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To improve the safety and efficiency of polishing operations in circular boiler headers,a new type of wheel-drive polishing robot was developed in this study.The robot was designed to grind weld beads on the inner walls of pipes in diameter between 550 mm and 714 mm.The robot consists of a moving structure,a positioning structure,and a polishing structure.Charge coupled device (CCD) cameras and line lasers are used in the robot’s vision system,thus the robot can be manually controlled to move,locate,and grind quickly and accurately.The experimental results showed that the robot performed well in practical applications.