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Research Papers

Design and Analysis of a High-Payload Manipulator Based on a Cable-Driven Serial-Parallel Mechanism

[+] Author and Article Information
Fei Liu

State Key Laboratory of Robotics and System,
Harbin Institute of Technology,
Harbin 150001, China;
School of Mechanical Engineering and Automation,
Harbin Institute of Technology,
Shenzhen 518055, China;
Xili University Town,
Shenzhen 518055, China
e-mail: liufei8715@163.com

Wenfu Xu

School of Mechanical Engineering and Automation,
Harbin Institute of Technology,
Shenzhen 518055, China;
Xili University Town,
Shenzhen 518055, China
e-mail: wfxu@hit.edu.cn

Hailin Huang

School of Mechanical Engineering and Automation,
Harbin Institute of Technology,
Shenzhen 518055, China;
Xili University Town,
Shenzhen 518055, China
e-mail: huanghitsz@gmail.com

Yinghao Ning

School of Mechanical Engineering and Automation,
Harbin Institute of Technology,
Shenzhen 518055, China;
Xili University Town,
Shenzhen 518055, China
e-mail: ning_ying_hao@sina.com

Bing Li

State Key Laboratory of Robotics and System,
Harbin Institute of Technology,
Harbin 150001, China;
School of Mechanical Engineering and Automation,
Harbin Institute of Technology,
Shenzhen 518055, China;
Xili University Town,
Shenzhen 518055, China
e-mail: libing.sgs@hit.edu.cn

1Corresponding authors.

Contributed by the Mechanisms and Robotics Committee of ASME for publication in the Journal of Mechanisms and Robotics. Manuscript received January 28, 2019; final manuscript received June 12, 2019; published online July 9, 2019. Assoc. Editor: Veronica J. Santos.

J. Mechanisms Robotics 11(5), 051006 (Jul 09, 2019) (15 pages) Paper No: JMR-19-1033; doi: 10.1115/1.4044113 History: Received January 28, 2019; Accepted June 12, 2019

In this paper, a lightweight high-payload cable-driven serial-parallel manipulator is proposed. The manipulator comprises one 3-degree-of-freedom (3-DOF) shoulder joint and one single-DOF elbow joint. Using a special tension-amplifying principle, which is an ingenious two-stage deceleration method, the proposed manipulator has a higher load/mass ratio than those of conventional manipulators. In this paper, the special tension-amplifying principle is discussed in detail. The shoulder and elbow joints of the proposed manipulator are driven by cables. The design of this cable-driven mechanism and the mobility of the joints are analyzed, and the structural parameters of the joints are optimized to improve the payload capacity. The size of the manipulator is close to that of a human arm because the actuators of the cable-driven mechanism can be rear-mounted. Because the elbow joint is located at the end of the shoulder joint and the driven cables of the elbow joint are coupled with the rotation of the shoulder joint, the manipulator is designed with decoupled cable routing. The overall configuration and cable routing of the manipulator are presented, and then, kinematics, joint stiffness, strength, and workspace of the manipulator are analyzed. Finally, we report on the fabrication of a physical prototype and testing of its joint stiffness, payload capacity, workspace, speed, and repeatability to verify the feasibility of our proposed manipulator.

Copyright © 2019 by ASME
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Figures

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Fig. 1

Sketch of human arm with load

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Fig. 2

Proposed 3-DOF CDPM

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Fig. 3

Three typical layout structures of the 3-DOF CDPM: (a) equal-proportionate structure, (b) and (c) unequal-proportionate structure

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Fig. 4

Single-DOF CDPM with two revolute pairs: (a) structure and (b) driving principle

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Fig. 5

Principle of tension amplification

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Fig. 6

Conceptual design of the manipulator structure

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Fig. 7

Kinematics model of the shoulder joint

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Fig. 8

Kinematics model of the elbow joint

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Fig. 9

Strength and stiffness curves of the 1-DOF joint with pulley reduction ratios n = 1, 4, 6

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Fig. 10

Strength and stiffness curves of the 3-DOF joint with pulley reduction ratios n = 1, 4, 6

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Fig. 11

Strength and stiffness of the 3-DOF joint in the direction of X-axis rotation

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Fig. 12

Workspace scatter cloud of the proposed manipulator: (a) three dimensional and (b)–(d) two dimensional

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Fig. 13

Structure of the elbow joint: (a) original one and (b) optimized one

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Fig. 14

Projection view of the joint model of Fig. 2 in plane A

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Fig. 15

Output torque of the 3-DOF joint in the direction of X-axis rotation

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Fig. 16

3D model of the proposed manipulator: (a) top view, (b) side view, (c) details of the shoulder joint, (d) details of the elbow joint, and (e) and (f) details of the cables routing

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Fig. 17

Snapshots of the motion of the manipulator: (a) 1-DOF elbow joint and (b) 3-DOF shoulder joint

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Fig. 18

Experimental setup for the joint stiffness test: (a) elbow joint and (b) shoulder joint

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Fig. 19

Experimental setup for the load test: (a) X-axis and Y-axis directions and (b) Z-axis direction

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Fig. 20

Experimental setup for workspace, speed, and repeatability test

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Fig. 21

Rotation range of the proposed manipulator

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Fig. 22

Repeatability test result of the proposed manipulator

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