Efficiently solving inverse kinematics (IK) of robot manipulators with offset wrists remains a challenge in robotics due to noncompliance with Pieper criteria. In this paper, an improved method to solve the IK for 6-DOF robot manipulators with offset wrists is proposed. This method is based on the Newton iteration technique, but it does not require a selection of initial estimation of joint variables. The solution is divided into two parts: the first part is to reconstruct a simplified structure with analytical IK solution, and the second part is to obtain a numerical solution by iteration. Further, a robot manipulator HSR-BR606 with an offset wrist is used as an example to specifically elaborate the mathematical procedure of the method and to investigate the algorithm in terms of accuracy, efficiency, and application of motion planning. A comparative experiment is conducted with a typical IK algorithm, which demonstrates a higher accuracy and shorter calculation time of the proposed method. The mean calculation time for a single IK solution required for this algorithm is only 4% of the comparison algorithm.

An unexpected path reversal is discovered for a serial robot with an offset-axis wrist over a finite range of proximity to the wrist singularity. This is replicated by a kinematic model. A prior spherical-wrist method transits the singularity with limited joint rate and acceleration under a constant rate of tool traversal. Accurate position is maintained by controlling a small deviation in orientation. Extensions to the method for an offset wrist (1) find the least-maximum deviation, (2) identify and locate where a path reversal occurs, and (3) use this point to control step size in a high-order predictor-correction path following procedure.