Abstract: It is an inevitable trend that intelligent devices such as robots are adopted to assist or replace human labour in live work. Focusing on the live working robot which is fixed in insulating aerial device with 6-axis collaborative robotic arms and works on 10 kV distribution lines, we calculated the insulation level of robot live work by the conventional method of insulation coordination. Moreover, based on the experiments for breakdown characteristics of typical air gaps and layer/surface insulation properties of insulation materials, the safety requirements were put forward. The tests show that, the switching impulse withstand voltage of main insulation should be at least 45.1 kV (peak) of phase to earth and 66.4 kV (peak) of phase to phase, and the power frequency (AC 50 Hz) withstand voltage of secondary insulation should be at least 15.2 kV (root mean square). The minimum electrical distance is 8.8 cm of phase to earth or 13.0 cm of phase to phase. The recommended minimum safety distance of a lead wire autonomously connecting robot is not less than 0.2 m. When adopting the "body-arm-wrist" triple insulation protection scheme, the insulation thickness of the robotic arm should not be less than 1 mm, and the overlapping distance of the joint rotating parts should not be less than 3 cm. A double-layer insulation and stacking structure suitable for flexible movement of 6-axis collaborative robotic arm joints is designed. The test results show that the developed insulation sheaths and connectors are able to meet the insulation requirements of 10 kV live work.