KUKA
| Company type | Public (formerly) |
|---|---|
| Industry | Industrial robots, factory automation |
| Founded | 1898 in Augsburg, Germany |
| Founder | Johann Josef Keller, Jakob Knappich |
| Headquarters | Augsburg , Germany |
Area served | Worldwide (including United States, EU, Australia, Canada, Mexico, Brazil, China, Japan, South Korea, Taiwan, India, Russia) |
| Products | Industrial robots, factory automation solutions |
Number of employees | 13,000+ (2014) |
| Parent | Midea Group (since 2016) |
| Website | www |
KUKA is a German-based producer specializing in industrial robots and factory automation solutions. In 2016, the company was purchased by the Chinese household appliance giant Midea Group.
With 25 subsidiaries worldwide, KUKA maintains a presence in countries such as the United States, European Union member states, Australia, Canada, Mexico, Brazil, China, Japan, South Korea, Taiwan, India, and Russia. The name KUKA is an acronym derived from its founders.
The division KUKA Systems GmbH delivers engineering expertise and automated production systems, employing approximately 3,900 personnel across twelve nations. Its facilities and machinery support automotive manufacturers including BMW, GM, Chrysler, Ford, Volvo, Volkswagen, Daimler AG, and Valmet Automotive. Additionally, it serves aerospace and industrial clients like Airbus, Astrium, and Siemens. This branch specializes in automation for processing both metallic and non-metallic materials across sectors such as automotive, energy, aerospace, rail transport, and agricultural equipment.
History
The Augsburg Acetylene Factory was established in 1898 in Augsburg, Germany by Johann Josef Keller and Jakob Knappich with the aim of producing affordable lighting solutions, household devices, and automobile headlights. By 1905, the company had expanded its product line to include autonomous welding equipment.
Following World War I, Keller and Knappich resumed manufacturing safety devices including manual and power winches and began fabricating large containers. This led to the creation of Bayerische Kesselwagen GmbH in 1922. The division developed superstructures for municipal vehicles and introduced the first large-scale garbage truck in 1927. The abbreviation KUKA originated that same year from "Keller und Knappich Augsburg." In Hungary, KUKA became synonymous with waste containers due to its early production of enclosed container garbage trucks.
Keller & Knappich GmbH merged with a segment of Industrie-Werke Karlsruhe AG to form Industrie-Werke Karlsruhe Augsburg Aktiengesellschaft, which was later shortened to KUKA.
Production of spot welding equipment began in 1936. By 1939, the workforce had grown to over 1,000 employees.
From 1934 onwards, KUKA expanded significantly by supplying machine tools and components for the armaments industry including Messerschmitt AG. During World War II, labor included prisoners of war and forced workers; in 1944 alone, Collective Camp II housed 1,400 laborers.
After the war's end, KUKA rebuilt its operations by resuming welding machine manufacture and diversifying into products such as double-cylinder circular knitting machines and portable typewriters.
In 1956, KUKA introduced the first automatic welding system designed for refrigerators and washing machines and delivered Volkswagen AG’s initial multi-spot welding line. The first friction welding machine followed a decade later in 1966.
The company supplied its first robotic welding system in 1971 for the Mercedes-Benz S-Class model. Two years later in 1973, KUKA launched its proprietary industrial robot named FAMULUS. At this time, the company was part of the Quandt group.
In 1980, the Quandt family divested their stake leading to the formation of a publicly owned enterprise. By 1981, KUKA’s core business was segmented into three entities: KUKA Schweissanlagen und Roboter GmbH, KUKA Umwelttechnik GmbH, and KUKA Wehrtechnik GmbH (which was sold to Rheinmetall in 1999). Additionally, LSW Maschinenfabrik GmbH became a subsidiary in 1982.
By 1993, KUKA developed its initial laser-roof-seam welding systems and expanded into adhesive bonding and sealing technologies by the following year. The company acquired Schwarzenberg GmbH, a tools manufacturer, while also extending its operations into China and the United States.
In 1995, KUKA divided into two subsidiaries under KUKA AG: KUKA Robotics Corporation and KUKA Schweißanlagen (now known as KUKA Systems). During this period, it joined key industry associations such as the Robotics Industries Association and the International Federation of Robotics.
By 1996 KUKA Schweissanlagen GmbH became an independent entity and by 1998 had become a leading manufacturer of welding equipment in Europe. In 2002 it provided pressing tools for automobile side panels made from high-strength steel. The launch of the KUKA RoboScan remote laser welding head came in 2003. Since 2006, KUKA Systems has operated a body shell manufacturing plant in Toledo, Ohio producing Jeep Wrangler bodies for Chrysler.
Reflecting its broadening scope into reshaping technologies, tooling solutions, bonding, sealing processes among others, KUKA Schweissanlagen GmbH was rebranded as KUKA Systems GmbH in 2007. In 2010 the company introduced flexibleCUBE—a standardized cell concept for welding machinery.
Specializing in industrial automation products both standardized and tailor-made, KUKA Systems focuses on joining technologies alongside component handling supported by comprehensive engineering consultancy to optimize production workflows.
In June 2016 China's Midea Group proposed approximately €4.5 billion (around $5 billion) to acquire KUKA; this acquisition was finalized in January 2017 when Midea secured a controlling stake of 94.55%.
Towards the end of 2017, KUKA announced workforce reductions affecting around 250 employees within KUKA Systems due to project-related challenges.
In November 2022 Midea Group completed full ownership by purchasing all remaining shares of KUKA AG.
Most robots produced are finished predominantly in "KUKA Orange," which serves as the official corporate color or alternatively black.
Corporate organization
Based in Augsburg, Germany, KUKA employed more than 13,000 individuals as of December 2014. While originally concentrating on the automotive industry, the company has expanded its operations across various sectors through five distinct divisions:
- Systems
- Robotics
- Swisslog Logistics Automation
- Swisslog Healthcare
- China
Key achievements
- 1971: Constructed Europe's inaugural welding transfer line for Daimler-Benz.
- 1973: Introduced FAMULUS, recognized as the first industrial robot worldwide with six electromechanically driven axes.
- 1976: Released the IR 6/60 robot, featuring six axes and an offset wrist design.
- 1989: Created a new generation of industrial robots equipped with brushless motors to minimize maintenance and enhance reliability.
- 2004: Launched KUKA LBR 3, the pioneering collaborative robot (Cobot) designed for safe interaction with humans, developed in partnership with the German Aerospace Center.
- 2007: The KUKA Titan was recognized as the largest and most powerful six-axis industrial robot, earning a Guinness World Record.
- 2010: Rolled out the KR QUANTEC series, offering payload capacities from 90 to 300 kg and reaches up to 3100 mm.
- 2012: Debuted KR AGILUS, a compact robot lineup optimized for high-speed tasks.
- 2014: Achieved worldwide attention through a viral video showcasing a Table Tennis robot competing against German professional Timo Boll; this campaign significantly increased brand exposure despite mixed feedback.
- 2016: Became part of Chinese conglomerate Midea Group following a $4.4 billion acquisition.
- 2018: Introduced KUKA i-do, a modular prototype of a consumer service robot presented at Hannover Messe, highlighting social robotics capabilities.
- 2024: Showcased cutting-edge innovations at Modex 2024.
System details
The KUKA system software serves as the fundamental operating platform for the entire control architecture, delivering vital functionalities required for robot operation.
Robots are equipped with the KUKA Control Panel (KCP), also known as the teach pendant, which includes a screen, axis control buttons (A1-A6), and an integrated six-degree-of-freedom mouse for manual programming modes. This pendant enables operators to view, edit, and develop programs. Manual axis manipulation necessitates activating an enabling switch on the pendant. The controller interfaces via a proprietary video connection and CAN bus responsible for safety interlocks and button functions.
Within the control cabinet, a robust computer communicates with the robot through the Multi Function Card (MFC), which oversees real-time servo drive electronics. The Digital Servo Electronics (DSE) board—usually integrated within the MFC—connects to the Resolver Digital Converter (RDW/RDC) board positioned at the robot base. This setup facilitates servo position feedback transmission.
The software operates two components concurrently: one is the user interface and program storage running on Windows Embedded platforms (Windows 95 for KRC1/early KRC2, Windows XP Embedded for KRC2, Windows 7 Embedded for KRC4), while the other is VxWin—a modified real-time operating system based on VxWorks—handling program execution and motion control by communicating with the MFC.
The systems support standard PC peripherals such as CD-ROM or floppy drives (in older controllers), USB ports, as well as ISA or PCI/PCIe slots to incorporate industrial automation interfaces including Profibus, Interbus, DeviceNet, and Profinet.
Aerospace
KUKA Systems provided the TIG welding cell utilized in the assembly of the Ariane 5 launcher's upper stage. TIG welding, a precision arc welding technique, is a core component of KUKA’s technology portfolio. The company also supplies machinery for fabricating aircraft structural parts. Prominent aerospace partners include Boeing, SpaceX, Bell, and Airbus.
Automotive
KUKA Systems delivers a diverse array of automation solutions tailored for joining and assembling vehicle body frameworks, ranging from compact automated lines to highly adaptable manufacturing systems. Their offerings encompass standalone equipment, subassemblies, full body structures, and mechanical part assembly. Services include disc assembly, vehicle body-to-chassis integration ("marriage"), and component fitting.
Major automotive clients comprise BMW, GM, Chrysler, Ford, Volvo, Hyundai, Volkswagen, and Daimler AG.
Rail Vehicle Manufacturing
KUKA Systems equips producers of locomotives, subway cars, and freight wagons with automated assembly lines and production solutions.
Photovoltaic Module Production
The company provides automation technologies covering every phase of photovoltaic module manufacturing, including brick sawing, cell manipulation, cross-tie soldering, framing processes, and packaging.
Welding Technology – General
In addition to automotive and rail applications, KUKA Systems supports sectors such as baby stroller fabrication and household appliance production for BSH (Bosch und Siemens Hausgeräte GmbH).
Certifications
- ISO 14001
- ISO 9001
- OHRIS – Occupational Health and Safety Certification
- VDA 6.4
- ISO 3834
- EN 9100
Application Domains
KUKA industrial robots are deployed across various industries including material handling, machine loading/unloading operations, palletizing tasks, as well as spot and arc welding—primarily catering to automotive and aerospace markets. Key sectors include:
- Transportation: Managing heavy payloads with superior load capacity and agility.
- Food and Beverage: Handling packaging machine loading/unloading, meat processing, stacking, palletizing, and quality inspection.
- Construction: Facilitating efficient material flow.
- Glass Industry: Performing thermal treatments and shaping of glass and quartz.
- Foundry and Forging: Employing heat- and dirt-resistant robots for deburring, grinding, drilling, and quality control near casting equipment.
- Woodworking: Executing grinding, milling, drilling, sawing operations alongside palletizing and sorting.
- Metalworking: Conducting drilling, milling, sawing, bending, punching; welding; assembly; loading/unloading processes.
- Stone Processing: Cutting and shaping ceramics and stone materials; collaborating exclusively with BACA Systems to advance robotic applications in this field.
KUKA Entertainment
In 2001, KUKA collaborated with RoboCoaster Ltd to create the first industrial robot capable of carrying passengers. This attraction features roller coaster-style seats mounted on robotic arms that perform programmable movements controllable by riders. The second-generation RoboCoaster G2 debuted in 2010 at Universal's Islands of Adventure in Orlando, Florida. It enhanced the ride experience by synchronizing robotic motions with attractions such as Harry Potter and the Forbidden Journey. The seats are secured to robotic arms attached to a track system that navigates through the attraction while coordinating with elements like animatronics and projection effects.
KUKA's partnership with RoboCoaster extends into Hollywood productions. Their robots appeared in films such as Die Another Day, where they portrayed laser-equipped adversaries, and The Da Vinci Code, featuring a robot delivering a cryptex to Robert Langdon.
In 2007, KUKA launched a simulator based on the RoboCoaster platform showcased in attractions like The Sum Of All Thrills at EPCOT in Lake Buena Vista, Florida.
More recently, KUKA robotic arms have been incorporated into Royal Caribbean cruise ships' bionic bars. Guests select drinks via tablet interfaces while robotic arms skillfully mix spirits, mixers, and liqueurs to prepare customized cocktails.