The present study focuses on the kinematic analysis of a PPPR spatial serial mechanism with a large number of geometric errors. The study is implemented in three steps: (1) development of a map between the end-effector position error and geometric source errors within the serial mechanism kinematic chains using homogeneous transformation matrix; (2) selection of geometric errors which have significant effects on end-effector positioning accuracy by sensitivity analysis; (3) kinematic analysis of the serial mechanism within which the geometric errors are modelled as interval variables. The computational algorithms are presented for positioning accuracy analysis and workspace analysis in consideration of geometric errors. The analysis results show that the key factors which have significant effects on end-effector position error can be identified efficiently, and the uncertain workspace can also be calculated efficiently.
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