A structure optimization method based on comprehensive performance index of workspace and energy cost was presented for serial manipulator structure. Based on the original structure design, this method takes the global conditioning index as a premise, and takes the workspace characteristics and energy cost in particular working area as a comprehensive performance index. By using the real coded genetic algorithm, this method optimizes manipulator geometric parameters to minimize the running energy cost and maintain the original workspace design. The calculation formulas of the comprehensive performance index of workspace and energy cost were deduced and a detailed manipulator structure optimization algorithm was also given. Results of the structural optimization of a 6R serial manipulator proved that this method can optimize structure parameters to save the energy cost efficiently, and the optimal manipulator satisfies all workspace constraints, which means this method can provide reference for the design of manipulator structure.
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