Optimization Design of Pipeline Intelligent Plugging Robot Slip Structure Based on Pipe Wall Wear Response

Pipeline intelligent plugging robots (PIPRs) are used for in-line isolation and emergency repair of oil and gas pipelines. During anchoring, slip teeth contact the inner pipe wall. This contact causes stress concentration, microslip, and local wear. Pipe wall wear may reduce pipeline service life and plugging reliability. This study proposes a wear-response-based optimization method for slip structure design. A simplified slip–pipe contact model was established. Wear depth was selected as the main response. Five slip structural parameters were used as design variables. The Box–Behnken Design (BBD) model was constructed to describe the relationship between structural parameters and wear depth. The Ant Lion Optimizer (ALO) model was introduced to search for the minimum-wear parameter combination. Contact stress and local deformation were used as auxiliary indicators for structural safety evaluation. Experimental tests were conducted to verify the simulation and optimization results. Strain-derived stress and wear scar morphology were compared with the numerical results. The results show that the optimized structure reduces the minimum wear depth to 0.045 mm. The experimental results agree with the simulation trend. This indicates that the proposed method can reduce pipe wall wear while maintaining anchoring reliability. The BBD–ALO framework provides a general optimization method for contact structures with wear constraints. This method can be applied to anchoring, gripping, and support structures in pipeline robots and other mechanical systems.