Overconstrained rational single-loop linkages are efficient, compact, and low-cost custom mechanisms, yet their deployment in industrial settings is limited. In simulations, rigid body formulations fail due to redundant constraints. This study presents a flexible multibody modeling framework based on the floating frame of reference formulation, and delivers an overall accuracy analysis of assembled linkages prototypes. The approach is validated against 3D-printed PLA prototypes of a Bennett four-bar mechanism, including variants with intentional joint-axis misalignment, which theoretically, from the rigid body point of view, cannot be assembled. A supplementary contribution is delivered in the form of a kinematic parameter identification methodology suited for this type of mechanism with ill-conditioned Jacobian. The experimental and simulation results are compared and reveal that these overconstrained mechanisms exhibit a self-assembling tendency -- structural compliance drives the assembly toward the ideal geometric configuration, distributing constraint stress throughout the structure. Additional qualitative demonstrations using cardboard tubes and bamboo sticks as link building blocks confirm that functional mechanisms can be realized from low-cost, unconventional materials with limited manufacturing accuracy. The proposed modeling pipeline is fully algorithmic and enables design optimization in the future.
Motion planning for rigid-body assembly poses a fundamental challenge in robotics due to tight geometric constraints. In such scenarios, feasible motions often require passing through (near-)zero clearance configurations in which the parts are tightly constrained by contact. In this work, we introduce Critical-Manifold Guided RRT (CMG-RRT), a sampling-based planner designed specifically for tight assembly problems. Our key observation is that in tight assemblies, valid solution paths lie on or near a critical manifold: the subset of configuration space consisting of poses with at least one contact point between parts. CMG-RRT guides exploration by adaptively biasing sampling toward neighborhoods of the critical manifold using a hierarchical subdivision of the configuration space. We prove that CMG-RRT is probabilistically complete under standard clearance assumptions. Empirical evaluation on challenging rotational assembly benchmarks demonstrates a 100% success rate across all tested instances, including, to the best of our knowledge, the first fully automatic solution of the Elk disentanglement puzzle. Our open source software is available through our project page: https://www.cgl.cs.tau.ac.il/projects/tight-assembly-planning.
Dror Livnat, Michael M. Bilevich, Michal Kleinbort +1
Conventional dynamics analysis of the human body is often constrained by the need for contact force and torque sensors and controlled laboratory environments. To address this issue, this study proposes an opticalmechanics kinematic-dynamic integrated estimation framework for multibody systems. Specifically, a constrained multibody model is established to describe the system dynamics, while image-measured kinematic quantities are used as non contact inputs for dynamic estimation. The unknown joint torque is then identified through a genetic-algorithm based optimization by minimizing the discrepancy between model-predicted and image-measured kinematic quan tities. Experimental validation on an air-bearing platform showed that the wrist joint torque estimated from image data achieved a mean absolute error of 0.46 Nm compared with sensor measurements. In the forward prediction test, the model-predicted angular velocity achieved a mean absolute error of 0.006 rad/s relative to the image-measured results. This study demonstrates the potential of combining image measurement and mechanical modeling for non-contact dynamic estimation in scenarios where direct force and torque measurement is difficult.
This paper examines three approaches for modeling the dynamics of a flexible-link 2-DoF robotic arm to address unmodeled dynamics not captured by rigid-body models. Two physics informed models combine rigid-body dynamics (RBD) formulations with a Gaussian Mixture Model (GMM) to capture residual model errors and linkage flexibility. A kinematics-based regression model serves as a purely data-driven baseline. Using an open-source dataset, torque predictions are first estimated using Ridge regression on kinematic features, while the physicsbased baseline is constructed from published specifications, and ordinary least-squares regression is subsequently used to estimate the same parameter set directly from data. Results show that the physics-based parameters yield the poorest accuracy, while regularized and least-squares estimators align more closely with measured torques. Residual analysis and error metrics highlight the limitations of purely parametric models for flexible-link systems and underscore the value of regularization and data-driven identification, supporting developments of semi-parametric residual learning methods.