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Study and validation of singularities for a Fanuc LR Mate 200iC robot

Conference Paper · June 2014


DOI: 10.1109/EIT.2014.6871803

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432

Study and Validation of Singularities for a Fanuc LR Mate 200iC


Robot
M. S. Abderrahmane1, A. M. Djuric2, W. Chen3, CP Yeh4

Abstract—Path planning and re-planning for serial 6 degree procedure to cover all configurations solution. An
of freedom (DOF) robotic systems is challenging due to the identification of the conditions covering all singular
complex kinematic structure which reflects in the direct and configurations of simple six-link manipulator was presented
inverse kinematic solutions. Industrial robots can move either in [6]. The kinematic position problems here are supposed to
in joint space, which use direct kinematic solver or Cartesian
have closed-form solutions. In [7], authors present an
space which use the inverse kinematic solver. The complexity in
robotics comes from the inverse kinematics, when the robot is algorithm that solves the IK for all six DOF, general or
moving in the Cartesian space. In that case singularity special manipulators. They combined symbolic and
conditions can occur. numerical computations. An improved Compact QP method
The singularity regions for the Fanuc LR Mate 200iC robot was presented in [8] to improve a Compact QP that was used
have been calculated by finding the determinant of the robot’s in earlier research which was trying to solve the Redundant
Jacobian matrix. The recursive Newton-Euler method and the
Inverse Kinematic. The workspace was decomposed in order
Vector multiplication method are used for the Jacobian matrix
generation and validation. The visual representations of the to decompose the Redundant Inverse Kinematics into two
singularity regions are done using the MTALAB tools, which subproblems. The work space in [9] was also decomposed
will help process designers to develop valid robot trajectories into achievable and unachievable after proposing an
and optimal layout designs. approach denoted Singularity Isolation Plus Compact QP
The validation of the results is done by using the Fanuc LR (SICQP). This decomposition of workspace permits
Mate 200iC robot available in our lab. For each singularity
decomposing the inverse singularity to two smaller inverse
position the Teach Pendant showed the error and the Robot
couldn’t move. kinematics problems, position and orientation kinematic
problems. The decomposition of the inverse kinematics
By visualizing the singularity regions location in advance, the
manufacturing layout design will be faster and more accurate. problem into subproblems was obtained in [10] using the
Product-of Exponentials Formula, POE. The reduction of the
I. INTRODUCTION complexity of the inverse kinematics using this method
permits a solution of several but simpler canonical
T The Inverse Kinematic, IK, was the subject to many
researches due to its importance. This solution is the
heart of programming robots. Many times, Jacobian matrix
subproblems. The wrist partitioned 6R robots were
investigated in [11]. It was shown here that all singular
positions are shoulder, elbow, wrist, or any combination
would be calculated as a means for resolving Singularity.
thereof. Wrist Singularity was investigated in [12] which
Most engineers fallow the convention introduced by Denavit
presents different methods for solving inverse kinematics
and Hartenberg in their 1955 research [2]. The most majority
when the robot is at or near singularity. The method
of industrial robots take advantage of Pieper’s theory
comprises factorizing the Jacobian matrix into a product of
introduced in [3] back in 1968 which states that if three
several factors, each one of them can be inverted easily. In
successive joints are intersecting, the robot’s inverse
the case of wrist-partitioned manipulators in terms of
kinematics problem can be solved in a closed-form. A
singular planes, [13] proposes a geometric representation of
geometric approach was presented in [4] for solving the
the kinematic singularities. It is shown in this research that
inverse kinematics for a 6 DOF Puma manipulator. In [5],
determinant of the Jacobian matrix of the manipulator is the
the author is proposing a technique that will determine
product of the distance metrics, or the distances from the
Singularity in motion simplifying the computational
controlled points on the end-effector to the singular planes.
Puma and Fanuc families were unified in [14] by developing
Manuscript submitted on March 15, 2014.
M. S. M. Abderrahmane, Master Student, Engineering Technology, a Unified Reconfigurable Puma-Fanuc Model. Singularity
Wayne State University, 4855 Fourth St., Detroit, MI 48202, U.S.A. conditions were investigated for the unified model, which is
(ff2478@wayne.edu). validated in this paper and proved to be correct after
Dr. A. M. Djuric, Assistant Professor, Engineering Technology, Wayne
State University, 4855 Fourth St., Detroit, MI 48202, U.S.A. plugging the Fanuc LR Mate 200iC parameters in the UPF
(ana.djuric2@wayne.edu). mathematical model, and compared to the results obtained in
Dr. W. Chen, Assistant Professor, Engineering Technology, Wayne State this work. A feedback inverse kinematics (FIK) was
University, 4855 Fourth St., Detroit, MI 48202, U.S.A.
(wchenc@wayne.edu). proposed in [15] in a new robust and computationally
Dr. CP Yeh, Professor & Head, Engineering Technology, Wayne State efficient method. FIK law is operating as a filter and
University, 4855 Fourth St., Detroit, MI 48202, U.S.A. (Yeh@wayne.edu). prevents this way from matrix manipulations. A redundancy-
resolution algorithm was developed in [16] to optimize the

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978-1-4799-4774-4/14/$31.00 ©2014 IEEE
433

joint space trajectory of arc-welding industrial robots of six- III. CALCULATION OF JACOBIAN MATRIX
rotation-axis since one DOF of redundancy remains when The goal of this research is to calculate and validate a
performing this task. Another robust method is presented in Jacobian matrix and the singularity conditions for the Fanuc
[17], but focusing on the discontinuity problem. The author LR Mate 200iC robot. The visualization of the singularity
of [18] introduced the double quaternion based kinematics regions can be utilized in layout designs, and the robot travel
formulation for solving the inverse kinematics of the general paths optimization.
6R robots. The inverse kinematics of an ABB IRB-1400 spot For robot manipulators, the Jacobian is defined as the
welding with 6 DOF was solved in [19] based on the method coefficient matrix of any set of equations that relates the
of geometry projection principle. The forward and inverse velocity state of the end-effector described in the Cartesian
kinematics of a KUKA KR-16KS robotic arm in the space to the actuated joint rates in the joint velocity space.
application of a simple welding process was investigated in See Equation 1.
[20]. The authors of [21] are investigating the inverse
X = Jq (1)
kinematics of 16 industrial 6DOF robots with offset wrist of
closed form equations. They solved theses manipulators For rotational joints the generalized coordinates are
analytically and numerically. In case that the manipulators presented expressed in Equation 2.
cannot be solved in closed form, they proposed an algorithm qi = θi (2)
to solve the inverse kinematics. The end effector velocity is expressed in terms of the linear
velocity of the origin of the end effector coordinate frame,
II. REVIEW OF FANUC LR MATE 200IC KINEMATIC MODE Vi and the angular velocity of the end effector ωi , and thus
For the Fanuc LR Mate 200iC robot Jacobian matrix we have:
calculation, first we ensure that its kinematic structure is ⎡v ⎤
valid. The kinematic structure and the related D-H X = ⎢ i ⎥ (3)
parameters [2] are presented in Figure 1 and Table 1, ⎣ωi ⎦
respectively [23]. The Newton-Euler recursive method was used for
calculation of the end effector linear and angular velocity.
θ4 d4 The linear velocity for revolute joints is:
z3 d6 ( vi )=i Ri −1 i −1 (0 vi −1 )+ i ( 0ωi )×i Ri −1 i −1 pi
i 0
(4)
z5 θ 6
y3 x3 W x6 = n The angular velocity for revolute joints is:
a3

y2 x2 θ5 E
i 0
( ωi )=i Ri −1 [
i −1 i −1 0
( ωi −1 )+ i −1θi ] (5)
z4 y4 The calculated Jacobian matrix J E is with respect to the
y5 x5 z6 = a
θ3 end-effector fame.
y6 = s
a2 x4 For the validation purposes the Jacobian matrix has been
z2
calculated using the Vector Method. See Equation 6.
z1 ⎡J ⎤
a1 JB = ⎢ V ⎥ =
⎣Jω ⎦ (6)
θ2 ⎡ Z 0 × Pn
0 0 0
Z 1 ×( Pn − P1 ) 0
Z 2 ×( Pn − P2 ) ..... 0
Z n −1 ×( Pn − Pn −1 ) ⎤
0 0
⎢ ⎥
⎣⎢ Z 0 Z1 Z2 ..... Z n −1 ⎦⎥
y1 x1 The calculated Jacobian matrix J B is with respect to the base
d1
fame. The J E matrix is found using the Equation 7.
z0 θ1
J B = 0R6 J E (7)
y0
x0
Both solutions are the same which confirms that the
calculated Jacobian matrix for Fanuc LR Mate 200iC robot
Fig. 1. FANUC LR Mate 200iC robot kinematic diagram [24] is correct. The general expression of the J B matrix is:
TABLE I ⎡ B J11 B
J12 B
J13 B
J14 B
J15 0 ⎤
D-H PARAMETER OF THE FANUC LR MATE 200IC ROBOT ⎢B B B B B ⎥
⎢ J 21 J 22 J 23 J 24 J 25 0 ⎥
JOINT di θi ai αi ⎢ BJ
B
B
J 32 B
J 33 B
J 34 B
J 35 0 ⎥ (8)
1 d1 = 330 θ1 = 0D a1 = 75 α1 = −90D J = ⎢ 31 B B B B B

⎢ 0 J 42 J 43 J 44 J 45 J 46 ⎥
2 0 θ 2 = −90D a2 = 300 α 2 = 180D ⎢ 0

B
J 52 B
J 53 B
J 54 B
J 55 B
J 56 ⎥⎥
3 0 θ3 = 180D a3 = −75 α 3 = 90D B B B
4 ⎣⎢ 1 0 0 J 64 J 65 J 66 ⎦⎥
d 4 = −320 θ4 = 0D 0 α 4 = −90D
5
These elements are determined in the next set of
0 θ5 = 0D 0 α 5 = 90D equations:
6 d 6 = −80 θ 6 = 180D 0 α 6 = 180D

2
434

B
J 11 = − sin(θ1 ) a1 − sin(θ1 ) a2 cos(θ 2 ) B
J 34 = sin(θ 4 ) sin(θ 5 ) sin(θ 2 − θ 3 )d 6 (24)
+ d 4 sin(θ1 ) sin(θ 2 − θ 3 ) − a3 sin(θ1 ) cos(θ 2 − θ 3 ) B
J 35 = d 6 cos(θ 2 − θ 3 ) sin(θ 5 )
(9) (25)
− sin(θ1 ) cos(θ 2 − θ 3 ) cos(θ 4 ) sin(θ 5 )d 6 + − d 6 sin(θ 2 − θ 3 ) cos(θ 4 ) cos(θ 5 )
sin(θ1 ) sin(θ 2 − θ 3 ) cos(θ 5 )d 6 + B
J 36 = 0 (26)
sin(θ1 ) cos(θ1 ) sin(θ 4 ) cos(θ 5 )d 6 B
J 41 = 0 (27)
B
J 12 = − cos(θ1 ) sin(θ 2 )a 2 − cos(θ1 ) sin(θ 2 − θ 3 ) a3
− cos(θ1 ) cos(θ 2 − θ 3 ) d 4 − cos(θ1 ) cos(θ 4 ) (10)
B
J 42 = − sin(θ1 ) (28)

sin(θ 5 ) sin(θ 2 − θ 3 ) d 6 − cos(θ1 ) cos(θ 5 ) cos(θ 2 − θ 3 )d 6


B
J 43 = sin(θ1 ) (29)
B
J13 = a3 cos(θ1 ) sin(θ 2 − θ 3 ) + d 4 cos(θ1 ) cos(θ 2 − θ 3 )
B
J 44 = − cos(θ1 ) sin(θ 2 − θ 3 ) (30)
+ cos(θ1 ) cos(θ 4 ) sin(θ 5 ) sin(θ 2 − θ 3 )d 6 + (11) B
J 45 = − cos(θ1 ) sin(θ 4 ) cos(θ 2 − θ 3 ) +
(31)
cos(θ1 ) cos(θ 5 ) cos(θ 2 − θ 3 )d 6 sin(θ1 ) cos(θ 4 )
B
J 14 = − sin(θ 5 ) cos(θ1 ) sin(θ 4 ) cos(θ 2 − θ 3 ) d 6
B
J 46 = cos(θ1 ) cos(θ 4 ) sin(θ 5 ) cos(θ 2 − θ 3 ) −
(12) (32)
+ sin(θ1 ) cos(θ 4 ) sin(θ 5 ) d 6 cos(θ1 ) cos(θ 5 ) sin(θ 2 − θ 3 ) + sin(θ1 ) sin(θ 4 ) sin(θ5 )
B
B
J 15 = d 6 cos(θ1 ) cos(θ 2 − θ 3 ) cos(θ 4 ) cos(θ 5 ) + J 51 = 0 (33)
d 6 cos(θ1 ) sin(θ 2 − θ 3 ) sin(θ 5 ) + (13) B
J 52 = cos(θ1 ) (34)
d 6 sin(θ1 ) sin(θ 4 ) cos(θ 5 ) B
J 53 = − cos(θ1 ) (35)
B
J 16 = 0 (14) B
J 54 = − sin(θ1 ) sin(θ 2 − θ 3 ) (36)
B
J 21 = a1 cos(θ1 ) + a2 cos(θ1 ) cos(θ 2 ) B
J 55 = − sin(θ1 ) sin(θ 4 ) cos(θ 2 − θ 3 ) −
(37)
+ a3 cos(θ1 ) cos(θ 2 − θ 3 ) − d 4 cos(θ1 ) sin(θ 2 − θ 3 ) + (15) cos(θ1 ) cos(θ 4 )
cos(θ1 ) cos(θ 2 − θ 3 ) cos(θ 4 ) sin(θ 5 )d 6 − cos(θ1 ) B
J 56 = sin(θ1 ) cos(θ 4 ) sin(θ 5 ) cos(θ 2 − θ3 ) −
(38)
sin(θ 2 − θ 3 ) cos(θ 5 )d 6 + sin(θ1 ) sin(θ 4 ) sin(θ 5 )d 6 sin(θ1 ) cos(θ5 ) sin(θ 2 − θ3 ) − cos(θ1 ) sin(θ 4 ) sin(θ5 )
B
J 22 = − sin(θ1 ) a 2 sin(θ 2 ) − sin(θ1 ) sin(θ 2 − θ 3 ) a3 B
J 61 = 1 (39)
− sin(θ1 ) cos(θ 2 − θ 3 ) d 4 − sin(θ1 ) cos(θ 4 ) sin(θ 5 ) (16) B
J 62 = 0 (40)
sin(θ 2 − θ 3 ) d 6 − sin(θ1 ) cos(θ 5 ) cos(θ 2 − θ 3 ) d 6 B
J 63 = 0 (41)
B
J 23 = a3 sin(θ1 ) sin(θ 2 − θ 3 ) + d 4 sin(θ1 ) cos(θ 2 − θ 3 )
(17)
B
J 64 = − cos(θ 2 − θ 3 ) (42)
+ sin(θ1 ) cos(θ 4 ) sin(θ 5 ) sin(θ 2 − θ 3 ) d 6
B
J 65 = sin(θ 4 ) sin(θ 2 − θ 3 ) (43)
+ sin(θ1 ) cos(θ 5 ) cos(θ 2 − θ 3 ) d 6
B
J 24 = − d 6 sin(θ 1 ) cos(θ 2 − θ 3 ) sin(θ 4 ) sin(θ 5 )
B
J 66 = − cos(θ 4 ) sin(θ 5 ) sin(θ 2 − θ 3 ) −
(44)
(18) cos(θ 5 ) cos(θ 2 − θ 3 )
− d 6 cos(θ 1 ) cos(θ 4 ) sin(θ 5 )
B
J 25 = d 6 sin(θ1 ) cos(θ 2 − θ 3 ) cos(θ 4 ) cos(θ 5 ) IV. DECOUPLI OF JACOBIAN
+ d 6 sin(θ1 ) sin(θ 2 − θ 3 ) sin(θ 5 ) − (19) Jacobian Matrix was decoupled or partitioned to
d 6 cos(θ1 ) sin(θ 4 ) cos(θ 5 ) simplify the calculation of the determinant in order to define
B Singularity conditions. The Jacobian matrix W J at the wrist
J 26 = 0 (20)
is calculated when d 6 = 0 . Its general form is presented in
B
J 31 = 0 (21) Equation 45.
B
J 32 = − a 2 cos( θ 2 ) − a 3 cos( θ 2 − θ 3 ) + ⎡ W J11 W J12 W J13 0 0 0 ⎤
⎢W W W ⎥
d 4 sin( θ 2 − θ 3 ) − cos(θ 2 − θ 3 ) cos( θ 4 ) sin(θ 5 ) d 6 (22) ⎢ J 21 J 22 J 23 0 0 0 ⎥
⎢W J W
J W
J 0 0 0 ⎥ (45)
+ sin(θ 2 − θ 3 ) cos(θ 5 ) d 6 W
J = ⎢ 31 W 32 W 33 W W W

⎢ 0 J 42 J 43 J 44 J 45 J 46 ⎥
B
J 33 = a3 cos(θ 2 − θ 3 ) − d 4 sin(θ 2 − θ 3 ) ⎢ 0

W
J 52 W J 53 W J 54 W J 55 W J 56 ⎥⎥
+ cos(θ 2 − θ 3 ) cos(θ 4 ) sin(θ 5 ) d 6 − (23)
⎢⎣ 1 0 0 W
J 64 W J 65 W J 66 ⎥⎦
sin(θ 2 − θ 3 ) cos(θ 5 ) d 6

3
435

V. ROBOT SINGULARITY PROBLEM x2


The configuration of 6 × 6 Jacobian matrix is singular if and
only if: Wrist θ 3 = −13.1906 D
x2
det(J ) = 0 (46)
θ 3 = 76 . 804 D z3
Most of the industrial robots with six DOF have 3-DOF
forearm and with a 3-DOF spherical wrist. In order to
simplify the calculation, matrix J can be divided into four y2 y2
x3 x3 Wrist
blocks of 3× 3 matrices. See Equation (47). z3
⎡J J12 ⎤
E
J = ⎢ 11 ⎥ (47)
J
⎣ 21 J 22 ⎦

According to [14], the Jacobian matrix B J can be decoupled


and will have the block triangular form:
⎡J 03×3 ⎤
W
J = ⎢ 11 ⎥ (48) Fig. 2. Configuration of the forearm boundary singularity for FANUC LR
⎣ J 21 J 22 ⎦ Mate 200iC robot

According to [14], the determinant of Jacobian is Similarly we found the boundary singularity located on the
independent of the velocity reference point selected then the y 2 axis as shown in Figure 2. The related Jacobian matrix is
following equation can be written:
given in Equation (57).
det(W J ) = det( E J ) (49)
⎡403.6715 300 0 ⎤
Combining equations (48) and (49) we have: 2
J11 = ⎢⎢ 0 - 328.6715 328.6715⎥⎥ (57)
det(W J ) = det( J11 ) det( J 22 ) (50) ⎢⎣ ⎥⎦
0 0 0
Now, the singularity condition of the Fanuc LR Mate 200iC
robot can be decoupled into two determinants: The forearm interior singularity is presented in Figure 3.
det( J11 ) = 0 and det( J 22 ) = 0 (51)
Wrist
The forearm singularities can be identified by checking the
determinant of the matrix J11 . This produced two conditions,
for forearm singularities. One is for boundary singularities,
equation (52): θ 3 = 34D
x2
Cb = −a3 sin(θ3 ) + d4 cos(θ3 ) = 0 (52) x3
and the other one is for the interior singularities, equation θ 2 = -29.78967 D

(53):
Ci = −a1 − a2 cos(θ2 ) − a3 cos(θ2 −θ3 ) + d4 sin(θ2 −θ3 ) = 0 (53)
The wrist singularities can be identified by checking the x1
determinant of the matrix J 22 . See equation 54.
det(J 22 ) = − sin(θ 5 ) = 0 (54)
D z0
This is true when θ 5 = 0 , or θ5 = 180 , which physically x0
means that joints 4 and 6 are aligned.
Fig. 3. Configuration of the forearm interior singularity for FANUC LR
Mate 200iC robot
VI. FANUC LR MATE 200IC SINGULARITY ANALYSIS
The related Jacobian matrix is shown in Equation (58).
Forearm Singularities:
⎡0 580.578 - 320.222⎤
By solving the Equation (52) for θ 3 using the D-H ⎥
0
J11 = ⎢⎢0 0 0 ⎥ (58)
parameters from Table 1, the boundary singularity is found.
⎢⎣0 75 74.045 ⎥⎦
The joint angle θ 3 = 76.8094 D and by observing the Figure 2
it can be seen that the wrist is located on the x2 axis and we When both boundary and interior singularities occur, θ 2 and
have the following Jacobian matrix: θ3 need to be solved. The angle θ3 is calculated by solving
2 2 0
J11 = J 0 J11 (55) the Equation (52). See Equation (59).
⎛d ⎞
⎡ 0 0 0 ⎤ θ 3 = atan2⎜⎜ 4 ⎟⎟ (59)
2
J11 = ⎢⎢ 0 − 628.671 328.671⎥⎥ (56) ⎝ a3 ⎠
⎢⎣− 75 0 0 ⎥⎦ There are two values for θ3 : 76.8094D or - 103.1906 D .

4
436

The value for θ 2 is solved by combining Equations 52 and z3


θ4
53 using the following procedure: z5 θ 6
A = K1K 2 (− a2 − a3 cosθ 3 − K 3d 4 sin θ 3 ) (60) y3 Wrist x6 = n
x3
B = K1 (a3 sin θ 3 − K 3 d 4 cosθ 3 ) (61) θ5
y4 z6 = a
z4
C = K1K 2 a1 (62) x5
y5 y6 = s

cos(θ 2 ) =
( )(
2 AC ± 4 A2C 2 − 4 A2 + B 2 C 2 − B 2 ) x4

(
2 A2 + B 2 ) (63) Fig. 6. Configuration of the Wrist singularity for FANUC LR Mate 200iC
robot
θ 2 = atan2(cosθ 2 , sin θ 2 ) (64) The robot home zero position, which is presented in Figure 1
D
The joint angle is calculated: θ 2 = 9 0 . The robot is moved to and the same in Figure 6, is singular because z3 is parallel to
the calculated singular position. See Figure 4. z5 . The associated Jacobian matrix is given in Equation 66.

y2 θ 3 = 180 D + 76 .804 D ⎡− 1 0 − 1⎤
D
θ 2 = − 90 + 90 D
0
J 22 = ⎢⎢ 0 − 1 0 ⎥⎥ (66)
⎢⎣ 0 0 0 ⎥⎦
x1 x2 Wrist
y1 x3
VII. EXPERIMENTAL VALIDATION OF FANUC LR MATE
200IC SINGULARITY
The experimental validation of the singularity regions has
been done using the Fanuc LR Mate 200iC robot available in
Fig. 4. Configuration of the forearm boundary and interior singularity for
the robotic lab at the Engineering Technology Division,
FANUC LR Mate 200iC robot Wayne State University.
Using the Matlab tools, the complete forearm singularity The state of both boundary and interior singularities, whose
(boundary and interior singularities) is visualized. See position is shown in Figure 3, is reached with Fanuc LR
Figure 5. The methodology used to visualize the singularity Mate 200iC robot and the same position and the Teach
space is adopted from [24]. Pendent values are shown in Figure 7.
The TP show an error: Closed to singularity.
(θ 1 )min = − 170 D (θ 1 )max = 170 D

Fig. 5. Visualization of the forearm boundary and interior singularity for Fig. 7. Experimental validation of the forearm boundary and interior
FANUC LR Mate 200iC robot singularity for FANUC LR Mate 200iC robot
The singularity space is calculated using the Joint limits The same procedure is done to validate the wrist singularity.
determined by Fanuc manufacturer. See Figure 8.
By substituting θ 2 = 90D and θ3 = 76.8094D into the J11 Joints 4 and 6 are
aligned because Joint 5
matrix, the following result is obtained: is almost zero.
⎡ 0 0 0 ⎤
0 ⎢
J11 = ⎢703.671 0 0 ⎥⎥ (65)
⎢⎣ 0 − 628.671 328.671⎥⎦
The TP show an error:
It is clear from Equation 65 that robot is in the singular Closed to singularity.
position.
Wrist Singularities:
The wrist singularity is determined in Equation 54. The Joint 5 is almost zero.
graphical representation of the wrist singular condition is
given in Figure 6. Fig. 8. Experimental validation of the wrist singularity for FANUC LR
Mate 200iC robot

5
437

VIII. CONCLUSIONS AND FUTURE WORK [16] Huo, Liguo, and Luc Baron. "The joint-limits and singularity
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shown and experimentally proved. The visual IEEE, 2010.
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