Modeling and validation of a serial-manipulator tubular bending robot for complex pipe forming

An integrated robotic system, comprising an industrial serial manipulator and a custom bending head, is proposed to address the limitations of traditional CNC pipe bending machines, such as frequent physical interference and challenges in single-step forming for intricate pipe fittings. The system is designed to ensure high processing efficiency and accurate shaping for complex tubular components. In this research, the coordinate system fixed to the linkage is established using the Denavit-Hartenberg (D-H) convention to represent the bending motion. The inverse kinematics for a given end-effector pose is resolved via a sequential analytical algorithm utilizing joint angle parameterization. A simulation model is developed using MATLAB’s Multibody toolbox to validate the proposed inverse kinematics method. The accuracy of the solution is verified through a rigorous comparison between simulation results and experimental pose data, demonstrating the system's viability and precision for automated pipe bending scenarios.