Robots taking care of power line maintenance

We have seen robots running, cooking, playing musical instruments and replying to customer chat queries. Or performing even more complex and functional tasks such as moving packages in warehouses, assisting the elderly and even undertaking house construction tasks. Robots now do anything and everything, and Italian national electricity transmission grid manager Terna has decided to put them to work for the general good by using them also for electricity grid maintenance. This becomes an increasingly complex matter in a time when infrastructure quality and resilience act as a defensive bulwark for energy transition, protecting against the consequences of climate change.

That's why Terna’s 70-odd ongoing innovation projects also include the study and testing of innovative robotics solutions to support activities in this field, particularly in “operation & maintenance” processes. The robot in this case comes from Japan, the result of a collaboration with the Japanese company Hibot. They developed an initial prototype that could move on the conductors (the high-voltage cables supported by pylons and carrying electricity) and on the shield wires (the parts protecting against electrical discharges from lightning, etc.) of overhead power lines. They are thus able to carrying out maintenance activities even when the lines are in operation and transmitting electricity. A very hazardous task that must be performed with the utmost care and safety at every step.

The automated solution was tested in 2024 on the systems of the Rondissone electrical substation, in the province of Turin. Initial tests ended successfully, aided by the robot’s special automatic tools, with the installation of components on the power line conductors and on the shield wires. The activity specifically involved checking the current status of the prototype's functionality, through tests on the pre-formed bars installed on the electricity-bearing cables, and tests on the shield wire warning spheres.

As Carla Napolitano, Head of Innovation at Terna says, «Robotic solutions like the one we are implementing with Hibot will work alongside our people and guarantee even higher levels of safetyduring the asset maintenance operations we perform daily throughout Italy. The development of innovative robotics solutions for the automation of operation & maintenance activities is one of the key factors of the digital transition that, as stated in our 2024-2028 Industrial Plan, will have to partner and support the energy transition. This project is part of our ongoing commitment to evolve, innovate and render these activities even more efficient by developing further cutting-edge technologies. The result will be improved infrastructure performance with significant benefits for the entire national electricity grid».

This is also Hibot’s mission, according to CEO Michele Guarnieri: «We firmly believe that our robotics solutions can not only make everyday life easier, but also really contribute to making the world a safer and more sustainable place». Paraphrasing father of robotics Isaac Asimov’s principals, Guarnieri reiterates that «the mission is to develop advanced robotic solutions that work for mankind» and not against it, as is sometimes feared, «promoting automation as a tool to improve safety, quality of life and operational efficiency in various sectors. One example of this commitment was the work we did to help make the Fukushima nuclear plant safe again. The project with Terna aligns perfectly with Hibot's mission: to create technology solutions that improve safety, sustainability and efficiency in industry, and that help our customers take full advantage of the opportunities of digital transformation. Our partnership with Terna has been an incredibly fruitful and satisfying experience right from day one».

One of the promoters of the initiative is Marco Forteleoni, head of Terna's Transmission Operator Factory, who has supported the prototype from its early stages. «This is a challenging and complex project, so it is a team operation combining varied specialist skills», he comments. «The goal is to develop innovative solutions increasingly geared towards business needs, with a particular focus on boosting the effectiveness and efficiency of operation & maintenance activities in the national electricity transmission grid».

The project has drawn in various key areas of the company, including the team lead by Antonio Piccolo, Head of Asset Management - Working Methods at Terna, who says he's confident about the steps to come: «The robot has been developed in progressive, evolutionary steps, and the results achieved so far give us confidence in the next phase of the project. In order to ensure the robot's full usability, we will focus on how to move on overhead power lines, ensuring weights and dimensions that favour manoeuvrability».

Following the laboratory tests and those carried out earlier this year at the Bertignano “test field”, October 2024 saw the second round of tests at the Rondissone plant, where the solution had already been tested in June with lines in service. In June, patent applications were filed for the solution thus far developed. The next step will be a new design phase, with the aim of completing the prototype and, by the end of 2025, starting the adoption process for this innovation to increase worker safety.

Innovation and digitalisation are two pillars of Terna's strategy: to achieve the goals of the twin energy/digital transition, as reported in the new 2024-2028 Industrial Plan presented on 19 March 2024, Terna has earmarked a 2 billion euros investment tranche out of the total 16.5 billion, which will be channelled towards digitalisation and innovation initiatives.