Torsion-resistant cables for robotics applications

The robotics industry is advancing rapidly, leading to a growing demand for specialized cables. As robots become increasingly complex, the electrical cables that power and control them must withstand constant movement and harsh conditions without compromising performance. Manufacturers today are developing electrical cables capable of enduring the challenges presented by advanced robotics, frequently employing innovative materials and new design techniques to meet these technological demands. This progress is crucial in ensuring that electrical cables are as advanced as the robots they support.

Cables used in robotics face various stresses: millions of continuous bends and twists create significant compression and tensile forces, putting considerable strain on the cable. Cable design must also account for rapid acceleration and deceleration, making abrasion resistance, cut resistance, and tear resistance essential. Additionally, high temperatures commonly encountered in robotic applications add another layer of stress to the cables.

Torsion and tensile forces are factors that standard cables cannot withstand as effectively as cables specifically designed for robotics. Robotic arms and components bend millions of times, and standard cables are unable to endure such demands in these applications.

2.1 Specialized design of torsion-resistant cables

To withstand millions of bends in industrial applications, robotic cables require a specialized design. Advanced torsion-resistant cables for robots are optimized for flexibility. Every component - from materials and shielding structure to the outer sheath - is designed to adapt to changing angles and diameters. This type of cable can handle the complex movements of robots. Within its operating range, torsion-resistant cables ensure efficient data transmission.

2.2 Torsion-resistant cables are essential solutions for 6-axis robots

In modern industrial applications, 6-axis robots are increasingly used to optimize production efficiency and automation. With the ability to move flexibly in six different directions, these robots must perform millions of complex movement cycles, including bending and twisting. As a result, torsion-resistant cables are essential components, ensuring stable and durable operation in demanding environments.

Torsion-resistant cables are specially designed to withstand the intense impact of continuous motion, featuring a durable material structure and protective sheath that minimizes damage risks. This design allows the cable system to adapt and respond flexibly to both horizontal and vertical torsional movements, reducing the likelihood of breaks or wear over time.

Benefits of using HELUDATA® ROBOFLEX®-recycle cables

• Saving money over cross-linked cables
• Halogen-free
• Heat-resistant from -40°C bis 105°C
• Good resistance to oil, chemicals and welding sparks
• UL and CSA approval
• Suitable for drag chains and robots, tested with 10 million changing bending and torsion cycles

Some notable torsion-resistant cables include:

• HELUKAT® PROFInet R+ CAT.5e SF/UTP PUR ROBOTIC: This cable offers excellent transmission characteristics with double shielding and is designed for applications with torsional loads, such as in robots.
• HELUKAT® 100T CAT.5 SF/UTP PUR TORSION: Characterized by high reserve capacity and outstanding performance, even after exposure to extreme conditions. Thanks to its clever structure, this electric cable can also achieve a long mechanical service life.
• HELUKABEL® BUS Cables Profibus L2 Torsion: This cable features a special torsion construction that allows it to be twisted and is completely halogen-free due to the use of a PUR sheath. The Festoon version is used for hanging or moving loads in chain applications.

Additionally, users may also refer to products such as HELUKAT® 600T CAT.7 SF/FTP PUR TORSION, HELUCOM® I-V4Y(ZN)Y (B), I-V4Y(ZN)11Y (C), and A-V(ZN)11Y