Durability testing of car seat heaters by Robot system

Occubot
The measuring system provides six measurement dimensions for forces and torques and ensures absolute accuracy. This provides the user with data about the actual forces and torques being exerted on the contact surface between the dummy and the seat. To adapt the overall system to a different seat, it is merely necessary to redefine the Base coordinate system.

Performance features:
Continuous adaptation of the forces and torques (every cycle) according to the degree of wear on the test object
Simple parameterization via special interfaces for endurance testing of all kinds
Ethernet interface to an external data acquisition system for saving all relevant test data required for advanced analysis and test logging (optional)
Many other process-specific features, such as an editor for simple definition of the Base coordinate system, “Search and Hold” function for constant forces, static load compensation, programmable test stops, and processing of multiple test objects, etc

Starting point / Task definition
For car seat heaters, technical perfection is not enough; they must also always satisfy customer requirements, no matter which type of seat the heater is installed in. Therefore the basic materials and system components used for the seat heaters must be tested continuously and optimized in accordance with the test results. Standard qualification testing includes the mechanical durability test series required by the automotive industry.

W.E.T. Automotive Systems AG, based in Odelzhausen near Munich, one of the world’s leading manufacturers of car seat heaters, carries out durability testing using the Occubot VI process. Here a KUKA KR 150 robot verifies whether or not heaters integrated into car seats or seat parts withstand the mechanical stress which they are subjected to during the lifetime of the car. Occubot VI is a flexible, programmable, load- and position-controlled test system with high repeatability. This method, which works with force/torque sensors, reproduces the motions and loads of a human body using dummies, thus replacing a wide range of costly, customized test devices with hydraulic or pneumatic drives. Occubot VI allows realistic simulation, for example, of someone getting into and out of the seat (ingress/egress test), or of strong pulsation or vibration during driving. In addition, there are jounce and squirm, rear fatigue, truck driver and clutch operation tests.

The measuring system provides six measurement dimensions for forces and torques and ensures absolute accuracy. This provides the user with data about the actual forces and torques being exerted on the contact surface between the dummy and the seat. It is possible to compensate for the static forces of the dummy itself in order to prevent them from giving rise to additional dynamic forces. The robot motions are also regularly adjusted in relation to the wear on the test object. And to adapt the overall system to a different seat, it is merely necessary to redefine the Base coordinate system.

System components / Scope of supply
KUKA KR 150 robot
PC-based KUKA KR C2 robot controller, including control panel with Windows interface
Force-torque sensor system
System software, including the application, setup and configuration programs
Various dummies
Robot programming
Commissioning