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As robots perform different tasks in various industries, these specialized cables, known as robotic cables, play an increasingly important role as automation changes the face of multiple industries. These cables enable various robotic applications to run smoothly and efficiently. Robotic cables can be found in everything from factory robotic arms to surgical robots, and they are essentially designed to withstand stresses such as twisting, bending, and continuous motion. This blog will cover what robotic cables are, their types, materials, and applications in various industries.
What Are Robotic Cables?
Robotic cables are specifically designed and developed for the unique mechanical stresses of robotic control systems. These cables can withstand repeated bends, twists, and flexes. They must be rigid and flexible enough to function correctly in harsh conditions, such as extreme temperatures, exposure to oils and chemicals, and constant motion. Whether it is power transmission, data transmission, or signal relaying, they deliver an uninterrupted functional experience and reliability.
Types of Robotic Cables
Robotic cables are available in a variety of models, each with specific motion properties:
- Continuous Flex Cables: These cables are designed to withstand back-and-forth oscillating motion around a single axis and are mainly used in automated machinery and conveyor systems.
- Torsion Cables: These cables are designed to withstand rotation around a central axis and are mainly used for servo-driven robotic arms and automation tools. They can withstand twisting and bending during complex movements. Types include:
- Torsional Data Cables
- Torsional Control Cables
- Hybrid Torsional Cables (a mix of data and power)
Materials and Construction
The quality of the materials used in robotic cables is critical to their work. Typically, they are made of finely drawn copper wire, which is flexible and durable. The outer jacket protects the cable from mechanical damage in harsh environments. In short, there are two common materials used for these robotic cables:
- PVC (Polyvinyl Chloride): Flexible and cost-effective, but not suitable for exposure to industrial oil environments.
- Polyurethane (PUR): Resistant to oils and chemicals and, therefore, suitable for industrial locations where large amounts of substances are exposed.
Applications of Robotic Cables
Robotic cables are used across various industries, each with specific demands:
- Industrial Robotics: In manufacturing environments, robots are typically used for welding, painting, and assembly. To protect operations, cables are subjected to high-frequency bending and twisting.
- Military Robotics: In military and aerospace applications, robots encounter extreme conditions, such as high temperatures and vibration. Cables used in these applications must meet strict Mil-Spec standards to ensure durability and reliability.
- Medical Robotics: During surgery, robotic hands must work with great dexterity and precision. The cables used here are designed to minimize interference and maximize flexibility during safe operation.
- Logistics Robotics: AGVs working in warehouses require robust, flexible cables for efficient operation within material-handling and storage systems.
Challenges for Robotic Cables
Robotic cables face several challenges unique to their environments:
- Flexibility and Durability: The cable should withstand millions of bends and twists without deterioration.
- Extreme Stress: The cable should withstand the robot’s sharp acceleration, deceleration, and other extreme mechanical forces, including any type of failure stress.
- Environmental Resistance: The cable should be able to withstand extreme temperatures, humidity, chemicals, and other harsh conditions to ensure performance in harsh environments.
Selecting the Right Robotic Cable
Selecting the right one for a robotic application involves the following considerations:
- Torsion-Optimized Design: The cable must protect itself from damage by being specifically shielded to mitigate rotational stresses and complex movements.
- Long Lifespan: Cables must have a degree of inherent durability. Therefore, lightweight cables that can last millions of cycles ensure minimal downtime and reduced maintenance costs.
- High Flexibility: Cables must bend with the robot’s movement without causing abrasion. They are often made of PTFE (polytetrafluoroethylene) resistant materials.
- Effective Cable Management: To ensure excellent performance, alignment devices such as triflex® help maintain proper bend radius and provide bulk protection in space.
Key Industries Using Robotic Cables
Robotic cables used in different industries have the following main functions:
- Manufacturing and Automation: It plays a role in assembly line processes, packaging systems, and automated processes that require reliable power and data transmission.
- Healthcare: Medical robotics requires flexible and precise cables to perform robot-assisted surgeries more safely and efficiently.
- Military and Aerospace: These robots must be equipped with cables that can remain flexible without losing functionality under extreme conditions, such as high temperatures and vibration interference.
- Logistics and Warehousing: Robot cables enable AGVs to operate efficiently and reliably for material handling.
Conclusion
Robotic cables are essential for safe and proper functioning. They can withstand extreme mechanical stresses and harsh environmental conditions to provide stable, uninterrupted performance. As robotics evolves, so does the need for more flexible, robust, high-performance cables.
Contact Us
Are you looking for customized cabling for your robotic system? Romtronic’s team of professionals is ready to help. Contact us to find the best cabling solution for your automation needs. Let us ensure your robot is always performing at its best – without exception.
You might also be interested in learning more about custom robot wire harnesses: Custom Robot Wire Harnesses.
Sam Wu is the Marketing Manager at Romtronic, holding a degree in Mechatronics. With 12 years of experience in sales within the electronic wiring harness industry, he manages marketing efforts across Europe. An expert in cable assembly, wiring harnesses, and advanced connectivity solutions, Sam simplifies complex technologies, offering clear, actionable advice to help you confidently navigate your electrical projects.
