In response to problems such as insufficient adhesion, difficulty in adjustment, and weak obstacle-crossing capabilities in traditional robots, an innovative design has been developed for a five-wheeled climbing robot equipped with a pendulum-style magnetic control adsorption module. This design effectively reduces the weight of the robot, and sensors on the magnetic adsorption module enable real-time monitoring of magnetic force. Intelligent control adjusts the pendulum angle to modify the magnetic force according to different wall conditions. The magnetic adsorption module, using a Halbach array, enhances the concentration effect of the magnetic field, ensuring excellent performance in high-load tasks such as building maintenance, bridge inspection, and ship cleaning. The five-wheel structural design enhances the stability and obstacle-crossing capability, making it suitable for all-terrain environments. Simulation experiments using Maxwell analyzed the effects of the magnetic gap and the angle between the adsorption module and the wall, and mechanical performance analysis confirmed the robot’s ability to adhere safely and operate stably.

Wall-climbing robots have broad application potential in industrial equipment inspection, chemical storage tank maintenance, and high-altitude operations. However, their practical implementation is challenged by the robots’ adhesion requirements in complex wall environments. This study uses a systematic methodology integrating computational simulation and experimental validation to design and optimize a magnetic adsorption system for wall-climbing robots. Firstly, an adjustable suspended magnetic adhesion unit is designed to achieve intelligent control of a wall-climbing robot’s adhesion force on a wall surface. The Maxwell software (AnsysEM21.1) is used to simulate and analyze the critical parameters of the magnetic adsorption unit, including the thickness of the magnet and yoke, as well as the distance and angle between the magnet and the wall surface. Then, a magnetic wheel is designed for the wall-climbing robot based on the optimization of the structure and parameters of the magnetic adhesion unit. The absorption and demagnetization of the magnetic wheels are achieved by rotating the magnetic absorption unit. Subsequently, the simulation results are verified on the experimental platform, and adhesion performance tests are conducted on both standard flat surfaces and inclined walls. The results show that the optimized single magnetic adhesion unit gives the wall-climbing robot an adhesion force of 2767 N under normal working conditions, with a simulation experiment error margin as low as 8.3%. These results both provide theoretical guidance and highlight practical methodologies for developing high-performance magnetic adsorption systems in complex operational environments.