International Conference on Control, Automation and Systems 2008

Oct. 14-17, 2008 in COEX, Seoul, Korea

Development of a New 6-DOF Parallel-kinematic Motion Simulator (ICCAS 2008)

1

Pham Ngoc, Joon-Ho Kim, and Han-Sung Kim1

School of Mechanical and Automation Engineering, Kyungnam University, Masan, Korea
(Tel : +82-55-249-2627; E-mail: hkim@kyungnam.ac.kr)

Abstract: This paper presents the development of a new 6-DOF parallel-kinematic motion simulator. The moving
platform is connected to the base by six PUS (Prismatic-Universal-Spherical) serial chains. Comparing with the
well-known Stewart-Gough platform-type motion simulator, it uses commercialized linear actuators mounted on the
fixed base whereas a 6-UPS manipulator uses telescopic linear ones. Therefore, the proposed motion simulator has the
advantages of lower inertia and easier fabrication over a 6-UPS counterpart. The inverse position, Jacobian and
workspace analyses are performed. Using inclined arrangement of universal joints, the workspace is greatly increased.
The prototype motion simulator and real-time controller using xPC have been developed. Basic six-axis motion test
with the ride of single operator has been sucessfully performed.
Keywords: Parallel-kinematic manipulator, 6-PUS motion simulator, high force and acceleration capabilities.

2. INVERSE POSITION ANALYSIS

1. INTRODUCTION
Motion simulators have been used in various areas,
such as flight and driving simulations, tire driving tester,
virtual reality environment, general purpose motion
generation, etc. Due to the advantages of low inertia,
high payload, and high force transimssion capability of
parallel manipulators, many different kinds of parallel
manipulators are developed for motion simulators [1-7].
Most 6-DOF motion simulators use the structure of
Stewart-Gough platform [1-6], which has relatively
large workspace and good force transmission capability.
However, it needs non-commercialized telescopic linear
actuators.
On the other hand, in a 6-PUS parallel manipulator
[8-10], all linear actuator are mounted on the fixed base
and are easily implemented with commercialized
products. The moving platform is connected to the fixed
base by six rods with spherical joints at both ends. Since
the rods are subject to only axial force, size may be
greatly reduced. Therefore, inertia of the moving parts
can be reduced significantly and mechanical fabrication
can be easily achieved.
In this paper, a 6-PSU parallel manipulator is
employed as the mechanism of a motion simulator, due
to easy fabrication and low inertia. The proposed
motion simulator will be utilized as a single-seated
motion simulator with virtual reality environment and
general motion/vibration generators.
This paper is organized as follows: first, the inverse
position analysis is presented. Second, the Jacobian
matrix is obtained, which yields the velocity and statics
relations. Third, the workspace is simulated with
different arrangement of universal joints. Finally, the
prototype 6-DOF motion simulator and real-time
controller using Simulink and xPC are presented.

The proposed parallel manipulator consists of six

PSU (Prismatic-Spherical-Universal) serial chains,
which connect the moving platform to the fixed base by
prismatic joints at Fi , spherical joints at Ai , and
universal joints at Bi , i = 1,2, " ,6 , respectively. In
each serial chain, linear actuator with ball screw is
implemented at prismatic joint. For the purpose analysis,
two frames A(x, y, z) and B(u, v, w) are attached to
the fixed base and moving platform, respectively. The
transformation from the moving platform to the fixed
base can be described by the position vector, x = OP
and the rotation matrix, R .
As shown in Fig. 1(a), the starting point of each
prismatic joint with the fixed frame is expressed by

f i = Rot ( z , f ,i )[ f x , f y ,0]T for i = 1,3,5 ,

f i = Rot ( z , f ,i )[ f x , f y ,0]T for i = 2,4,6 ,

(1)

ui = Rot ( z , f ,i )[1,0,0] for i = 1,2,",6 ,

T

where Rot (z ) denotes the rotation matrix about the

z-axis and f = [0, 2 / 3, 2 / 3, 2 / 3, 2 / 3, 0] . As
shown in Fig. 1(b), the center point of each universal
joint with respect to the moving frame is given by
bi = Rot ( w, b ,i )[bx ,by ,0]T for i = 1,3,5 ,
bi = Rot ( w, b ,i )[bx , by ,0]T for i = 2,4,6

(2)

where b = [ / 3, / 3, , , / 3, / 3] .
Referring to Fig. 2, the vector-loop equation for the
ith leg can be written by

li si = x + Rbi f i d i ui for i = 1,2,",6 .

2370

(3)

Taking the dot product with itself yields

li2 = t iT t i 2(t iT ui )d i + d i2 for i = 1,2,",6 ,

where J = J x J q1 . Also, using the principlel of virtual

work, the statics relation is determine as

(4)

where t i x + Rbi f i . Solving Eq. (4) for d i gives

the following solution for the inverse position analysis.
d i = (t iT ui ) (t iT ui ) 2 (t iT t i li2 ) ,

w = J ,

(11)

where w = [ f T , m T ]T and = [ f1 , " , f 6 ]T .

(5)

where only plus sign is chosen, because the negative leg

length is physically not feasible.

F2

F3

B2
B1

F1

fy
fy

3. JACOBIAN ANALYSIS

fx

by
by

u
B4

F6

In order to obtain the velocity and statics relations,

the Jacobian is analyzed by the theory of screw. As
shown in Fig. 2, the twist of the moving platform is the
sum of all the joint screws [11],
j =6

T =  j ,i S j ,i for i = 1,2,",6 ,
j =1

B6

F5

(7)

(8)

where q = [d1 ,", d6 ]T and

(9)

S 4 ,i
Ai

ui

fi
Fi

S 3,i
S

2 ,i

S 1,i

Figure 2. Vector-loop diagram and joint screws of ith leg.

4. WORKSPACE ANALYSIS
The parallel manipulator has several advantages for
motion simulators, such as low inertia, high force
transmission capability, and high stiffness. However, it
suffers from small workspace. The workspace of the
6-PSU manipulator is limited by fixed leg lengths,
strokes of linear actuators, and unversal joint angles.
The initial directional vector of each unversal joint is
defined as the vector perpendicular to two joint axes
when joint angles are zeros. If the difference between
the initial directional vectors of universal joints and the
fixed legs, Ai Bi can be minimized, the workspace can
be increased when the angle limits of universal joints
are given, i.e., = 40 D .
The initial directioanl vectors of lower and upper
universal joints expressed in the fixed frame are given
by

Therefore, the velocity relation is obtained by

J T T = q ,

S 6 ,i
S 5 ,i

ri = Rbi

li s i

d i ui

Taking the orthogonal product of both sides of Eq. (6)

with Eq. (7) and arranging the results in a matrix form
yields

s
s
Jx = 1 " 6 ,
r1 s1 r6 s 6
J q = diag ( s1T u1 ,", s 6T u6 ) .

Bi

Rbi

si

ri s5,i
ri s 6,i
r s
, S 6 ,i =
S 4,i = i i , S 5,i =

.
si
s 5 ,i
s 6 ,i

J xT T = J q q

B5

(a) fixed points

(b) moving points
Figure 1. Point locations with respect to each frame.

where all screws are expressed in axis coordinate, and

( ri li si ) s 2,i
(ri li si ) s3,i
u
S 1,i = i , S 2,i =
, S 3 ,i =
,
s
s 3 ,i
0
2 ,i

s
si = i for i = 1,2,",6
ri si

bx

F4

(6)

The reciprocal screw reciprocal to all the joint screws

except the actuated joint screw is the line passing
through points, Ai and Bi .

B3

(10)

2371

sin u
ua ,i = Rot ( z, f ,i ) 0 for i = 1,2,",6 ,
cos u

(12)

[thx: -15 [deg]]

[thx: 0 [deg]]
300

200

200

100

100

100

0
-100

( bx , by )

(200.0, 76.0)

Fixed leg length ( l f )

Stroke ( d )

690.0
400.0

[Angle: 0 [deg]]

[Angle: 10 [deg]]
600
Z-Axis [mm]

Z-Axis [mm]

600
500
400
300

400
300

-300 -200 -100

0
100
X-Axis [mm]
[Angle: 20 [deg]]

200

300

-300 -200 -100

0
100
X-Axis [mm]
[Angle: 30 [deg]]

200

300

200

300

600
Z-Axis [mm]

600
Z-Axis [mm]

500

500
400
300

500
400
300

-300 -200 -100

0
100
X-Axis [mm]

200

300

-300 -200 -100

0
100
X-Axis [mm]

-100

-300
-300 -200 -100
0
100
X-Axis [mm]
[thy: 0 [deg]]
300

300

200

200

100

100

0
-100

200

-300
-300 -200 -100
0
100
X-Axis [mm]
[thy: +15 [deg]]
300

300

0
-100

-300
-300 -200 -100
0
100
X-Axis [mm]
[thz: 0 [deg]]
300

300

200

100

100

Y-Axis [mm]

200

0
-100
-200

200

200

300

300

200

300

200

0
-100

-300
-300 -200 -100
0
100
X-Axis [mm]

200

100

-100

-300
-300 -200 -100
0
100
X-Axis [mm]
[thz: +15 [deg]]
300

300

-200

-300
-300 -200 -100
0
100
X-Axis [mm]

300

-200

Y-Axis [mm]

200

200

200

-200

-300
-300 -200 -100
0
100
X-Axis [mm]
[thz: -15 [deg]]
300

0
-100
-200

Y-Axis [mm]

200

Y-Axis [mm]

Y-Axis [mm]

-300
-300 -200 -100
0
100
X-Axis [mm]
[thy: -15 [deg]]
300

Y-Axis [mm]

-200

-200

Table 1. Kinematic parameters of 6-PSU.

Parameters
Values [mm]
( fx , fy )
(404.4, 57.5)

Y-Axis [mm]

300

200

-200

where u is the incident angle between the initial

directional vector and the z-axis.
The main kinematic parameters are already selected
from design considerations and the values are listed in
Table 1. Using the kinematic parameters and inverse
position analysis, the workspace is simulated for
different u angles. As seen in Figs. 4 and 5,
increasing u gives much larger workspace volume.
However, the workspace does not increase at more than
u = 30D . Figure 5 shows the workspaces on the
XY-plane with the height of 500mm at different rotation
angles about the x-, y-, and z-axes. It is noted that larger
rotation angle about the z-axis is possible and the
manipulator can rotate more than 15D about the three
axes at the center

[thx: +15 [deg]]

300

Y-Axis [mm]

Y-Axis [mm]

0
ub ,i = R Rot ( w , b ,i ) sin u for i = 1,3,5 ,
cos u
0
ub ,i = R Rot ( w , b ,i ) sin u for i = 2,4,6 ,
cos u

100
0
-100
-200

200

300

-300
-300 -200 -100
0
100
X-Axis [mm]

Figure 5. Workspace on the XY-plane

( u = 30 D and h=500mm.)

5. PROTOTYPE DESIGN
In this section, the prototype system of a 6-PSU
parallel-kinematic motion simulator is presented.
First, the control system consists of six AC servo
motors and drivers, PC-base real-time controller (or
target PC) equipped with DAQs, and host PC. The host
PC communicates with the target PC by LAN. The
control program written by Simulink is made up of
trajectory generator, six-axis joint controllers, and data
loggers as shown in Fig. 6, which is downloaded and
running on the target PC. For the ease control and
monitor of signals and parameters from and to real-time
program running on the target PC, the menu is
programmed with GUIDE as shown in Fig. 7. The major
parameters of linear actuators are listed in Table 2.
Second, figures 8 and 9 shows 3D CAD modeling
and the prototype 6-PSU parallel motion simulator.
Basic linear and rotational motions along and about the
three axes are already tested with the ride of single
operator.
Finally, the performance of the motion simulator is
evaluated roughly. The moving object including six legs,
one chair and one man operator is simply modeled as
the mass of 100kg with the center at (0, 0, 500) [mm] in
the moving frame, volume of 1 1 1[m 3 ] and uniform
density. The tested point is where the moving plate is at
(0, 0, 500) [mm] with respect to the fixed frame.

Figure 3. Workspace on the XZ-plane.

[Angle: 0 [deg]]

Z-Axis [mm]

Z-Axis [mm]

600

500
400
300

500
400
300

-300 -200 -100

0
100
Y-Axis [mm]
[Angle: 20 [deg]]

200

300

-300 -200 -100

0
100
Y-Axis [mm]
[Angle: 30 [deg]]

200

300

200

300

600
Z-Axis [mm]

600
Z-Axis [mm]

6. CONCLUSION

[Angle: 10 [deg]]

600

500
400
300

500
400
300

-300 -200 -100

0
100
Y-Axis [mm]

200

300

-300 -200 -100

0
100
Y-Axis [mm]

Figure 4. Workspace on the YZ-plane.

The 6-PSU parallel manipulator is developed for a

6-DOF motion simulator, which has the advantages of
lower inertia and easier fabrication over the
Stewart-platform. The inverse position and Jacobian are
analyzed. The increased workspace is obtained by
considering the arrangement of universal joints. The
prototype motion simulator is developed. The feasibility
of the proposed motion simulator is verified through
basic six-axis motion test. Future research will focus on

2372

the verification of performances and the development of

virtual reality environment and feasible applications.
Table 2. Linear actuator parameters.
Parameters
Values
Linear actuator
KR45H10B+640LP0
AC Servo Motor
HF-KP43B (400W)
Thrust [rated (max)]
816.8 (2,387.6) [N]
Velocity [rated (max)]
500.0 (1,000.0) [mm/sec]
Table 3. Expected performances of the 6-PSU simulator.
Direction
Velocity
Acceleration
Linear (X, Y)
500 mm/s
1.1g
Linear (Z)
469 mm/s
4.3g
Angular (x, y)
72 deg/s
1,460 deg/s2
Angular (z)
176 deg/s
2,750 deg/s2
Figure 9. Prototype of a 6-PSU parallel motion simulator.

REFERENCES
[1]

Figure 6. Control program using Simulink.

Figure 7. Menu for the control program.

D. Stewart, A Platform with Six Degrees of

Feedom, Proc. Inst. Mech. Eng., 180 Part, Vol. 1,
No. 15, pp. 371-386, 1965.
[2] K. L. Cappel, Motion Simulator, United States
Patent, January, 3, 1967.
[3] G. P. Bertollini, et al., The General Motors
Driving Simulator, SAE paper 940179, 1994.
[4] J. P. Merlet, Parallel Robots, Springer, Dordrecht,
Netherlands, 2006.
[5] S. E. Salcudean, et. al, A Six Degree-of-freedom,
Hydraulic, One Person Motion Simulator, IEEE
Int. Conf. on Robotics and Automation, pp.
2437-2443, San Diego, May, 8-13, 1994.
[6] W. P. Koevermans, et. al., Design and
Performance of the Four D.O.F. Motion Systems
of the NLR Research Flight Simulator, AGARD
Conf. Proc. No. 198, Flight Simulation, pp.
17-1~17-11, La Haye, October, 20-23, 1988.
[7] http://www.moog.com
[8] M. Honegger, et. al., Adaptive Control of the
Hexaglide, a 6 DOF Parallel Manipulator, IEEE
Int. Conf. on Robtoics and Automation, pp.
543-548, New Mexicon, April, 1997.
[9] J. P. Kim and J. H. Ryu, Inverse Kinematic and
Dynamic Analyses of 6-DOF PUS Type Parallel
Manipulators, KSME International Journal, Vol.
16, No. 1, pp. 13-23, 2002.
[10] A. B. Rao, S. K. Saha, and P. V. M. Rao,
Dynamics Modelling of Hexaslides using the
Decoupled Natural Orthogonal Complement
Matrices, Multibody System Dynamics, Vol. 15,
pp. 159-180, 2006.
[11] L. W. Tsai, Robot Analysis: The Mechanics of
Serial and Parallel Manipulators, Wiley, 1999.

Figure 8. 3D CAD modeling of the prototype.

2373