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