Measurement model and calibration experiment of over-constrained parallel six-dimensional force sensor based on stiffness characteristics analysis

An over-constrained, parallel six-dimensional force sensor has various advantages, including its ability to bear heavy loads and provide redundant force measurement information. These advantages render the sensor valuable in important applications in the field of aerospace (space docking tests, etc). The stiffness of each component in the over-constrained structure has a considerable influence on the internal force distribution of the structure. Thus, the measurement model changes when the measurement branches of the sensor are under tensile or compressive force. This study establishes a general measurement model for an over-constrained parallel six-dimensional force sensor considering the different branch tensions and compression stiffness values. Numerical calculations and analyses are performed using practical examples. Based on the parallel mechanism, an over-constrained, orthogonal structure is proposed for a six-dimensional force sensor. Hence, a prototype is designed and developed, and a calibration experiment is conducted. The measurement accuracy of the sensor is improved based on the measurement model under different branch tensions and compression stiffness values. Moreover, the largest class I error is reduced from 5.81 to 2.23% full scale (FS), and the largest class II error is reduced from 3.425 to 1.871% FS.