Cable-driven manipulators present significant dexterity and compliance in highly complex environments, which shows potential advantages for its application in the aerospace engineering. However, the application of the manipulators is still constrained by their inherent limitations, such as the large size and mass of the driving base, low load capacity and nonlinear complex models. In this paper, we design a novel cable-driven underactuated manipulator (CDUM) with high load capacity and less actuator motor, and propose a multi-level kinematic model for the proposed CDUM. The CDUM with 7 degrees of freedom is driven by three motors, which is composed of two segments. The segment 2 is capable of both telescoping and rotational movements, which is driven by two cables. To enhance its load capacity, a novel worm joint is designed for segment 1. Moreover, the joints of each segment can move with equal rotation angle and translational displacement by utilizing synchronous mechanism. Based on the structural features of the manipulator, the multi-level kinematics from the actuator variables to manipulator end-effector are expounded, including the actuator-joint kinematics and joint-end kinematics. Especially, the decoupled kinematic equation is derived to illustrate the coupling motion principle between joint variables of a single joint of segment 2. Finally, computational simulations are conducted to analyze the performance of the proposed mechanism and verify the method proposed in this work. The numerical results demonstrate that the cable-driven manipulator moves smoothly and the proposed nonlinear kinematics model is effective.
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