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I'm Martin's assistant and just wanted to specifiy our problem a little bit, because I just discovered that the IK solver very rarely suceeded.

I'd run:

rosrun openrave --database inversekinematics --robot=katana6m90a.robot.xml --usecached --iktests=1000 --iktype=translationdirection5d

with the following results:

 openravepy.databases.inversekinematics: success rate: 0.001000, wrong solutions: 0.002000, no solutions: 0.997000, missing solution: 0.000000

Maybe that helps, if anybody has an idea what could be wrong in our approach.