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KUKA OccuBot: the intelligent test system

The KUKA OccuBot is a fully automated measuring system. With utmost precision, a six-axis robot checks how safe and stable vehicle and airplane seats are under continuous mechanical loads. The furniture industry uses the OccuBot for the testing of seating furniture.

The functioning of the OccuBot

The OccuBot test system comprises a total of six components which simulate the motions and loads of a human body using force/torque sensors and dummies. This manner of testing enables the optimal reproduction of realistic and practical situations, such as egress and ingress movements.

The OccuBot also tests the wear of the material. For example, it uses continuous rotational motion to test how quickly the material on a seat back wears down.

Advantages of the KUKA OccuBot

  • Maximum flexibility and precision:
    through measurement in six dimensions, the OccuBot helps to determine forces and torques with utmost precision and flexibility. This provides you with data about all forces and torques being exerted on the contact surface where the dummy touches the seat. 
  • Continuous adaptation:
    for each test cycle performed by the dummy, the forces and torques are adapted according to the wear of the object. The Ethernet interface allows you to attach an external data acquisition system. This allows you to monitor the wear throughout the complete runtime and save the relevant test data.
  • Simple parameterization and efficient processes:
    the position of the dummy is freely defined by a time stamp. Thanks to its curved lines, the robot can move to any position at a precisely defined time. This is achieved through a wide variety of functions, such as an editor for the simple definition of the Base coordinate system, a “Search and Hold” function for constant forces or the processing of multiple test objects.

The OccuBot in action

Measuring robot carries out continuous load tests on car seats

OccuBot: Components and scope of supply

The OccuBot is made up of six components. Their interaction make the robot a fully-automated test system ready for immediate use. The following components are included in the scope of supply:

 The robot: KR 210 R2700 prime

The basis of the KUKA OccuBot test system is the KR 210 R2700 prime, an industrial robot belonging to the KR QUANTEC series. Its six axes, which can move freely in space, provide it with maximum flexibility. They ensure comprehensive reachability for any configurable seat position and, thanks to their robustness, are ideally equipped for the demanding conditions of endurance tests.
The KR 210 R2700 prime from the KR QUANTEC series forms the basis of the OccuBot system.

The controller: Standard KR C4 ed. 2015

The KR QUANTEC is controlled by the supplementary KR C4 ed 2015 system component. This control system is a robust cabinet module which, in addition to proven standards, contains the OccuBot test system specially designed for a tailor-made force/torque sensor and the associated sensor box.

The KUKA KR C4 controller ed. 2015 is the heart of the OccuBot. 

The sensor: FT-NET Omega 160 force/torque sensor

With the OccuBot, the high precision measurement of the performed motions and loads is carried out via the FT-NET Omega 160 force/torque sensor. It is mounted on the flange of the KR QUANTEC. At a regular intervals of 12 milliseconds, the sensor polls measurement equipment and robot position data, logs them and immediately processes them further.
The FT-NET Omega 160 OccuBot sensor acquires all measurement data at 12-millisecond intervals.

Operator control: KUKA smartPAD

With the KUKA smartPAD, operation of the OccuBot system is particularly simple and convenient: simply enter the test configuration for the seat test directly during programming. Through its intuitive user interface and the comfortably large 8.4-inch, antireflection touch display, you can – in combination with the KR C4 controller – control up to eight axes without switching. 

The KUKA smartPAD is extremely user-friendly and offers maximum mobility.

The dummy: KUKA OccuForm dummy

The KUKA OccuForm dummy is used in the OccuBot test procedure to achieve the most realistic simulation of the forces and torques occurring. Thanks to the precise measurement of the sensor, you receive precise data for all points that the dummy touches on the seat surface. Through smart programming, it is possible to compensate for the static forces of the dummy in order to prevent the rise of additional dynamic forces.
During every OccuBot test, the KUKA OccuForm dummy gives its best.

The software: KUKA.OccuBot 3.1

Besides a configuration tool, the KUKA.OccuBot 3.1 software used for OccuBot tests also contains the application software KUKA.User Tech 3.2 and KSS 8.3. Both of these components are essential. As an option, KUKA.DIS 3.0 can also be installed. This third software enables data to be recorded and exported to a PC via USB interface.