Optimized Venturi-Ejector Adsorption Mechanism for Underwater Inspection Robots: Design, Simulation, and Field Testing

Stable adhesion on non-magnetic, steep, and irregular underwater surfaces (e.g., concrete dams with cracks or biofilms) remains a challenge for inspection robots. This study develops a novel adsorption mechanism based on the synergistic operation of a Venturi-ejector and a composite suction cup. The mechanism utilizes the Venturi effect to generate stable negative pressure via hydrodynamic entrainment and innovatively adopts a composite suction cup—comprising a rigid base and a dual-layer EPDM sponge (closed-cell + open-cell)—to achieve adaptive sealing, thereby reliably applying the efficient negative-pressure generation capability to rough underwater surfaces. Theoretical modeling established the quantitative relationship between adsorption force (F) and key parameters (nozzle/throat diameters, suction cup radius). CFD simulations revealed optimal adsorption at a nozzle diameter of 4.4 mm and throat diameter of 5.8 mm, achieving a peak simulated F of 520 N. Experiments demonstrated a maximum F of 417.9 N at 88.9 W power. The composite seal significantly reduced leakage on high-roughness surfaces (Ra ≥ 6 mm) compared to single-layer designs. Integrated into an inspection robot, the system provided stable adhesion (>600 N per single adsorption device) on vertical walls and reliable operation under real-world conditions at Balnetan Dam, enabling mechanical-arm-assisted maintenance.