A haptic device provides force feedback by means of a simulator in which the force, position, velocity etc. of a probe are used as input data. If there exist dimensional errors in the device mechanism and installation errors in the sensors, the simulator cannot calculate correctly actuator torques/forces and the displayed force becomes distorted, which means the force is not proportional to the operator's force. In the present paper, the magnitude of the distortion which depends largely on the type and dimension of the mechanism is evaluated kinematically and statically by proposing Nonlinearity Index. A numerical example is shown to illustrate the characteristics of the index. Moreover, an optimal kinematic design system for haptic devices by means of Genetic Algorithm with consideration of the nonlinearity of displayed force in addition to the operability, spatial output-isotropy and size of the mechanism is proposed and applied to a device as a master-arm of a master-slave system assisting precision task such as assembling small packaging substrates.
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