Development of a flexible robotic system with a custom end-effector for helmet mechanism endurance testing

This thesis presents the design and preliminary experimental validation of a flexible robotic platform for repetitive functional testing of motorcycle helmet mechanisms. The system integrates a Dobot CR10 collaborative robot, a custom 3D-printed end-effector, a stepper-motor actuation mechanism, an Arduino-based controller, and computer-based supervisory control. The platform was tested on the main visor, internal sun visor, upper air vent, and chin mechanism of one helmet, as well as the main visor of a second helmet with a different geometry. Each configuration was operated for twenty consecutive cycles. The experiments demonstrated successful automated actuation, collision-free operation, and consistent controller-reported trajectories and cycle timing. The results support the feasibility of using a reprogrammable robotic platform for flexible laboratory-scale functional testing while reducing repetitive manual intervention. Future improvements include force/torque sensing, vision-based localization, closed-loop end-effector feedback, independent metrology, and longer-duration test campaigns.