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

A bstract: This paper introduces a new concept of applying a parallel mechanism in automated fiber placement for aerospace part manufacturing. By investigating the system requirements, a 4-DOF parallel mechanism consisting of two RPS(revolute-prismatic-spherical joints) and two UPS(universal-prismatic-spherical joints) limbs with two rotational and two translational 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 two UPS limbs with the platform and base sizes are used in the optimization which gives a new design of a 4-DOF 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 automated fiber placement.

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