Structural design and control strategy of a cable-driven robot under high-altitude facade conditions with large span and multiple constraints

Purpose This paper explores the challenges of using cable-driven parallel robots on high-altitude, large-span facades, where redundancy in multicable systems and the elastic deformation of the cables are significant issues. This study aims to improve the accuracy and stability of the work platform through enhanced control strategies. These strategies address the redundancy in multicable systems and reduce the risks associated with cable deformation and mechanical failures during large-span movements. Design/methodology/approach The paper proposes a dynamic model for a four-rope parallel robot designed explicitly for large-span applications. The study introduces a position–force control strategy incorporating kinematic inverse solutions and a rope dynamics model to account for rope elasticity and its effects. This approach increases the number of system equations to match the unknowns, effectively solving the redundancy problem inherent in multicable systems. In addition, the tension changes of ropes and the stability of the working platform are examined under different motion distances ( X = 50 m and X = 100 m) and varying Young’s modulus values ( K = 5000 MPa and K = 8000 MPa). Findings This study’s large-span rope force–position control strategy successfully resolves the typical nonlinear characteristics and external disturbances in multicable parallel systems. By continuously monitoring and adjusting cable tension and end positions, this strategy ensures precise control over each cable’s tension, optimizes the distribution of cable tensions and maintains the system’s stability and response speed. The analysis in this paper indicates that this control strategy significantly improves the motion accuracy of robots operating on large-span high-altitude facades. Practical implications Industry adoption: The design and control strategies developed for the four-cable-driven parallel robot can be adopted by companies specializing in facade maintenance, construction or inspection. This could lead to safer, more efficient and cost-effective operations, especially in challenging environments like high-rise buildings. Innovation in robotic solutions: The research can inspire innovation within the field of robotics, particularly in developing robots for specific applications such as large surface maintenance. It showcases how adaptive control and stability can be achieved in complex operational scenarios. Safety improvements: By demonstrating a more stable and precise control mechanism for navigating large facades, the study could contribute to significant safety improvements, reducing the risk of accidents associated with manual facade maintenance and inspection tasks. Originality/value This paper combines the force/position hybrid control method with actual robotic applications, offering a novel solution to the complex issue of controlling cable-driven parallel robots in challenging environments. Thus, it contributes to the field. The proposed method significantly enhances the precision and stability of such systems and provides robust technical support for high-precision tasks in complex mechanical settings.