A Model-Based Digital Toolbox for Unified Kinematics and Dimensional Synthesis in Parallel Robot Design

A unified digital toolbox is introduced for kinematics analysis and dimension synthesis of parallel robots, addressing challenges in configuration diversity and computational complexity. By integrating hierarchical kinematic modeling with screw theory, the toolbox establishes standardized analytical frameworks for mobility, inverse kinematics and dexterity evaluation. A modular toolbox architecture—comprising interactive, data, external module, database and functional layers—enables systematic design, workspace estimation and dexterity-driven optimization. A hybrid MATLAB-C++ interface ensures computational efficiency and scalability. The efficacy of the toolbox is demonstrated through a case study on a novel 2UPR-2RPS parallel mechanism, achieving optimized dimensional parameters (k1 = 0.85, k2 = 1.3, k3 = 0.85, k4 = 1.3) with a mean dexterity index of 0.637 and validated workspace symmetry. Results confirm that the toolbox streamlines the design process, ensures computational accuracy and enables rapid adaptation to new robotic configurations. This work provides a robust foundation for advanced parallel robot design, offering significant potential for industrial and research applications requiring high-precision motion control.