A High-Payload Wall-Climbing Robot Using Passive Bistable Suction Cups

Climbing robots face significant challenges when navigating unstructured environments, where reliable attachment to irregular surfaces is critical. We present a novel mobile climbing robot equipped with compliant pin-array structured grippers that passively conform to surface irregularities, ensuring stable ground gripping without the need for complicated sensing or control. Each pin features a vertically split design, combining an elastic element with a metal spine to enable mechanical interlocking with microscale surface features. Statistical modeling and experimental validation indicate that variability in individual pin forces and contact numbers are the primary sources of grasping uncertainty. The robot demonstrated robust and stable locomotion in indoor tests on inclined walls (10-30 degrees) and in outdoor tests on natural rocky terrain. This work highlights that a design emphasizing passive compliance and mechanical redundancy provides a practical and robust solution for real-world climbing robots while minimizing control complexity.

Animals such as squirrels and even bears have adapted to rapidly climb up trees and other complex vertical terrain, but achieving comparable agility has been a challenge for climbing robots. Existing robots often use walking gaits and move conservatively to stay in contact with the surface, which limits the range of dynamic maneuvers. In this paper we present a 290 g robot that, to our knowledge, is the first to climb vertically by bounding (with an aerial phase). We leverage a co-design workflow, in which the morphology and trajectory are jointly optimized for fast locomotion, subject to adhesion force limitations seen in spined grippers. The resulting trajectory includes a rapid maneuver that launches the robot vertically, and an aerial reorientation that brings the front grippers back to the surface using the rear leg as an inertial tail. We evaluate the resulting jump forces in 2D force space and demonstrate that the optimized morphology is capable of continuous climbing at a speed of 0.375 m/s (1.97 body lengths/s), and can also achieve ground locomotion and transition to a vertical surface. Our work proposes design insights for the jump-climbing maneuver and serves as an important step toward creating climbing robots with agility on par with that of animals.

To enable reliable climbing locomotion of quadruped robots on ferromagnetic surfaces, this paper presents a high-load-density electro-permanent magnetic foot with controllable adhesion, featuring force-feedback circular Halbach-net electro-permanent magnet (CHN-EPM) adhesion units and a magnetization control system. Due to its three-dimensional magnetic circuit structure and flux-concentration effect, the CHN-EPM enables a distributed parallel magnetic flux path with enhanced flux utilization, resulting in reduced sensitivity to air-gap variations and allowing effective adhesion to be maintained even under partial contact conditions. The proposed CHN-EPM generates a maximum adhesion force exceeding 1000 N with a load-to-weight ratio over 200:1. A magnetization driver and a two-stage pulse current control strategy are developed to regulate the excitation current amplitude and duration, enabling accurate and reliable magnetization. By incorporating a flexible pressure sensor for contact force feedback, the system can effectively monitor attachment and detachment states, ensuring robust adhesion switching under uncertain contact conditions. The proposed system is integrated into a commercial quadruped robot (Unitree GO2), demonstrating high-load adhesion on ceiling and vertical-wall surfaces and stable locomotion on painted, perforated, and curved ferromagnetic surfaces.