Mechatronic design solution for planar overconstrained cable-driven parallel robot

Cable-driven parallel robots (CDPRs) combine the successful features of parallel manipulators with the benefits of cable transmissions. The payload is divided among light extendable cables, resulting in an energy-efficient system that can achieve high end-effector acceleration over a huge workspace. A CDPR is formed by a set of actuation units, and a mobile platform, working as an end-effector (EE). The cables, driven by the actuation units, are guided inside the robot workspace using a guidance system and then connected to the mobile platform. The variation of cable lengths is responsible for the EE displacement throughout the robot workspace. These features result in easily reconfigurable systems where the workspace can be modified by relocating the actuation and guidance units. Nevertheless, the use of CDPRs in industrial environments is still limited, due to the drawbacks of employing flexible cables. Indeed, cables impose unilateral constraints that can only exert tensile forces and, consequently, the EE cannot withstand any arbitrary external action. To enhance the robot’s controllability, CDPRs can be overconstrained by employing a number of cables higher than the degrees of freedom of the EE. This allows cables to pull one against the other and to keep the overall system controllable over a wide range of externally applied loads. In this thesis, an eight-cable, planar, overconstrained CDPR is designed: the robot has the deployable and reconfigurable features required by the task. In particular, this CDPR has its actuation units installed into the EE mobile platform, and the frame anchor points can be rearranged to obtain a discrete reconfiguration. The cable arrangement, location of anchor points and mechanical design have been studied, by implementing a hybrid optimisation procedure. The genetic algorithm is combined with a local minimum optimiser, maximizing the CDPR volume index and deriving a mechanical design for the prototype.