This paper deals with the design of a three-degree-of-freedom (3-DoF) parallel kinematic mechanism (PKM) with high orientational capability. First, a type synthesis method based on Grassmann line geometry and a line-graph method is proposed, and a novel 3-DoF PKM is derived based on this method. Thereafter, the parasitic motions of the derived mechanism are identified under two different orientation description methods, i.e., Tilt-and-Torsion angles (T&T angles) and Roll-Pitch-Yaw angles (RPY angles), and the kinematic optimization considering the motion/force transmissibility is carried out. On this basis, the orientational capability of the discussed mechanism is investigated, and the high orientational capability is demonstrated. The design of the 3-DoF PKM in this paper is very meaningful to the development of the five-axis machine tools with hybrid architectures. The design methods of type synthesis and kinematic optimization can also be used in the design of other PKMs.

We present a new numerical optimal design for a redundant parallel manipulator, the eclipse, which has a geometrically symmetric workspace shape. We simultaneously consider the structural mass and design efficiency as objective functions to maximize the mass reduction and minimize the loss of design efficiency. The task-oriented workspace (TOW) and its partial workspace (PW) are considered in efficiently obtaining an optimal design by excluding useless orientations of the end-effector and by including just one cross-sectional area of the TOW. The proposed numerical procedure is composed of coarse and fine search steps. In the coarse search step, we find the feasible parameter regions (FPR) in which the set of parameters only satisfy the marginal constraints. In the fine search step, we consider the multiobjective function in the FPR to find the optimal set of parameters. In this step, fine search will be kept until it reaches the optimal set of parameters that minimize the proposed objective functions by continuously updating the PW in every iteration. By applying the proposed approach to an eclipse-rapid prototyping machine, the structural mass of the machine can be reduced by 8.79% while the design efficiency is increased by 6.2%. This can be physically interpreted as a mass reduction of 49 kg (the initial structural mass was 554.7 kg) and a loss of 496 mm3/mm in the workspace volume per unit length. The proposed optimal design procedure could be applied to other serial or parallel mechanism platforms that have geometrically symmetric workspace shapes.

This paper investigates the kinematic calibration of a 3-DOF parallel mechanism based on the minimal linear combinations of error parameters. The error mapping function between the geometric errors and the output errors is formulated and the identification matrix is generated and simplified. In order to identify the combinations of error parameters, four theorems to analyze the columns of the simplified identification matrix are introduced. Then, an anti-disturbance index is presented to evaluate the identification performance. On the basis of this index, measurement strategy is developed and optimal measuring configurations are given. After external calibration, linear interpolation compensation is applied to improve the terminal accuracy further. Results of experiment show that the method used in this paper is effective and efficient, and the errors are convergent within two iterations generally. This method can be extended to other parallel mechanisms with weakly nonlinear kinematics.