In current robot calibration approaches, the error propagation and identification of serial and parallel robots fail to be solved intuitively and generically, resulting in an inefficient calibration implementation and a low accuracy improvement. In this article, we present a generic error modeling method of serial robots and extend to parallel robots by finite and instantaneous screw (FIS) theory. The differential map and the explicit description of FIS on the robot motions enable a concise error modeling of the serial robot. The identifiability of errors in serial robot is discussed. The maximum independent errors are proved to be 4r + 2p + 6, where r and p are the numbers of revolute and prismatic joints, respectively. Based on the error mapping of serial limbs, reciprocal twist and wrench are introduced to consider the interaction among limbs and reveal the error propagation of the parallel robot. Then, the identification algorithms with high robustness and efficiency are investigated for the serial and parallel robots. Specifically, the conventional ill-conditioning problems of parallel robots are addressed. Finally, the proposed kinematic calibration framework for both types of robots are compared with the existing methods, and verified by simulations and experiments. The results show that our calibration approach improves the robot accuracy in a robust and efficient manner.

© 2016 Elsevier Ltd This paper for the first time presents a finite screw approach to type synthesis of three-degree-of-freedom (DOF) translational parallel mechanisms (TPMs). Firstly, the finite motions of a rigid body, a TPM and its limbs are described by finite screws. Secondly, given the standard form of a limb with the specified DOF, the analytical expressions of the finite screw attributed to the limb are derived using the properties of screw triangle product, resulting in a full set of the 3-, 4- and 5-DOF limbs that can readily be used for determining all the potential topological structures of TPMs. Finally, the assembly conditions for type synthesis of TPMs are proposed by taking into account the inclusive relationship between the finite motions of a TPM and those of its limbs. The merit of this approach lies in that the limb structures can be formulated in a justifiable manner that naturally ensures the full cycle finite motion pattern specified to the moving platform

Unifying the models for topology design and kinematic analysis has long been a desire for the research of parallel kinematic machines (PKMs). This requires that analytical description, formulation and operation for both finite and instantaneous motions are performed by the same mathematical tool. Based upon finite and instantaneous screw theory, a unified and systematic approach for topology design and kinematic analysis of PKMs is proposed in this paper. Using the derivative mapping between finite and instantaneous screws built in the authors’ previous work, the finite and instantaneous motions of PKMs are analytically described by the simple and non-redundant screws in quasi-vector and vector forms. And topological and parametric models of PKMs are algebraically formulated and related. These related topological and parametric models are ready to do type synthesis and kinematic analysis of PKMs under the unified framework of screw theory. In order to show the validity of the proposed approach, a kind of two-translational and three-rotational (2T3R) 5-axis PKMs is taken as example. Numerous new structures of the 2T3R PKMs are synthesized as the results of topology design, and their Jacobian matrix is obtained easily for parameter optimization and performance evaluation. Some of the synthesized PKMs have outstanding capabilities in terms of large workspaces and flexible orientations, and have great potential for industrial applications of machining and manufacture. Among them, METROM PKM is a typical example which has attracted a lot of attention from global companies and already been developed as commercial products. The approach is a general and unified approach that can be used in the innovative design of different kinds of PKMs.

The Hessian matrix, one of the most pivotal parts in a robotic system's acceleration model, is a prerequisite for dynamic modeling and control of parallel robots. Aimed at providing a straightforward and effective way for modeling, design, and control of parallel robots, a new approach to formulate the Hessian matrix using the finite and instantaneous screw theory is presented in this paper. The new approach is generalizable in that it can be used to formulate the Hessian matrix of any parallel robot in a simple and concise manner. It also provides a theoretical foundation for the dynamic control of industrial robotic systems with parallel structures. The new approach is verified through comparison with the traditional exponential matrix method. The Exechon parallel robot and a hybrid serial-parallel robot are used as examples to further detail the procedures of this approach. The acceleration model formulated in this paper is closely related with the topological and parametric models, resulting in a unified mathematical framework for modeling and control of parallel robots.