Abstract—this paper presents the analysis and development of the model, dynamics and control of new self-reconfigurable machinery systems. These machinery systems combine as many properties of different open kinematic structures as possible and can be used for a variety of applications. The kinematic design parameters, i.e., their Denavit-Hartenberg (D-H) parameters, can be modified to satisfy any configuration required to meet a specific task. By varying the joint twist angle parameter (configuration parameter), the presented model is reconfigurable to any desired open kinematic structure, such as Fanuc, ABB and SCARA robotic systems. The joint angle and the offset distance of the D-H parameters are also modeled as variable parameters (reconfigurable joint). The resulting self-reconfigurable machinery system hence encompasses different kinematic structures and has a reconfigurable joint to accommodate any required application. Using the Newton-Euler (N-E) recursive approach, the dynamic parameters of a reconfigurable joint are calculated and presented. A nonlinear control law is developed for a general reconfigurable joint using Lyapunov second method achieving asymptotic stability and the required performance objectives. Automatic model generation of a 3-DOF reconfigurable machinery system is constructed and demonstrated as a case study which covers all possible open kinematic structures. This research is intended to serve as a foundation for future studies in reconfigurable control systems. I. INTRODUCTION The new manufacturing environment is characterized by frequent and unpredictable market changes. A manufacturing paradigm called Reconfigurable Manufacturing System (RMS) was introduced to address the new production challenges. The Reconfigurable Manufacturing System is designed for rapid adjustments of production capacity and functionality in response to new circumstances, by rearrangement or change of its components and machines. Such new systems provide exactly the capacity and functionality that is needed, when it is needed [1]. These systems’ reconfigurability calls for their components, such as machines and robots to be rapidly and efficiently modifiable to varying demands [2]. In the literature, modular robotic R.Al Saidi is a PhD Candidate with the Mechanical, Automotive & Materials Engineering Department, University of Windsor, 401 Sunset Avenue, Windsor, Ontario N9B 3P4, Canada (alsaidi@uwindsor.ca ). (Corresponding author) Dr. Bruce Minaker is an Associate Professor with the Mechanical, Automotive & Materials Engineering Department, University of Windsor, 401 Sunset Avenue, Windsor, Ontario N9B 3P4, Canada. Phone: (519) 253- 3000 Ext. 2621 e-mail: bminaker@uwindsor.ca . systems are presented as a solution for reconfigurable machinery systems. An automated generation of D-H parameters methodology has developed for the modular manipulators [3]. The authors derived the kinematic and dynamic models of reconfigurable robotic systems using D-H parameters for different sets of joints, links and gripper modules. Furthermore, a library of modules is formed from which any module can be called with its associated kinematic and dynamic models. In [4], a modular and reconfigurable robot design is introduced with modular joints and links. The proposed design introduces zero links offset to increase the robot’s dexterity and maximize its reachability. A modular and reconfigurable robot (MRR) with multiple working modes was designed [5]. In the proposed MRR design, each joint module can independently work in active modes with position or torque control, or passive modes with friction compensation. With the MRR, the joint module was designed as a hybrid joint in working modes and not in the sense of mechanical motion. A reconfigurable robotic system was proposed [6] and achieves the reconfigurability by utilizing passive and active joints. In [7], an automated approach was presented to build kinematic and dynamic models for assembled modular components of robotic systems. The developed method is applicable to any robotic configuration with a serial, parallel or hybrid structure. Reconfigurable “plug and play” robot kinematic and dynamic modeling algorithms are developed [8]. These algorithms are the basis for the control and simulation of reconfigurable modular robots. The reconfigurable robotic system (RRS) was regarded as a modular system [9]. A Task-based configuration optimization based on a generic algorithm was used to solve a pre-defined set of modules for specific kinematic configuration [10]. A modular and reconfigurable robot for industrial purposes has been introduced [11]. The PROFACTOR GmbH has presented a modular and reconfigurable robot with power cube (Mechatronical Components) modules. These modules were designed to be identical and self-contained with actuation, memory, and mechanical, electrical and embedded programming. The main drawbacks of the modular robotic systems proposed in the literature are the high initial investment necessary in modules that remain idle during many activities, and the significant lead time for replacement of the components prior to performing a specific task. II. RESEARCH MOTIVATIONS Current machines (CNC mills, robots, etc…) have physical limitations with respect to their configurations and capabilities. They are preconfigured to do specific tasks. For example: the typical 5-DOF (3R-2T) CNC machine has three rotational and two translational joints with fixed coordinate frames (D-H parameters), which cannot be automatically Analysis and Development of Self-Reconfigurable Open Kinematic Machinery Systems R. Al Saidi, Dr. B.Minaker 2013 IEEE International Conference on Automation Science and Engineering (CASE) TuBT6.5 978-1-4799-1515-6/13/$31.00 ©2013 IEEE 966