Inverse kinematics of a 5-axis hybrid robot with non-singular tool path generation

This paper deals with non-singular tool path generation of a 5-axis hybrid robot named TriMule, which is designed for large part machining in situ. It is observed that at a singularity pose sudden changes occur in rotation of the C-axis and lengths of three telescopic legs. It is found that when the tool axis rotates about the axis normal to the plane expanded by the tool axis and the singular axis, the singular axis itself is forced to rotate simultaneously about the same axis in the opposite direction. This exploration enables the minimum rotation angle of the tool axis to be determined accurately for avoiding singularity and reducing machined surface errors caused by tool axis modification, leading to the development of an algorithm for non-singular tool path generation by modifying a partial set of the control points of B-splines. Both simulation and experiment on a prototype machine are carried out to verify the effectiveness of this approach.