Workspace Analysis and Path Planning of a Novel Robot Configuration with a 9-DOF Serial-Parallel Hybrid Manipulator (SPHM)

The development of serial or parallel manipulator robots is constantly increasing due to the need for faster productivity and higher accuracy. Therefore, researchers have turned to combining both mechanisms, sharing the advantage from serial to parallel or vice versa. This paper proposes a new configuration design for a serial-parallel hybrid manipulator (SPHM) using the industrial robotic KUKA Kr6 R900 and 3-DOF parallel spherical mechanism. The Kr6 R900 has six degrees of freedom (6-DOF) divided into three joints for translation (x, y, z) and another three joints for orientation (A, B, C) of the end-effector and the 3-DOF parallel spherical mechanism with three paired links. On the contrary, each limb of the parallel spherical mechanism consists of revolute–revolute–spherical joints (3-RRS). This mechanism allows translation movement along the <i>Z</i>-axis and orientation movements about the <i>X</i>- and <i>Y</i>- axes. The new hybrid will enrich the serial manipulator in movement flexibility and expand the workspace for serial and parallel manipulator robots. In addition, a complete conceptual design is presented in detail for the new robot configuration with a schematic and experimental setup. Then, a comprehensive mathematical model was derived and solved. The forward, inverse kinematics, and workspace analyses were derived using the graphical solution. Additionally, the new hybrid manipulator was tested for path planning. Moreover, an experimental setup was prepared to test the selected path. Finally, the new robot configuration can enlarge the workspace of both manipulators and the selected path matched to the experimental test.