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Research Papers

Singularity-Free Workspace Aimed Optimal Design of a 2T2R Parallel Mechanism for Automated Fiber Placement

[+] Author and Article Information
Dongming Gan

Robotics Institute,
Khalifa University of Science,
Technology and Research,
Abu Dhabi 127788, UAE
e-mail: dongming.gan@kustar.ac.ae

Jian S. Dai

School of Natural and Mathematical Sciences,
King’s College London,
University of London,
London WC2R 2LS, UK

Jorge Dias

Robotics Institute,
Khalifa University of Science,
Technology and Research,
Abu Dhabi 127788, UAE
Faculty of Science and Technology,
Institute of Systems and Robotics,
University of Coimbra,
Coimbra 3030-790, Portugal

Rehan Umer

Aerospace Research and Innovation Center,
Khalifa University of Science,
Technology and Research,
Abu Dhabi 127788, UAE

Lakmal Seneviratne

Robotics Institute,
Khalifa University of Science,
Technology and Research,
Abu Dhabi 127788, UAE
School of Natural and Mathematical Sciences,
King’s College London,
University of London,
London WC2R 2LS, UK

1Corresponding author.

Manuscript received June 26, 2014; final manuscript received March 1, 2015; published online July 17, 2015. Assoc. Editor: Xianmin Zhang.

J. Mechanisms Robotics 7(4), 041022 (Nov 01, 2015) (9 pages) Paper No: JMR-14-1149; doi: 10.1115/1.4029957 History: Received June 26, 2014; Revised March 01, 2015; Online July 17, 2015

This paper introduces a new concept of applying a parallel mechanism in automated fiber placement (AFP) for aerospace part manufacturing. By investigating the system requirements, a 4DOF parallel mechanism consisting of two revolute–prismatic–spherical joints (2RPS) and two universal–prismatic–spherical joints (2UPS) limbs with two rotational (2R) and two translational (2T) motions is proposed. Both inverse and forward kinematics models are obtained and solved analytically. Based on the overall Jacobian matrix in screw theory, singularity loci are presented and the singularity-free workspace is correspondingly illustrated. To maximize the singularity-free workspace, locations of the 2UPS limbs with the platform and base sizes are used in the optimization which gives a new design of a 4DOF parallel mechanism. A dimensionless Jacobian matrix is also defined and its condition number is used for optimizing the kinematics performance in the optimization process. A numerical example is presented with physical constraint considerations of a test bed design for AFP.

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Figures

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Fig. 1

A serial robot arm based AFP system [34]

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Fig. 2

A 2RPS–2UPS parallel mechanism based AFP system: (a) the proposed AFP system and (b) a 2RPS–2UPS parallel mechanism

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Fig. 3

Representative kinematics model of the 2RPS–2UPS parallel mechanism

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Fig. 4

Selected points and directions on the platform

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Fig. 5

Singularity loci and configurations: (a) example I and (b) example II

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Fig. 6

Maximum singularity-free workspace (a) for a given d and (b) a circle in θ = π/2 plane

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Fig. 7

Effect of parameters a1 and b1: (a) maximum singularity-free workspace and (b) kinematics performance

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Fig. 8

Effect of parameters ϕb1 and ϕa1: (a) maximum singularity-free workspace and (b) kinematics performance

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Fig. 9

Effect of parameters ϕa1 and ϕa3: (a) maximum singularity-free workspace and (b) kinematics performance

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Fig. 10

Effect of parameter ϕb1 and ϕb3: (a) maximum singularity-free workspace and (b) kinematics performance

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Fig. 11

The optimized mechanism configuration

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Fig. 12

Effect of parameters λl and ψmax: (a) maximum singularity-free workspace and (b) kinematics performance

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