Climbing Tests and Dynamic Simulation of a Cable-Climbing Mechanism for Stay Cable De-Icing Robot

In winter, stay cable sheaths are prone to icing, which increases cable loads and poses a falling-ice hazard upon thawing. While manual and chemical de-icing are common methods, their safety and cost drawbacks make robotic de-icing a promising alternative. Robotic de-icing offers a promising alternative. However, to protect the sheath from damage, the de-icing blade is designed to minimize contact with its surface. Consequently, a thin layer of residual ice is often left behind, which reduces the surface friction coefficient and complicates the climbing process. This study evaluates the climbing performance of a self-manufactured cable-climbing mechanism through laboratory tests and dynamic simulations (ADAMS). A physical prototype was built, and dynamic simulations of the cable-climbing mechanism were conducted using Automated Dynamic Analysis of Mechanical Systems (ADAMS) software. The preliminary validation results demonstrate that the mechanism is capable of maintaining stable climbing under extreme conditions, including a friction coefficient of 0.12 to reflect thin-ice variability and indicated stable climbing even at μ = 0.12), a vertical inclination of 90°, and a load of 12 kg, confirming the design’s validity. Furthermore, we analyzed key parameters. A lower friction coefficient requires a higher clamping force and adversely affects the climbing speed due to increased slip. Similarly, an increased payload elevates the mechanism’s deflection angle, spring force, and wheel torque, which in turn reduces the climbing speed. Cable inclination has a complex effect: deflection decreases with slope, yet clamping force peaks near 70°, showing a bell-shaped trend. This peak requirement dictated the damping spring selection, which was given a safety margin. This ensures safe operation and acceleration at all other angles. Limitations: The present results constitute a feasibility validation under controlled laboratory conditions and rigid-support simulations. The long-term effects of residual ice and field performance remain to be confirmed in planned field trials.