In recent years, high-quality surfaces with large areas and curvatures have been increasingly used in engineering, but the precision machining and inspection of such surfaces is a particular challenge. Surface machining equipment needs to have a large working space, high flexibility, and motion accuracy to meet the demands of micron-scale precision machining. However, meeting these requirements may result in extremely large equipment sizes. To solve this problem, an eight-degree-of-freedom redundant manipulator with one linear and seven rotational joints is designed to assist in the machining described in this paper. The configuration parameters of the manipulator are optimized by an improved multi-objective particle swarm optimization algorithm to ensure that the working space of the manipulator completely covers the working surface and that the size of the manipulator is small. In order to improve the smoothness and accuracy of manipulator motion on large surface areas, an improved trajectory planning strategy for a redundant manipulator is proposed. The idea of the improved strategy is to pre-process the motion path first and then use a combination of the clamping weighted least-norm method and the gradient projection method to plan the trajectory, while adding a reverse planning step to solve the singularity problem. The resulting trajectories are smoother than those planned by the general method. The feasibility and practicality of the trajectory planning strategy are verified through simulation.
Keywords: configuration optimization; large area surface; large curvature; redundant manipulator; trajectory planning.