Robots in the Factory of the Future: Challenges and Opportunities for Cable Manufacturers

The integration of industrial robots has revolutionized manufacturing, boosting efficiency and productivity. However, the constant three-dimensional movements in automated factories impose significant stress on robot cables, presenting a challenge for cable manufacturers. This article explores the opportunities and challenges for cable manufacturers in providing robust cables for the factory of the future.

Challenges for Robot Cables

Robot cables must withstand continuous three-dimensional movements, subjecting them to extreme stress. Traditional linear motion cables are unsuitable for such applications. Robot cables require unique designs, featuring compact and closely braided structures with high-pressure extruded outer jackets. This "hardness" enables cables to follow the motion patterns of energy chains seamlessly. Additionally, force-compensating elements, loose braiding, slip planes, and innovative shield concepts are necessary to maintain functionality after millions of torsional stress movements.

igus? Cable Technology

igus?, a leading cable specialist with over 50 years of experience, has developed cables incorporating damping elements and torsional-force-absorbing felt. These cables are specifically designed for applications with continuous changes in torsional stress, offsetting forces acting on the cores and maintaining functionality even after repeated direction changes. Shielded cable types with force redistribution and gliding elements ensure the necessary freedom of movement, minimizing tensile and compressive forces, and preventing premature conductor breakage.

Optimum Protection with the triflex? R Robot Energy Chain

igus? triflex? R robot energy chain offers reliable protection for robot cables during movements. Based on the three-chamber principle, it allows independent opening and closing of the chambers, ensuring the supply hose is protected from deformation regardless of the robot's axial position. Adherence to minimum bending radii ensures process reliability, avoiding costly plant failures.

Testing for Reliability and Reduced Costs

igus? subjects their chainflex? moving cables to extensive testing in a 3,800 m2 laboratory, twisting and torsioning the cables while measuring core resistance. While robot applications pose testing challenges due to movement variability, igus? decades-long experience and data analysis allow them to offer a 36-month guarantee on mechanical specifications. This enables precise planning for mechanical engineering processes, reducing downtime and maintenance costs.

Predictive Maintenance with isense Technology

igus? smart plastics, known as isense, incorporate sensors that monitor the condition of cables and energy chains. These sensors measure wear during operation, transmitting data to the icom communication module. With icom.plus, customers can integrate data into their equipment, enabling predictive maintenance through continuous service life monitoring. Machine learning and AI provide precise information on solution durability, alerting users to necessary replacements in advance.