Design and kinematics of a novel rigid-flexible coupling hybrid robot for aeroengine blades <i>in situ</i> repair

Purpose This paper aims to present the mechanical design and kinematics of a novel rigid-flexible coupling hybrid robot to develop a promising aeroengine blades in situ repair technology. Design/methodology/approach According to requirements analysis, a novel rigid-flexible coupling hybrid robot is proposed by combining a three degrees of freedom (DOF) parallel mechanism with a flexible continuum section. Then the kinematics models of both parallel mechanism and flexible continuum section are derived respectively. Finally, based on equivalent joint method, a two-step numerical iterative inverse kinematics algorithm is proposed for the whole robot: (1) the flexible continuum section is equivalently transformed to a 2-DOF spherical joint, thus the approximate analytical inverse kinematic solution can be obtained; (2) the accurate solution is derived by an iterative derivation of both parallel mechanism and flexible continuum section. Findings To verify structure scheme and the proposed kinematics modeling method, numerical simulations and prototype experiments are implemented. The results show that the proposed kinematics algorithm has sufficient accuracy and computational efficiency in the whole available workspace, that is end-effector position error and orientation error are less than 0.2 mm and 0.01° respectively, and computation time is less than 0.22s. Originality/value A novel rigid-flexible coupling hybrid robot for aeroengine blades in situ repair is designed. A two-step numerical iterative inverse kinematics algorithm is proposed for this unique hybrid robots, which has good accuracy and computational efficiency.