Energy-efficient propeller-driven climbing robot design based on glass-fiber reinforced polymer

Three techniques were investigated to optimize the performance of a propeller-driven climbing robot: i) materials optimization using glass fiber reinforced polymer (GFRP) laminates with three distinct configurations — symmetric cross-layer (0°/90°), antisymmetric cross-layer (0°/90°), and antisymmetric angle-layer (±45°), ii) optimization of the robot chassis structural topology using density-based methods, and iii) laminate thickness (0.5–3.0 mm) and fiber content (50–70 v%). Optimal performance was achieved for an antisymmetric angle-layer configuration of 2.2 mm with 60 v% fiber content, resulting in a weight reduction (6.8%). Combined with a topologically optimized chassis design (20.1% weight reduction), the entire system achieves a 23.5% weight reduction, which translates into energy savings (23.6% torque reduction and 17.3% thrust reduction) while maintaining structural integrity. These results set a new standard for energy-efficient climbing robot designs, thanks to the synergistic optimization of materials and structures.