By Sun Chao and Yu Liang

On April 27, the AI-powered "Yuchao Feixiang" robot completed its first successful live-line operation in Henan Province. The robot was precisely deployed onto the 500 kV Mahui Transmission Line at Tower 036 by a heavy-lift drone, and successfully executed line traversal and nut replacement tasks—a first for the province and a major breakthrough in safe, efficient power grid maintenance.

Developed by State Grid Henan Extra-High Voltage Company, the "Yuchao Feixiang" robot consists of a powered locomotion mechanism and a multi-degree-of-freedom robotic arm. The locomotion unit integrates an onboard power supply, visual positioning system, and precision drive modules, enabling accurate navigation to designated work sites. Equipped with built-in "eyes" (high-definition cameras) and "tactile feedback" (force sensors), the robotic arm leverages an advanced AI model for intelligent decision-making, automatically locating pinholes and nuts to independently complete pin insertion and nut fastening. Ground operators receive real-time HD video feeds via the drone to monitor and verify all operations.

"The robot's locomotion mechanism resembles an elephant's sturdy body, providing stable support and movement, while the robotic arm acts like a dexterous elephant trunk that bends freely at multiple angles to grasp objects and perform precise manipulations," explained an on-site technician. This design inspiration gave the robot its name "Yuchao Feixiang" (literally "Henan EHV Flying Elephant").

"After two years of intensive R&D, this small step the robot has taken on the transmission line represents a landmark in Henan's EHV live-line operation technology," said a company spokesperson. Traditional EHV live-line work is defined by the "three highs": high voltage, intense electric fields, and high-altitude environments. Previously, workers had to climb towers or use insulated aerial lifts to reach equal potential for operations, which carried significant safety risks, required strenuous physical labor, and took much longer to complete.

By replacing human workers in these high-risk tasks, the "Yuchao Feixiang" robot cuts the time required for a single operation from 2 hours to just 1 hour. It also outperforms humans in operational precision and force control, delivering substantial efficiency gains while significantly reducing the risk of personnel exposure to hazardous conditions and lowering labor demands.

Looking ahead, State Grid Henan Extra-High Voltage Company will continue to expand the robot's capabilities to support additional critical EHV maintenance tasks, including insulator replacement, spacer replacement, and conductor and ground wire repair. The company aims to promote widespread and deeper integration of robotic systems in EHV live-line operations, ensuring the safe and stable operation of Henan's power grid through safer, more efficient and "zero-perception" maintenance (meaning no disruption to power supply for end users).