A single-loop 7R spatial mechanism that has three motion modes with the same instantaneous DOF but different finite DOF

Multi-mode mechanisms, including kinematotropic mechanisms, are a class of reconfigurable mechanisms that can switch motion modes with the same or different DOF (degree-of-freedom). For most of the multi-mode mechanisms reported in the literature, the instantaneous (or differential) DOF and finite DOF in a motion mode are equal. In this paper, we will discuss the construction, reconfiguration analysis, and higher-order mobility analysis of a multi-mode single-loop 7R mechanism that has three motion modes with the same instantaneous DOF but different finite DOF. Firstly, the novel multi-mode single-loop 7R spatial mechanism is constructed by inserting one revolute (R) joint into a plane symmetric Bennett joint-based 6R mechanism for circular translation. The reconfiguration analysis is then carried out in the configuration space by solving a set of kinematic loop equations based on dual quaternions and the natural exponential function substitution using tools from algebraic geometry. The analysis shows that the multi-mode single-loop 7R spatial mechanism has three motion modes, including a 2-DOF planar 5R mode and two 1-DOF spatial 6R modes and can transit between each pair of motion modes through two transition configurations. The higher-order mobility analysis shows that the 7R mechanism has two-instantaneous DOF at a regular configuration of any motion mode and three instantaneous DOF in a transition configuration. The infinitesimal motions that are not tangential to finite motions are of second-order in transition configurations between 2-DOF motion mode 1 and 1-DOF motion modes 2 or 3 or first-order in transition configurations between 1-DOF motion modes 2 and 3.