Design, dynamic modeling and testing of a novel MR damper for cable-stayed climbing robots under wind loads.

To increase the adaptability of bridge construction equipment in high-altitude settings, this study examines a magnetorheological (MR) damper designed for cable-stayed climbing robots. Initially, a novel damper incorporating a spring-MR fluid combination and three magnetic circuit units is developed. A robot-cable-wind coupling dynamic model is subsequently formulated via Hamilton's principle, based on force analysis. The simulation results indicate that the damper's maximum output force is 204.60 N, with optimal working currents of 0.2 A (Force 4) and 0.4 A (Force 7). To verify the analysis, testing is conducted using an MR damper. The results reveal an average relative error of 4.60% for the actual output damping force. When mounted on the robot, the climbing speed range, average relative error, and maximum relative error are controlled within 0.66 mm/s, 0.78% and 2.5%, respectively. This approach allows for the rapid selection of suitable working currents and markedly enhances the climbing stability of the robot.