Wire robots consist of a movable end-effector which is connected to the machine frame by motor driven wires. Since wires can transmit only tension, positive wire forces have to be ensured. During workspace analysis, the wires forces need to be calculated. Discrete methods do not produce satisfying results, since intermediate points on the discrete calculation grids are neglected. Using intervals instead of points leads to reliable results. Formulating the analysis problem as a Constraint-Satisfaction-Problem (CSP) allows convenient transition to the synthesis problem, i.e. to find suitable designs for practical applications. In this paper, two synthesis approaches are employed: Design-to-Workspace (i.e. calculation of an optimal robot layout for a given workspace) and an extension called Design-to-Task (i.e. calculation of the optimal robot for a specific task). To solve these optimization problems, the paper presents approaches to combine the reliability and robustness of interval-based computations with the effectiveness of available optimizer implementations.

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