Cables in robotic applications must endure a lot. They are subject to intense mechanical strain, thermal stress, and are often installed in confined spaces. But what options exist for tailoring cables to these demands? And is it worth it even for small batch sizes? This article provides the answers.
When Standard Cables Become a Weak Point
In robotic systems, cables are in constant motion. Millions of bending cycles, tight radii, fluctuating temperatures, or exposure to aggressive substances like oil and cleaning agents put them under constant stress. If cables are not carefully designed to match the specific environment and mechanical strain, failures, unexpected downtimes, and high maintenance costs can result. Companies must ask themselves a key question: What are the options for customizing cables to meet my mechanical, thermal, and electrical requirements? And is it viable even for small quantities?
Mechanik, Temperatur, EMV: Was Kabel im Robotereinsatz leisten müssen
Die Anforderungen an Roboterkabel sind vielfältig und oft gleichzeitig hoch. Eine zuverlässige Kabellösung muss daher in mehreren Dimensionen anpassbar sein – von innen nach außen.
Mechanics, Temperature, EMC: What Robotic Cables Must Handle
Robotic cables face a wide range of requirements that are often simultaneously demanding. A reliable cable solution must therefore be adaptable on multiple levels – from the inside out.
Mechanical Durability Through Stranding and Cabling
In highly dynamic applications, cables undergo extreme movements. Stress from bending, torsion, and tension requires a stranding design precisely tailored to these motion profiles. Cabling techniques such as bundled stranding significantly increase bending resistance and improve flexibility. The strand diameter and overall cable cross-section should also be tailored to the installation space and the required mobility within the robot arm or drag chain. At Sumcab Robotics, customer-specific strand geometries and cabling designs are used that are optimized for movement radii and cycle loads in robot-supported systems.
Temperature and Chemical Resistance Through Suitable Materials
Environmental conditions also play a major role in addition to mechanical stress. High temperatures, oils, coolants, and cleaning agents can degrade materials. The choice of insulation and jacket materials is therefore critical to cable longevity. While PVC may suffice for basic applications, polyester insulations or abrasion-resistant polyurethane jackets are often better suited. They offer higher thermal stability, better resistance to chemicals, and reduced wear.
Reliable Data Transmission With Hybrid Cables
In modern robotic systems where power and data cables are routed together, reliable shielding is essential. Without a well-designed EMC (Electromagnetic Compatibility) concept, interference can impair sensors, communication, or control systems. The cable structure – including shield separation, symmetrical pairing, and optimized strand positioning – is crucial for signal integrity.
Hybrid cables developed by Sumcab, for example, combine power and data conductors in a single cable design. Through optimized shielding concepts, interference can be minimized – even under demanding EMC conditions, such as in systems with sensitive measuring equipment or cameras.
Custom Cable Development – Even Without Mass Production
While many industrial cable manufacturers are geared toward large production volumes, robotic applications often require small but highly specialized batches. Whether for prototypes, special machines, or retrofit projects, the demand for customized cable solutions is present even in small quantities.
Thanks to in-house cable production at its Spanish parent plant, Sumcab can manufacture application-specific cables from as little as 100 meters. Modular production processes allow cable construction, materials, and shielding to be flexibly adapted to both technical and economic requirements. This makes custom cable solutions economically viable even for smaller batch sizes.
Conclusion: Custom Cables Pay Off in the Long Run
Robotic applications place high demands on cables – mechanically, thermally, and electrically. Relying on standard solutions increases the risk of failures and short service life. Customizing cable structure, materials, and shielding not only improves reliability but also reduces long-term maintenance costs.
Providers like Sumcab Robotics offer the technical consulting, development experience, and production flexibility needed to tailor cable solutions precisely to robotic applications – even in small quantities. Those who define their needs early on will save time, effort, and costs down the line.