A wall-climbing robot developed by a research team at Harbin Engineering University in Heilongjiang province has been deployed at a wind power plant in Nanjing, Jiangsu province, marking the first real-world test of technology the team hopes will replace dangerous manual inspections at height.

The robot uses suction rather than magnetic force to grip surfaces, allowing it to climb metal, glass, and other smooth vertical materials without damaging the protective coatings on wind turbine towers, a limitation of conventional magnetic-adsorption systems. It can carry up to five kilograms of detection equipment and is fitted with a camera system capable of identifying cracks, rust, and structural defects on tower surfaces, according to Zhang Lanyong, a professor from the university's College of Intelligent Systems Science and Engineering.

The eight-member team behind it, comprising two teachers and six students from the university's Xiaoping National Innovation and Technology Team, began development in July 2025 to meet the needs of Nanjing Wind Power Technology, and completed a working prototype by March this year. The team members have an average age of around 20.

"When we first received the company's demand, we were both excited and nervous," said team member He Kai, a first-year master's student. "Wind turbine towers can be tens of meters high, making traditional manual inspections risky and costly, so we wanted to use robots to climb high instead of people."

From designing the blueprints to the first prototype, the team underwent hundreds of suction force tests and climbing algorithm optimizations. Each failure led to minor adjustments until the machine was able to walk on uneven walls.

The robot is also set for a broader deployment. The university has reached an agreement with State Grid Heilongjiang Electric Power Company to use the technology for winter inspections of transmission towers and substation infrastructure across Heilongjiang, where cold temperatures make manual tower climbing particularly hazardous.

"The harsh winter in Heilongjiang makes it extremely challenging to inspect power grid facilities, and manual tower climbing operations are very risky," said Zhang. "The robot is resistant to low temperatures and strong winds, which will empower the intelligent upgrade of power operation and maintenance with cutting-edge technology and fill the technical gap in the field of high-altitude power intelligent inspection within the province."

Video by Zhou Huiying/China Daily