Proceedings of the 2014 IEEE/SICE International
4
Symposium on System Integration, Chuo University,
Tokyo, Japan, December 13-15, 2014
Design, Modeling and Control of a Wall Climbing Robot Crossing-
over Obstacles
Ali M. Mohamed, Zakarya A. Zyada, Member, IEEE and E. A. El-Shenawy

Abstract— Recently, wall climbing robots have attracted
much attention because of its importance in many applications
such as cleaning, painting, fire fighting, tanks and walls
inspection. This paper presents the design, modeling and
control of a wall climbing robot, crossing over obstacles with
heights more than the current ones. The proposed climbing
robot consists of two mobile robots connected with a link and
two revolute joints. The climbing robot is designed in a way
that during crossing over obstacles, one of the mobile robots
adheres to the wall while the other mobile robot with its
connected link forms a 2 DOF arm crossing over obstacles. An
impeller based vacuum is generated giving the adhering
capability to each mobile robot. The model of the climbing
robot is presented in both stationary and motion modes. A PID-
computed torque controller is designed to the 2 DOF arm for
crossing over obstacles and the presented simulation results
show the validity of the proposed controller.
I. INTRODUCTION
Recently climbing robots have received much attention
by many researchers for its important applications. Wall
climbing robots would be applied for cleaning, painting, fire
fighting, transferring loads, gas tanks inspection, long line
welding and nuclear power station inspection. Applying wall
climbing robot in those applications saves costs of human
operators and scaffolds used; and avoids working in
dangerous environments for human, [1], [2]. There are many
types of wall climbing robots; they can be classified,
according to locomotion mechanism, to crawled, wheeled,
legged, tracked, and hybrid robots. Crawled robots use
sliding segments such as permanent magnets or suction cups,
where they move on smooth surfaces. They have the
difficulty of crossing over obstacles, [3]. Wheeled robots
have many locomotion mechanisms for wheels arrangement
where they may have 3 up to 6 wheels. Those robots are fast
but they can cross over small obstacle like city climber robot
I, II in USA. Legged robots have better capability in crossing
over obstacles and dealing with wall cracks but they are
complex in control and low in speed; e.g. NINJA and
RAMR1 [4]. Tracked robots also have better ability to cross
over obstacles [4], [5]. Hybrid robots use wheels during the
Manuscript received September 5, 2014. This work was supported in
part by the Department of Research and Graduate Studies, Faculty of
Engineering, Tanta University of Egypt.
A. M. Mohamed is a Master student with the Dept of Mechanical Power
Engineering, Tanta University (phone: +20-10-6257-0757; fax:+20-40-345-
3860; e-mail: eng.Ali_10@yahoo.com).
Z. A. Zyada, (being on leave from his permanent job as an Associate
Professor with the Dept of Mechanical Power Engineering, Tanta Univ. of
Egypt) is with the Faculty of Mechanical Engineering, Universiti Teknologi
Malaysia, Johor Bahru, Malaysia. (e-mail: zzyada@f-eng.tanta.edu.eg).
E. A. El-Shenawy, is an Associate Professor with the Dept of
Mechanical Power Engineering, Tanta University, Tanta Egypt. (e-mail:
shenawy49@yahoo.com).
978-1-4799-6944-9/14/$31.00 ©2014 IEEE
SaA1B.
normal motion and legs during crossing over obstacles. The
hybrid wall climbing robot of [6] uses suction cups to adhere
and two modules to move. Another example of hybrid robot
is presented in [7], where it is constituted of three modules.
The three modules move on wheels where during crossing
over obstacles two modules are fixed to the wall and the third
crosses over obstacles.
According to the adhesion force, wall climbing robot can
adhere to the wall using magnetic, gripping, vacuum and
biological inspired adhesion principle. Magnetic force comes
from permanent magnet or electrical magnetization. These
robots applying magnetic adhesion are suitable only for
ferromagnetic surfaces, [8]. Adhesion applying gripping to
walls use mechanical mechanisms, [9]. Vacuum suction
force has many sources of generation such as suction cup
connected to vacuum pump, rotating impeller and passive
suction cup. Robots based on vacuum pump have hoses
which may achieve some problem in moving and navigation.
Suction based on impeller uses rotating impeller to achieve
pressure drop inside chamber and so the required vacuum,
[10]. Also passive suction cup is used to have vacuum using
an elastic material. By pressing the elastic material, vacuum
is achieved so this method is simple and has low cost, [2].
Biological inspired adhesion depends on dry adhesion and
nano-scaled hair adhesion, [11]. City climber robot III, [10],
is consisted of two modules to transfer from a plane to
another and it works for 30 min using battery. Alicia robot,
[7], is consisted of three modules. Each module has
universal AC motor working with an external source and
cable to achieve a vacuum and so the required adhesion
force. Its 3rd version has a pneumatic circuit connected to the
robot to enable it to cross over obstacles with a height of
about 12 cm. Using cables and hoses affect the motion of the
robot and decrease its payload, [2]. Bit climber robot uses
high speed rotating impeller inside a chamber, [12]. It can
cross over small obstacles up to 1 cm. LARVA, [13], is a
wall climbing robot used for wall inspection and it can cross
over obstacles up to 1 cm in height.
The design of a wall climbing robot, presented in this
paper, solves the problems of cables and hoses in other
designs, using batteries. Also, the presented design has the
capability to cross over obstacles up to 15 cm height, which
is more than the highest obstacle in the literature (up to
authors’ knowledge). The robot is about 5 kg’s and it can
carry loads up to 0.5 kg during the normal motion on walls.
The robot consists of two modules connected by a link.
When there is an obstacle, the front module is fixed to the
wall and the back module is turned using two servo motors
to cross over the obstacle. The design and modeling of the
robot, considering the required adhesion force in different
46
phases of climbing, is presented. The model of the 2 DOF
arm is derived and a PID computed torque control is
simulated to control the turning arm of the robot.
This paper will be organized as follows: in section II, the
design of the robot is presented. In section III, 2 DOF robot
arm kinematic model is discussed, containing both forward
and inverse kinematics. In section IV, arm dynamic model is
derived applying Newton-Euler formulation. In section V,
mobile robot adhesion force, in both static and dynamic
conditions of the robot as well as during crossover obstacles Figure 1. Wall climbing robot.
is derived and presented. In Section VI, arm SIMULINK
model and the results of the PID computed torque control is
presented. Section VII, presents the conclusions and future
work.
II. ROBOT DESIGN
Realizing that robot design has a great effect on the
application and so the required adhesion force, many aspects
are taken into consideration like the chosen material, the
locomotion system and the actuators power source. The
requirements adopted for the current climbing robot design
are: payload of 0.5kg; adhesion force of 300N; capability of Figure 2. Mobile robot module
crossing over obstacles up to 15 cm in height and 15 cm in
width; free of cables and/or hoses and suitability to move on
rough surfaces.
The designed robot consists of two mobile robot modules
connected with a link as shown in Fig.1. The connecting link
is made of acrylic and it is 50 cm length. The thicknesses of
the plates of the mobile robot modules and of the connecting
link are checked to bear stresses using the software “Solid
Works” applying the designing loads. The selection of the
actuators depends on the model of arm and adhesion force
analysis as well be presented later in section V. At the two Figure 3. Impeller design and its parameters
joints, there are two servo motors each one provides about
24 N.m torque. The robot adheres to the wall through bristle skirt sealing and rubber inflated tube. The flexible
suction using high speed rotating impeller; its speed is bristle skirt sealing will work all the time to achieve good
between 7000 to 30,000 rpm [14]. The motor used to resistance to air flow and permit the air to enter to avoid
achieve the adhesion force is a BLDC motor, 0.0727Kg and robot getting stuck. The rubber inflated tube sealing is an
198W with 11.1V input. inflated tube which will work only in the case of crossing
As shown in Fig. 2, each module of the mobile robot has over obstacles.
a body made of acrylic plate with 2mm thickness and 30 cm Using the inflated tube will increase pressure drop in
in diameter. Acrylic is suitable because of its light weight vacuum chamber at the same motor speed and so decrease
compared to other materials such as aluminum. The the required power consumption[15].To move the inflated
cylindrical shape of the body is considered the best for its tube in linear motion perpendicular to the wall, rack and
wall’s uniform pressure distribution. The locomotion pinion mechanism and four servo motors about 0.13N.m
mechanism is based on four wheels; two drive wheels and toque for each are used.
two passive ball wheels. Each drive wheel is connected to a III. ARM KINEMATIC MODEL
1N.m servo motor. The adhesion force is based on suction,
by a high speed impeller made of aluminum. It has the One of the main objectives of the designed robot is to
following dimensions: inlet diameter D1 = 0.04 m, outlet cross over obstacles. The approach of overcoming obstacles
diameter D2 = 0.12 m, inlet width B1 = 0.015 m, outlet width is proposed to be as shown in Fig. 4. The arm forward
B2 = 0.005 m, inlet installation angle β1A = 50o, outlet kinematics, that is to find the position of the 2nd mobile robot
installation angle β2A = 30o and blades number Z = 9, as module given joints motions, is presented in this section.
shown in Fig. 3. The adhesion force is affected greatly with Also, the inverse kinematics, that is to find the required
the sealing and the gap between the mobile robot modules motor angles of rotation to reach the specified position and
and the wall. The sealing of the robot is made of flexible orientation of the 2nd mobile robot module, is presented.

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A. Forward Kinematics
The robot consists of three links; the first one is the 1st
mobile robot module considering it as the base (i.e. link 0),
link 1 connects the two mobile robot modules; link 2 is the
2nd mobile robot module. Fig.4 (a) and (b) show the assigned
frames at each joint frame or-xryrzr, o1-x1y1z1, o2-x2y2z2 and
the world frame O0-X0Y0Z0. Fig.4 (c) shows the robot arm
when one module is completely adhered (fixed) to the wall
and the other is turned by the angles of rotation 1 and 2.
During the motion of the robot on the wall its position
changes, ror   x or y or z or  is the vector relating
T

the original frame O0-X0Y0Z0 to the 1st joint frame or-xryrzr

Figure 4. (a), (b) the assigned frames to the robot, (c) The robot during
and zor = L0 which the same length of link 1 so L0 = 0.2 m. cross over the obstacles.
The transformation matrix relating the frame o2-x2y2z2 to the
original frame is, 0T2 [16]. TABLE I. shows the robot link TABLE I. ROBOT LINK PARAMETERS
parameters according to D-H convention.
c12 -s12 0 L1c1  L2 c12  xor  Joint no. Variable ai(m) di/m i/o i
  1 1 L1 = 0.2 0 0 1
0T   0 0 -1 yor  (1) 2 2 L2 = 0.5 0 0 2
2
 s12 c12 0 L1 s1  L2 s12  Lo 
 
0 0 0 1 
where si = sini, ci = cosi, sij = sin(i +j) and cij =
cos(i +j)
B. Inverse Kinematics
Considering the task point o2 = (px,py)T , the origin of
frame o2-x2y2z2 where px and py are the position components
of the 2nd mobile robot module during crossing over
obstacles. The inverse kinematic of the arm can be
calculated as following, [21],
 p 2  p y 2 - l12 - l 2 2 2 p x 2  p y 2 - l12 - l 2 2  (2)
  A tan 2   1- ( x
2 ) , 
 2l1l 2 2l1l 2  Figure 5. (a) The assigned frame at the end of 1st stage, (b) at the start of
 
 2 
the 2nd stage.
 p (l  l c  )  p l s    p x (l1  l 2c 2 )  p y l 2s  2  
1  A tan 2   1-  x 1 2 2 2 2 y 2 2  ,  
  px  p y  px 2  p y 2
     
(3)
For the robot to cross over the obstacles there are two
stages. In the 1st stage, the 1st module is fixed and the 2nd
module is turned. In the 2nd stage, the 2nd module will be
after the obstacle and the 1st module before the obstacles, in
this case the frame will be replaced as shown in Fig.5 where
in Fig.5 (a) at the end of 1st stage and Fig.5 (b) at the
beginning of the 2nd stage. Due to the frame replacement of
the position of xor will change.
xor  of the 2nd stage   xor  of the 1st stage   L2 (4)
Fig.6 shows the simulation of the robot crosses over an
obstacle, where in Fig.6 (a) the 1st module adheres to the Figure 6. (a) The 1st module cross over the obstacle during the first stage,
wall and the 2nd module rotates until it crosses over the (b) the 2nd module crosses over the obstacle during the second stage
obstacle. In Fig.6 (b) the 2nd module adheres to the wall
while the 1st module rotates. The arm during crossing over where θ1 ϵ [0o 180o] and θ2 ϵ [-90o 90o] to move the 2nd
an obstacle will be at singular configuration when θ2= 0o. To module to cross over an obstacle.
deal with that there are many methods depending on IV. ARM DYNAMIC MODEL
transforming of the work space and depending on neural
network [17], [18]. Transforming the work space is suitable The dynamic model of the robot is derived applying
as it is easy to implement, controlling the velocity and Newton -Euler formulation which is helpful in calculating
acceleration and the error in the trajectory can be estimated the required torque of each motor. Also the estimated forces
[19]. In this work, θ1 and θ2 are found applying (2) and (3) affect the fixed module of the mobile robot during crossing

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over obstacles[20]. Assuming cg1 and cg2 are the centers of Fsp  K spdj Fsd , Fsd  K sdj Fa ; j  1,3 (11)
gravity of the links 1 & 2, respectively; where the centers of And considering
gravity will not be at the centers of the links due to Ffs  µs Fss  µs K s Fa (12)
components mass distribution. The 1st and 2nd mobile robot
In a similar way, Ffp, Ffd can be estimated. Taking into
modules have masses m1 & m2 respectively. τ1 and τ2 are the
account an assurance co-efficient factor, Kr, as in [19] Then
applied torques. Iz1 and Iz2 are the inertia of links 1 & 2 Fa can be expressed from (8) and (9) as:
respectively. g is the acceleration of gravity. The arm K r GTHgT cos  K r GTHgT cos 
dynamic model can be expressed as follows, [21]: Fa1  , Fa 2 
L2 (1  2 Kspd 1  Ks1  2 Ksd 1) L2 (2 Kspd 3  Ks 2  2 Ksd 3  1)
 D1 D 2  1  C 11 2 C 112  C111  1   G1   1  2 Kspd 3  Ks 2  2 Ksd 3  1
 d 1 d 2                  (5) Fa1  K Fa 2 where K  (13)
   2   C 11 1 0   2  G 2   2  1  2 Kspd 1  Ks1  2 Ksd 1
where: B. Motion Mode Analysis
D 1  2m 2Cg 2 L 1c 2  m 2L 12  m 2Cg 2 2  Iz 2  m 1Cg 12  Iz 1 During the motion the friction force on the drive wheels
D 2  m 2Cg 2 2  Iz 2  m 2Cg 2 L 1c 2 C 11  -m 2Cg 2L 1s  2 will be in the same direction of motion as they are the
traction force moving the robot on the wall. The friction
d 1  m 2Cg 2 L 1c 2  m 2Cg 2  Iz 2
2
d 2  m 2Cg 2 2  Iz 2 forces on the passive wheels will be in the opposite direction
G 1  m 2Cg 2 gcs  12  m 1Cg 1gcs  1  m 2L 1gcs  1 G 2  m 2Cg 2 gcs  12 of motion, shown in Fig.8. Assuming the robot will move
upward with an acceleration a and applying 2nd Newton
V. MOBILE ROBOT ADHESION FORCE ANALYSIS law,  Fx  ma x , then
The robot will adhere to the wall because of the vacuum 2Ffd1  2Ffd 3 - 2Ffp1 - Ffs1 - 2Ffp3 - Ffs 2 - GT cos   Ma
adhesion force, Fa, applied by a high speed rotating impeller. Using (11), (12), (13) and applying the assurance co-
The robot has a mass M, total weight GT, and its center of efficient kr then,
gravity distance away from the wall is HgT. As Fa1, Fa2 affect
num
the 1st and 2nd mobile robot modules, there are reaction forces Fa1  where num  K r GT cos   Ma
Fp, Fd and Fs on the passive wheels, drive wheels and seal den
respectively. Using the friction co-efficient µp, µd, µs, the den  [2(µd1  µp1Kspd1 )Ksd1  µs1Ks1 +(2(µd3  µp3Kspd3 )Ksd3  µs2 Ks2 ) / K ]
supporting force on the wheel Fspj, Fsdi, and Fssi can be turned
to friction forces Ffpj, Ffdi, and Ffsi on the passive and driving Applying (13) then: Fa2 = Fa1/K.
wheels and the seal.  is the inclination angle of the robot to C. Crossing-over Obstacles Mode Analysis
the wall [12] ,[22]. In the static mode, there is no motion and When the robot moves on the wall, obstacles are to be
the two modules of the mobile robot will adhere to the wall detected by an ultrasonic sensor. If there is an obstacle, the
by turning on the two brushless motors. In motion mode, all first module of the robot becomes fixed to the wall and the
mobile robot motors are applied to move the robot forward. second model is to be turned, using the servo motors at each
A. Static Mode Analysis joint, to cross over the obstacle. The forces on the fixed
In this mode, the robot will be stationary. Only the two module are the supporting forces on the passive wheels, the
brushless motors, achieving the vacuum and so the adhesion driving wheels, the seal, the weight of the first module, the
force, are to be operated. The friction forces are in the internal force between link 0 and link1 and the torque
opposite direction of the weight as shown in Fig. 7. applied on link 0 due to the rotation of the link1 and link2 as
Assuming each module has the equal force on the wheels of shown in Fig.8. Applying Newton 1st law,  FX = 0, then:
the same type. G1 cos   Fx
Fa  (12)
 Fz = 0, then: [2µp1 K spd 1 K sd 1  2µd 1 K sd 1  µs1 K s1 ]
Fa1  Fa 2  Fss1  2Fsp1  2Fsd1  Fss 2  2Fsp3  2Fsd 3 (6)  Fz = 0, then:
 FX = 0, then: Fy
GT cos   Ffs1  2Ffp1  2Ffd1  Ffs 2  2Ffp3  2Ffd 3 (7) Fa  (13)
[1- 2 K spd 1 K sd 1 - 2 K sd 1 - K s1 ]
 MA1 = 0, where A1 is the center of the 1 module st
 Mp2 = 0, then:
Fa 2 L2  2Fsp3 L2   Fss 2  2 Fsd 3  L2  GT HgT cos  (8) d
Fx L2  Fy  G1cg 2  T
M A2 = 0, where A2 is the center of the 2nd module Fa  2 (14)
Fa1 L2  GT HgT cos   2Fsp1 L2   Fss1  2Fsd1  L2
(9)
d
[1  K s1  2 K sd 1  2 K spd 1 K sd 1 ]
2
Considering the supporting force has a relation with the
adhesion force, [23],[24] then VI. ARM CONTROL AND SIMULATION RESULTS
Fssi  K si Fai (10) Crossing-over obstacles, the arm will rotate to locate the
where i  1, 2 and Ksi [0.35 0.5] . 2nd module after the obstacle. Although the velocity and
Based on the measurements of force on wheels and
sealing of [20], it is assumed that:

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 Figure 9. Block diagram representing the PID computed torque control

VII. CONCLUSIONS
Figure 7. Static and dynamic mode of the mobile robot A wall climbing robot crossing over-obstacles more than
15 cm in height and width in designed and presented.
Applying the presented simple design of two modules and
one link in between connected with active revolute joints, it
is possible to cross over obstacles up to 15 cm. Applying the
novel deign of two types of sealing, bristle skirt and rubber
tube, the adhesion force and so decrease the power
consumption can be reduced. Analysis of the robot adhesion
force in different modes, static, motion and crossing-over
obstacles to derive the required adhesion force as well as the
force of motion is presented. Applying high speed rotating
impeller, to achieve the adhesion force, is useful in avoiding
Figure 8. Force on joint 1 during crosses over the obstacle
the cables and hoses of the traditional applied pneumatic
circuits. A PID computed torque controller is designed,
acceleration dynamic components of the arm are small
simulated and its results show satisfactory performance with
compared to its gravitational force, it is taken into account
small errors in the joints angles, velocities and accelerations.
for more accurate results during simulation. However, in the
Implementing an experimental prototype of the presented
future-real time implementation, dynamics will be neglected.
system and applying a suitable algorithm for real time
A PID computed torque control, neglecting friction forces, is
control will be the next target of authors. The extension
applied to control the arm whose dynamics is described in
would also include: applying multistage impellers to
(5). Using MATLAB / SIMULINK, simulation of the arm
increase the adhesion force and applying skid steering to
dynamics and PID computed torque control is achieved
have turning motion capability.
[25],[21]. It is possible to achieve a stable control with error
equation as: 4

Kv e  K p e  Ki e  0
theta1
(15) 3
theta1 dot
theta1 doubledot

Applying a control law as:

theta2
theta2 dot
2
accelaration(rad/s 2)

theta2 doubledot
d  Kv e  K p e  Ki  e)  C (q, q )  G(q)
  D(q)(q
velocity (rad/s),
angle (rad),

(16) 1

The Block diagram of the control system is shown in

Fig.10. Table II shows the PID parameters of the controller. 0

The control law is applied on the 1st stage where the first -1

mobile module crosses over an obstacle then to make the

second module cross over (i.e. the 2nd stage and so all the
-2
0 1 2 3 4 5 6 7 8 9 10
time (s)

robot crosses over the obstacle), the same controller is

Figure 10. Reference trajectory of the 1 st and the 2nd joints.
applied after reversing the direction of the motors. Fig.10
shows the reference trajectory to make one module crosses the torque of each joint

over the obstacles and the corresponding torque is shown in 16

torque 1
14
Fig.11. As shown in Fig.12, there is a good agreement torque 2

between the actual and desired angles of the 1st and 2nd
12
torque 1 (N.m), torque 2 (N.m)

10
joints. The errors in the 1st and 2nd joint angles are less than 8

0.0006 rad. Also in Fig .13, the error in the angular velocity 6

in the 1st and 2nd joint doesn’t exceed 0.0001 rad/s. In Fig.14, 4

the angular acceleration of the 1st and 2nd joints and the error 2

is less than 0.2 rad/s2. 0

-2

TABLE II. PID CONTROLLER PARAMETERS -4

0 1 2 3 4 5 6 7 8 9 10
time (s)
Joint no. kP Kv Ki
1 100 20 100 Figure 11. The desired torque of the 1st and 2nd joints.
2 100 20 100

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