New KUKA operating system includes a virtual robot controller

KUKA said the combination of the KUKA System Software, technology stacks, and the latest web technologies offers new possibilities. | Source: KUKA

KUKA last week unveiled the iiQKA.OS2 operating system. which it said is scalable, customizable, and includes a complete virtual robot controller. The company claimed that its system is ready for artificial intelligence and the new ISO 10218:2025 industrial robot safety standard.

It also said iiQKA.OS2 is “cyber-resilient,” making digital manufacturing future-proof. KUKA added that a robot controller with the operating system is easier to use and more accessible. This is thanks to combination of a web-based user interface and the ability to use one’s own teach pendants or the KUKA smartPAD.

KUKA said iiQKA.OS2 combines the proven core of its KUKA.SystemSoftware (KSS) and a modern user interface with modular safety to meet automation requirements. The company asserted that its decades of development experience, a modern tech stack, and the latest web technologies offer new possibilities in terms of functionality, user experience, and workflows.

KUKA engineering suite enables customization

iiQKA.OS2 can not only enhance the efficiency of production automation but also simplify it, said KUKA. The new iiQKA.UI web-based user interface and customizable application modules enables companies and production facilities of all sizes to integrate both virtual and real robot controllers. The company said this includes everyone from small and midsize businesses (SMBs) to OEMs.

The portfolio also includes realistic load data analysis, allows development of customer-specific software packages, and provides comprehensive simulation. Users can also make changes and adjustments quickly and easily without physical hardware, according to KUKA.

In combination with the advanced iiQWorks engineering suite, iiQKA.OS2 enables the simulation of multiple robots and their peripherals. As a result, KUKA said, users can more easily adhere to project schedules, use resources efficiently, and put systems into operation more quickly.

iiQWorks can handle all robot kinematics

With the new operating system, all KUKA robot kinematics can run with the same system through the KR C5 and KR C5 micro controllers for iiQKA.OS2. This includes Delta and SCARA robots, as well as six-axis robots of all payload capacities. KUKA said this will initially apply to small robots and then to large robots later in 2025.

The system can also be used without a teach pendant with a “use your own device” feature. The KUKA smartPLUG can be docked onto a commercially available tablet and connected with a USB cable. This allows the robots to be programmed and operated intuitively and quickly on the iiQKA.UI.

iiQKA.OS2 can detect errors at an early stage, thanks to various engineering functions, said KUKA. These include simulation, offline programming, and comprehensive tests in a virtual environment. This reduces risks and costs considerably, the company said.

An optional expansion board from NVIDIA is available with the KR C5 and KR C5 micro for iiQKA.OS2. The board enables the integration of AI for vision applications. In addition, the system will be ready for the new ISO 10218:2025 and IEC 62443-certified – and therefore ready for future challenges, said KUKA.

The Augsburg, Germany-based company is an international automation group with sales of more than EUR 4 billion ($4.5 billion U.S.) and around 15,000 employees. It offers industrial robots, autonomous mobile robots (AMRs), including controllers, software, and cloud-based digital services, as well as fully connected production systems for a wide range of industries.

The company won a 2025 RBR50 Robotics Innovation Award for its work assisting with larvae breeding on Danish insect farms. Learn more about the RBR50 at the RBR50 Gala and Showcase at the Robotics Summit & Expo next week in Boston.

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