler water-cooled walls, this study proposes the design and optimization of a non-contact magnetic adhesion module for a wall-climbing robot. The robot integrates a four-wheel independent drive system with a non-contact magnetic adhesion mechanism, enabling stable movement and reliable operation on complex vertical surfaces. A finite element simulation approach using Ansoft Maxwell is employed to analyze the influence of critical structural parameters on the magnetic adhesion performance. Key parameters, including yoke thickness and permanent magnet spacing, are systematically optimized. Results show that the magnetic adhesion force increases significantly with yoke thickness until magnetic saturation is reached at 8 mm, after which further increase yields diminishing returns; thus, a 10 mm yoke thickness is selected to balance performance and material efficiency. To mitigate adhesion force fluctuations during horizontal movement, a staggered arrangement of horizontal and vertical magnetic modules is introduced, offset by half the water-wall tube pitch (27.25 mm), effectively enhancing motion stability. The optimized module has been successfully applied in field deployments at thermal power plants, enabling automated inspection and cleaning of boiler walls, and demonstrating strong practical value and application prospects.