KUKA, the Augsburg-based automation group, is the world's only manufacturer of industrial robots that can also be used for passenger carrying in amusement parks. KUKA robots are able to whirl passengers through the air or simulate the experience of flight on a magical broom. The range of individual experiences can also be significantly expanded through the addition of Virtual Reality.
KUKA's orange robots are typically well known for their use in the automotive and other industrial sectors. However, not as well known is that some KUKA robot types are also used in the entertainment ride sector where there is less welding, milling or assembly, but instead allow for the ultimate thrill ride. Due to the special motion capabilities the robots are well known by amusement parks under the name “KUKA passenger“. In addition to the large theme parks of well-known Hollywood film studios who use these special robots, smaller amusement parks and even cruise ships also rely on KUKA passenger robots. Visitors can even experience certain film scenes when on the robotic ride systems and programmed accordingly to make them part of the story themselves. They are able to experience thrilling journeys seated and secured in individual gondolas attached to the robot arm, and like being on a real roller coaster - off they go. The robot is able to simulate nearly every conceivable ride dynamic, such as a corkscrew, rocket launch or wave-like movements thanks to a combination of freely programmable motions. "In addition to our wide range of industrial robots, as a major global robot manufacturer it is also important for us to develop alternative applications and markets. We want to demonstrate the numerous advantages of robots to the general public and bring them to life," says Mike Beaupre, Business Development Manager Americas & Asia at KUKA.
Robust hardware from KUKA
The implementation of theme park rides based on the KUKA passenger robot is challenging. "On the one hand, there is an extremely high demand and responsibility placed on safety. On the other hand, the demand on KUKA passenger robot-based rides is growing for more customized ride solutions. In order to meet the requirements, we work very closely with specialized partners who understand all of the specific requirements and are able to implement our robots into specialized ride systems on a global basis," explains Mike Beaupre.
There are two versions of KUKA passenger robots which are the six-axis KR 600 R2830 passenger and the KR 700 R2510 passenger as a four axes version, allowing the load capacity to be increased to up to 800 kg. This makes it possible to transport up to four people on each robot.
Safety comes first
"The reason why we are the only manufacturer of industrial robots that also offers robots for the entertainment sector is the very high commitment to meeting various theme park industry safety regulations. We are the only ones to meet these requirements," says Julian Stockschläder, Business Development Manager Entertainment EMEA and Product Manager Entertainment & Education at KUKA. For the system to be allowed to be operated in amusement parks in Europe, TÜV certification in accordance with EN 13814 (DIN 4112) is required for passenger carrying applications. Numerous safety precautions must be implemented and maintained on the robots in order to meet these requirements. Depending on the overall ride safety concept, this may include additional safety brakes for each axis, or a higher-level secondary control system based on the "golden profile" principle and integrated by the ride builder. In this way the entire ride system can be continuously monitored by the secondary control, so in any case of a programmed path deviation the ride can be stopped safely and quickly. In addition to specialized brakes and controls, all individual components are subject to very high quality assurance standards. KUKA not only demands material certificates from the suppliers, but every structural component as well as every drive component is X-rayed to ensure process reliability and eliminate any potential weak points. The assembly of passenger robots also differs from the production of classic industrial robots. On the one hand, production at the KUKA plant takes place on a separate line. On the other hand, only specially trained personnel are allowed to assemble these robots.
When the robots have completed assembly and initial control testing they are then turned over for individual testing and certification by TÜV staff. For this purpose, all component manufacturing certificates from suppliers as well as from 3rd party X-ray testing must be submitted for review and proving they are defect-free, to the acceptance of the brakes and the overall control system functionality. Not just the robot is tested and certified, but the entire system including the KR C4 control unit; or in the case of the KUKA passenger ride system, the passenger seat/restraint system and even the safety barrier fence. The individual acceptance according to EN 13814 (DIN 4112) is not passed until all components have been tested without any objections. This certifies the robot and/or robot ride system can then be used in amusement parks throughout the EU.
There is also a special and separate requirement for amusement parks in China. In order to be allowed to operate there, a demanding certification process together with the state authority "China Special Equipment Inspection and Research Institute" (CSEI) is necessary. As a first step, a hardcopy of all development documents must be thoroughly checked. In the next step, CSEI representatives check whether the manufacturing process of the critical components meets the requirements, and only then construction of the robots can begin. At the end the final acceptance takes place and checked documents are then sealed and maintained for any possible future checks to ensure the robots have been manufactured according to plan.
Advantages over classic rides
The higher cost of certification is well worth it. On the one hand, safety is always the top priority, on the other hand, the growth prospects in the amusement park industry are positive. Compared to other rides such as roller coasters or using Stewart platforms, KUKA passenger robots offer numerous advantages. With a range of approx. 3 meters and fully coordinated motion they have a high degree of freedom of movement. This results in the second advantage: the robot's programmability means that it is able to run various path programs and thus create an individual ride experience. So-called "dark rides", i.e. theme rides, are also possible when the robot is mounted on a moving ride vehicle. This means the robot can follow scenes known from popular films or characters, for example. For the future - as a third advantage or unique selling point - the "Real Time" experience is conceivable. This means that the movement of the robot can be influenced by the passengers' own actions. This allows simulations such as those of a flight simulator to be realized. Virtual Reality (VR) is another field of application that is enjoying increasing popularity. The technology has improved rapidly in recent years and offers incredible potential. Using specialized programming methods the KUKA passenger robot is able to follow movements based on what passengers see in their VR headsets or as projected on a domed screen. If this is properly done using a mathematical model, the movement of the robot exactly matches the VR content and negative passenger experiences such as kinetosis will not occur.
Partners implement customer-specific solutions
The exact correspondence of the robot's movements to the film scenes or VR programs is made possible by software from longtime KUKA partner and industrial services provider, BEC Rides. "Together with our partners, we implement the films desired by the customer for the driving experience. Based on the film, our software converts the movements shown into the robot's movement in real time. This is unique worldwide," says Martin Gerlich of BEC. BEC has been a KUKA system partner for 15 years and, among many other things specializes in the programming and implementation of rides based on KUKA passenger robots. With a wide range of implementation options, from flight simulators to Hollywood films to VR applications, the company offers a broad spectrum of ride programs. In addition to its software expertise, BEC also optimizes robot motion. According to Martin Gerlich: "The robot has a limited range. This would lead to problems with longer accelerations, as the travel path of the robot arm would eventually end. We therefore simulate the acceleration with a linear motion before letting the robot tip slightly backwards. This pushes the passengers into the seat. While they believe to drive forward, the robot actually moves back again.“
Due to the wide range of possible applications, there is great demand for rides based on KUKA passenger robots. "There is great potential for growth, especially in the USA and China. In Asia we are currently experiencing a real catch-up boom in the leisure sector," says Martin Gerlich.