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The measurement of large forces and the presence of errors due to dimensional coupling are significant challenges for multi-dimensional force sensors. To address these challenges, this paper proposes an over-constrained six-dimensional force sensor based on a parallel mechanism of steel ball structures as a measurement module. The steel ball structure can be subject to rolling friction instead of sliding friction, thus reducing the influence of friction. However, because the structure can only withstand unidirectional pressure, the application of steel balls in a six-dimensional force sensor is difficult. Accordingly, a new design of the sensor measurement structure was designed in this study. The static equilibrium and displacement compatibility equations of the sensor prototype's over-constrained structure were established to obtain the transformation function, from which the forces in the measurement branches of the proposed sensor were then analytically derived. The sensor's measurement characteristics were then analysed through numerical examples. Finally, these measurement characteristics were confirmed through calibration and application experiments. The measurement accuracy of the proposed sensor was determined to be 1.28%, with a maximum coupling error of 1.98%, indicating that the proposed sensor successfully overcomes the issues related to steel ball structures and provides sufficient accuracy.

Design and Analysis of the Measurement Characteristics of a Bidirectional-Decoupling Over-Constrained Six-Dimensional Parallel-Mechanism Force Sensor