1. -1-
Research Experience
1. Independent research of Second-generation of 360bot—360botG2
Self-funded research
Shenyang Institute of Automation, Chinese Academy of Sciences (SIACAS)
09/2012-Present
Project Summary:
As in my previous modular robot (explained in project 3), individual modules got
independent mobility. But the module's steering capability was not effective and this
would impede its application. Then I wanted to design another novel module or
make some improvement of previous version to bring modular robot into the real
world (Figure 1- 1). Driven by my dissatisfaction and deep interest, I began this
project in my spare time.
Figure 1- 1. Scenario that the 360botG2 system is taking exploration tasks
After all, I have considered four main aspects in the design of the unit module (1)
good locomotion capabilities, especially to strengthen steering capability, (2)
maximize the use of the DOFs for displacement and reconfiguration processes, (3) a
trade-off between the module’s mobility and the reconfiguration capability, and (4) a
simple mechanism design that reduces manufacturing cost, decreases the complexity
when controlling the modules and increases the overall robustness of the system.

2. -2-
Project Results:
Finally, a new version (called 360botG2, as shown in Figure 1- 2), which has a
breakthrough in the mobility, has been designed and implemented after enormous
efforts, and even the money to fabricate the prototypes was saved from my living
cost. Certainly, some methods were sought to reduce manufacturing cost like that 3D
printer technology were used to produce main structures. The individual module
uses only two continuous rotational DOFs (Figure 1- 3) that contribute to both
locomotion (Figure 1- 5, 7, and 8) and reconfiguration (Figure 1- 6). An integrated
active connection mechanism (mechanical latches based and active magnetic aided
mechanism) is designed to increase the fault-tolerance (Figure 1- 4). In locomotion
mode, it uses a rotating cube to provide forward locomotion (Figure 1- 5) and a
rotating plate to perform steering (Figure 1- 7). This design has shown to be quite
exceptional in rough terrain conditions as an independently mobile module (Figure 1-
8). Preliminary locomotion tests in different environments demonstrate its mobility
and potential applications for exploration. Besides, the module can be used as a pan
and tilt mount for a sensor and this sensor could be easily moved around in this
mode to scan areas for exploration or mapping. These presented with clarity in a
movie attachment.
Figure 1- 2. A overall view of 360botG2 with
standard orientation(a). Three sub-pictures
show the most used functions: going straight
(b), normal turning mode(c) and efficient
turning mode or a pan-tilt platform (d)
Figure 1- 3. Structure design and DOFs
arrangement

3. -3-
Figure 1- 4. Front view of integrated
connector with ACM and magnetic guidence
(a). The 3D model of ACM(b).
Prototype of ACM(c)
Figure 1- 5. The straight moving process of
360botG2
Figure 1- 6. Sub-picture(a) shows that right
module helps the left module recover from
invalid orientation. Configuration in (b)
shows that a module is lifted to assemble
three dimensional configurations.
Figure 1- 7. The steering strategies of
360botG2: normal steering mode (a),
and right angle steering mode(b)
Figure 1- 8. These video frames show the
exploration work in unstructured
environments: (a) on outdoor brick floor,
(b) and on grassland with weeds.
Conclusion:
This project is an extension of my previous research in Self-Reconfigurable Modular
Robot (SRMR) and is totally driven by my interest. An improved module, which has a

4. -4-
breakthrough in its mobility and brings SRMR into real world, has been designed and
fabricated successfully. All work, except the electrical part, is done by myself and I am
proud of this robot.
2. Design a Device for Power Transmission Line Maintenance Robot
to Remove Entanglements
Master Project, Project with the Northeast Power
State Key Laboratory of Robotics, SIACAS
03/2013-Present
Dr. Wang Hongguang, Professor
Dr. Chang Yong, Associate Professor
Project Summary:
External entanglements on transmission line always result in a flashover due to
insufficient dielectric distance, especially in rainy days, which causes great loss for
society. Most entanglements are removed manually by lineman up to now and this
work is very dangerous and laborious as shown in Figure 2- 1. This project is to
design a power transmission line maintenance robot to assist lineman to remove the
hazardous entanglements easily and efficiently. My main job in this project is to
design a clearing device for this robot.
Figure 2- 1. The entanglements clearing jobs by lineman
Project Results:
Finally, a power transmission line maintenance robot with a composite clearing
device has been designed and implemented (Figure 2-5). The clearing mechanism
consists of a heating cutting tool (Figure 2-2), a blade cutting tool (Figure 2-3) and a
lifting device (Figure 2-4). The heating cutting tool is mainly used to remove thread
like entanglements which is combustible. The blade cutting tool is used to remove
cloth like or incombustible entanglements. These two sub-tools can deal with most
kinds of entanglements on power lines. A special lifting device is installed and this
can control the movement of two sub-tools separately with one actuator. The

5. -5-
effectiveness of the proposed mechanical design is verified and demonstrated by
numerous experimental studies (Figure 2-6). Aim at the practical application, the
future work should mainly be oriented toward the optimum design of the
mechanical structure.
Figure 2- 5. Prototype of Entanglements
Clearing Robot (a) and Elements of Clearing
Device (b,c,d)
Figure 2- 6. Experiments photos of
clearing procedure. Pictures (b, c and d) show
that thread like entanglements are removed
by heating cutting tool, picture (f, g and h)
show that the cloth like entanglements are
removed by blade cutting tool
Conclusion:
A novel clearing device, which consists of more than a hundred of mechanical parts,
is implemented to remove entanglements on power line. This is the most complex
Ribbon Shape
Heating Wire
Support
Links
Figure 2- 4. Model of
lifting device
Figure 2- 2. Model of
heating cutting Tool
Figure 2- 3. Model of
blade cutting tool

6. -6-
mechanism I have ever made, no matter in design stage or assembly process, and
more than three innovations are realized in this product. Experiments are conducted
to validate the device's applicability.
Publications:
 Cao Yanjun, Wang Hongguang, Chang Yong, etc. A Hazard Entanglements
Clearing Robot for Power Transmission Line with Composite Clearing Tool [C]
(Accepted by IEEE-CYBER2015).
 Wang Hongguang, Cao Yanjun, Chang Yong, etc. A Device to Remove
Hazard Entanglements on Power Transmission Line [P] (Application Number:
201410826433.2)
3. Designed and Fabricated A novel Mobile Self-Reconfigurable
Modular Robots—360bot
National University Student Innovation Program (NUSIP), Graduation Project
Tianjin University of Technology
10/2009-06/2012
Dr. Ge Weimin, Professor
Project Summary:
The target of this project was to develop a robot that could change its shape to meet
the variable requirements in different tasks, like the rescue job after earthquake or
exploration in unstructured environments. Our dream was to design a robot like the
transformer in the movie, but we later knew that this was too difficult to realize by
several undergraduate students. After some idealistic and impracticable fancy
designs being denied, we were upset and became stuck. One day I watched a video
by accident, which showed that tons of small intelligent cubes were built into various
complex configurations. The robots, which were Self-Reconfigurable Modular Robots
(SRMR) that I knew later, astonished and sparked me at that moment. Then I turned
to this kind of robot to deal with our task. With further review, we figured that the
mobility of unit module was important to the self-reconfiguration and self-assembly.
To improve the mobility of unit module became our new goal. Finally, a novel
modular robot, named as 360bot (Figure 3- 1), was developed and experiments were
implemented.

7. -7-
Figure 3- 1. “ Transformer” by 360bots and the prototype of 360bot
Project Results:
An innovative modular self-reconfigurable robot was designed and implemented,
namely 360bot, which had a continuous rotational degree of freedom. In addition to
the common features of conventional modular robots, each module could move
independently with its special and simple structure (Figure 3- 2, Figure 3- 3). The
mechanism of each module was designed with multiple connections, including four
connected faces and five connection modes, which enabled the modular unit
possessing multi-directional rotational degrees of freedom, and increased the
functions and types of the modular reconfiguration system. After structure design,
kinematic and dynamic modeling, and simulation, prototypes of 360bot were made
and evaluation was made by experiments. The configurations of double modules
were summarized and analyzed (Figure 3- 4). My BS thesis, which based on this
project, got the 2nd Prize in Graduation Design (Thesis) Competition of Tianjin
Division. A journal paper of this robot was published in the best academic journal in
robotic field in China.
Figure 3- 2. Independent mobility of 360bot
Figure 3- 3. The principle of 360bot’s steering capacity

8. -8-
Figure 3- 4. Configurations with strengthened mobility by double modules
Conclusion:
In this project, I made my first practical robot of my life. A novel module, which had
good performance with simple structure, was designed and fabricated. I experienced
all procedures of a robot fabricating process and these strongly improved my
research ability. A journal paper of this robot was published in the best academic
journal in robotic field in China.
Publications:
 CAO Yanjun, GE Weimin, ZHANG Huajin. Structure Design and Simulation
Analysis of an Innovative Modular Self-Reconfigurable Robot-360bot[J].
ROBOT, 2013,35(5): 568-575,606
 Cao Yanjun, Ge Weimin, Wei Xuan. Modular Unit of Reconfigurable
Modular Robots [P], China: CN202225936U, 2012-05-23
 Ge Weimin, Cao Yanjun, Wei Xuan. Reconfigurable Modular Robots [P],
China: CN102381378A, 2012-03-21
4. Structure design and Simulation of Insulator Detection Robot for
500kV Transmission Line
Project with the Northeast Power
State Key Laboratory of Robotics, SIACAS
01/2014-09/2014
Dr. Wang Hongguang, Professor
Dr. Pan Xinan, Associate Professor
Project Summary:
Power transmission line maintenance robot is designed to monitor the running
conditions and find out the damages of the power grids. The insulator detection
robot is designed mainly for detecting the vertical insulator strings with faulty
insulators on the strain tower. The functions of this robot include locomotion on
vertical insulator strings, protection of electromagnetic compatibility and insulation
design. My job in this project is to design a basic mechanism model and then make
simulations to evaluate the mechanism design and improve its moving performance.
Project Results:
The basic mechanism was designed as shown in Figure 4- 1. The working processes
that the robot climbed vertical insulators were simulated in RecurDyn (Figure 4- 2)

9. -9-
after acquiring the kinematic model. The simulation results under different motion
definitions provided Information that was used to select the motors. Finally a
trade-off control plan between the velocity and the torque was designed to acquire
good working performance (Figure 4- 3).
Figure 4- 1. The mechanism design of insulator detection robot and its simplified model for
simulation
Figure 4- 2. Simulations of process of climbing up one unit insulator
Figure 4- 3. Optimized velocity of insulator detection robot

10. -10-
Conclusion:
What I have done in this project mainly included design of a basic mechanism model,
simulations to verify the working principle, evaluation of the mechanism design,
improvement to acquire better performance and to get the preliminary information
for motor selection.
5. Other projects
In addition to projects above, there are some other projects that give me a lot of
experience. In the 2009 National Undergraduate Engineering Training Integration
Ability Competition, experience from design to machining of a carbon-free car gave
me an important guidance for my subsequent studies. A competition in 2010, which
was to program a smart car to track the specified path, strengthened my programing
skill. Many small projects from when I was young also contributed to my manual
ability a lot. For example, when I was 14 and with my father’s help, I tried to make a
mechanism of wood to assist people to make dumplings. Although the results of
these projects were not always successful, they have brought significance for my
development.