Rotation-axis direction uncertainty in clearance bounds

Rotation-axis direction uncertainty in clearance bounds accounts for a robot rotating about a direction different from the modeled direction. Even an exactly located pivot does not determine the final occupied geometry if its axis direction is uncertain. Rotation acts through a rotation matrix; Rodrigues rotation formula computes that matrix from a unit axis and rotation angle.^[ref]

Assume the pivot $c$ and principal rotation angle $0\le \theta \le \pi$ are known and shared by both models. Let the unit axes be $u,\hat{u}$, separated by $\alpha$, and suppose every occupied point obeys $\Vert p-c\Vert \le R$. The endpoint discrepancy isIt measures error against a nominal endpoint, not total motion from the initial position.

One exact operator norm calculation uses the unit quaternions $(\cos (\theta /2),u\sin (\theta /2))$ and its modeled counterpart. Their scalar product isThe relative rotation has half-angle cosine $|d|$. A rotation through angle $\beta$ moves a perpendicular unit vector by $2\sin (\beta /2)$, givingConsequently, if the direction error is at most ${\alpha }_{\max }\le \pi$,The cap $2R$ follows because both endpoints lie on the same radius-$R$ sphere. The bound vanishes at zero rotation and, for small axis error, scales approximately as $2R\sin (\theta /2){\alpha }_{\max }$. Opposite oriented axes represent the same rotation at $\theta =\pi$; the conservative inequality need not capture that special cancellation.

For an original rotary-tool example, $R=0.50\mathrm{m}$, $\theta =90^{\circ }$ and ${\alpha }_{\max }=1^{\circ }$ give an endpoint-error allowance of $0.01234\mathrm{m}$, about $12.34\mathrm{mm}$. A direction tolerance that looks small numerically can consume a substantial clearance margin at a long tool tip.

A combined pivot and axis uncertainty in rotational clearance must add or jointly bound pivot-location error, angle error and direction error without double-counting a shared coordinate-frame error. The fixed-axis formula in pivot-location uncertainty in a rotational clearance bound addresses a different contribution. For a proposed test, observe multiple rigid fiducials over several angles, fit pivot and direction, and validate independent endpoint measurements against the claimed enclosure. Geometric robot motion planning needs the resulting occupied-body bound along the path, rather than only at its final orientation.^[ref]

Combined pivot and axis uncertainty in rotational clearance bounds the occupied-point error of a rotating robot when its modeled pivot and axis direction are both uncertain. Adding separate bounds is valid only after specifying the same physical points, coordinate frame and endpoint quantity. A rigid rotation is represented by a rotation matrix, obtainable from a unit axis and angle through Rodrigues rotation formula.^[ref]

Let the nominal initial point and pivot be $\hat{p},\hat{c}$, with $r=\hat{p}-\hat{c}$ and $\Vert r\Vert \le \hat{R}$. Let actual values be $p=\hat{p}+\delta p$ and $c=\hat{c}+e$, where $\Vert \delta p\Vert \le {ϵ}_p$ and $\Vert e\Vert \le {ϵ}_c$. The actual and nominal rotations $Q,\hat{Q}$ have the same known principal angle $\theta \in [0,\pi ]$, while their unit axis directions differ by at most ${\alpha }_{\max }$. Expanding the actual endpoint and subtracting the nominal one gives the exact identityThe three terms isolate initial-point error, pivot error and direction-induced rotation error without assigning one error twice.

An orthogonal matrix preserves length, and $\Vert I-Q{\Vert }_2=2\sin (\theta /2)$. The axis-direction result in rotation-axis direction uncertainty in clearance bounds givesThereforeThe radius in this expression is the nominal $\hat{R}$, because the initial-point perturbation has already been accounted for by $Q\delta p$. Replacing it by an inflated radius is safe but may count some uncertainty conservatively twice. The pivot term uses the actual $Q$, whose rotation angle is shared and known in this model.

For an original tool-motion example, take $\hat{R}=0.50\mathrm{m}$, $\theta =90^{\circ }$, ${\alpha }_{\max }=1^{\circ }$, ${ϵ}_c=1\mathrm{mm}$ and ${ϵ}_p=0.2\mathrm{mm}$. The respective allowances are approximately $0.200$, $1.414$ and $12.341\mathrm{mm}$, totaling $E\approx 13.955\mathrm{mm}$. If every nominal occupied point is at least $20\mathrm{mm}$ from a fixed, exactly known obstacle, the actual clearance is at least $20-E\approx 6.045\mathrm{mm}$, provided point correspondence and the enclosure hold for the entire body at that orientation.

That last inference follows from the triangle inequality for set distance. An additional obstacle-position allowance must be subtracted separately when the obstacle is uncertain. A final-orientation calculation alone does not establish a bound along the intervening trajectory; robot motion planning constrains the whole continuous path.^[ref]

Shared-frame cancellation in rotational clearance uncertainty explains why a joint model can be tighter: translating the robot, pivot and obstacle coordinate descriptions together changes none of their relative clearances. A physical pivot displacement with a fixed obstacle is different. A proposed rotary-stage experiment fits pivot and direction in one frame, withholds fiducial observations at intermediate angles, and checks measured point errors against the bound. Uncertain rotation angle or changing structural deformation requires a further model; neither is included silently in ${\alpha }_{\max }$.