Design and Kinematic Analysis of a Metamorphic Mechanism-Based Robot for Climbing Wind Turbine Blades

Wind turbine blades feature complex geometries and operate under harsh conditions, including high curvature gradients, nonlinear deformations, elevated humidity, and particulate contamination. This study presents the design and kinematic analysis of a novel climbing robot based on a 10R folding metamorphic mechanism. The robot employs a hybrid wheel-leg drive and adaptively reconfigures between rectangular and hexagonal topologies to ensure precise adhesion and efficient locomotion along blade leading edges and windward surfaces. A high-order kinematic model, derived from a modified Grubler–Kutzbach criterion augmented by rotor theory, captures the mechanism’s intricate motion characteristics. We analyze the degrees of freedom (DOF) and motion branch transitions for three representative singular configurations, elucidating their evolution and constraint conditions. A scaled-down prototype, integrating servo actuators, vacuum adhesion, and multi-modal sensing on an MDOF control platform, was fabricated and tested. Experimental results demonstrate a configuration switching time of 6.3 s, a single joint response time of 0.4 s, and a maximum crawling speed of 125 mm/s, thereby validating stable adhesion and surface tracking performance. This work provides both theoretical insights and practical validation for the intelligent maintenance of wind turbine blades.