Wind-Resistance Stability Analysis of a Magnetic Adhesion Wall-Climbing Obstacle-Crossing Robot for Offshore Wind Turbines

To address the challenges of adsorption instability and obstacle-crossing difficulties faced by wall-climbing robots in the harsh operation and maintenance (O&M) environment of offshore wind turbine (OWT) towers, this paper presents the design of a magnetic-adhesive wall-climbing robot with a planetary-gear configuration and investigates its wind resistance stability. First, the magnetic circuit layout is optimized through finite element analysis, revealing that the F-16 continuous planetary configuration (16 poles) effectively suppresses magnetic flux leakage and forms an integrated magnetic pad, maintaining adsorption force at a large air gap of 20 mm, thereby enhancing magnetic robustness during obstacle crossing and making it the optimal choice for high-load offshore conditions. Second, an unsteady flow field model based on the Kaimal turbulence spectrum is constructed to analyze aerodynamic loads. Fluid–structure interaction (FSI) simulations demonstrate that at a height of 30 m, the turbulence integral scale matches the robot dimensions, and combined with the Venturi effect of gap jet flow, this leads to peak turbulence intensity and pitching moment, creating a hazardous, pronounced aerodynamic amplification condition. Finally, an anti-slip stability model is established, revealing that vertical wall climbing represents the critical loading scenario; the magnetic adhesion system must deliver a total adsorption force of no less than 1000 N to resist a 35 m/s wind speed under low-friction conditions, providing a quantitative design basis for anti-wind safety. This study integrates magnetic circuit optimization, turbulence-resolved aerodynamics, and macroscopic anti-slip mechanics, offering theoretical support and engineering guidance for the safe deployment of intelligent O&M equipment for offshore wind power. Bench-scale measurements of magnetic adhesion force, friction coefficient, and translation force fluctuation support the exponential-decay magnetic model and the multi-wheel phase-interleaving concept; however, the current 4 × 16-pole prototype delivers ~627 N at the 2 mm working gap, below the 1000 N design target. The design methodology is therefore validated, while the current physical configuration requires further iteration of the working gap or magnet grade before it can be considered operationally adequate.