During the in-line geometric inspection phase, each robot had to move quickly and perform complex turns while verifying key reference points using vision cameras. However, this highly demanding operation subjected the cables to extreme stress, leading to frequent breakages and, as a result, unplanned interruptions on the production line.

The impact was significant: each stoppage required technicians to be deployed to replace the cabling, disrupting the process flow and affecting the plant’s overall efficiency. Renault needed a robust, adaptable solution capable of withstanding the robot’s aggressive movements while also providing continuous system monitoring.

The Solution

In the industrial robotics environment, the dresspack—the set of cables, hoses, and support elements that follow the robotic arm—plays a key role in ensuring operational reliability under demanding working conditions. As part of the solution designed by SUMCAB, an optimized dresspack was integrated specifically to protect the cables of the onboard vision system from continuous torsional stress. It adapts to the robot’s complex movements and significantly improves the durability of the overall assembly.

SUMCAB’s technical proposal was comprehensive, combining bespoke mechanical design and predictive software. First, the SUMOTEX™ system was applied: a highly resistant, lightweight, and flexible textile energy chain. This system protects the cabling through an airbag-like structure that cushions the robotic arm’s movements, minimizing friction and wear—even in areas of direct contact with the robot chassis. Thanks to this technology, an optimal balance was achieved between mechanical flexibility and functional protection of the system.

In parallel, the performance of the original camera cable was enhanced with the SUMFLEX® Mechatronic range, a solution developed specifically for environments with high demands in bending, torsion, and repetitive motion. This cable—optimized in collaboration with Renault’s team—ensures not only a longer service life, but also better compatibility with the routing of the assembly and the robot’s complex movements.

To complete the solution, SUMOSENSE™ was incorporated: an intelligent monitoring module that maintains and supervises the air pressure inside the energy chain. This device automatically regulates airflow, records real-time pressure maps, and issues visual alerts via a traffic-light-style system. In addition, if connected to the plant’s control network, it enables direct interaction with centralized monitoring systems, triggering notifications or automated responses in the event of deviations.

All data collected by the system is sent to the cloud and managed through artificial intelligence tools. This digital ecosystem makes it possible to monitor the condition of the energy chain and cables at all times, generate historical records, detect behavioral patterns, and anticipate potential failures. Thanks to this predictive maintenance approach, the system learns from the process itself, increasing reliability over time and enabling informed decisions based on real data. SUMCAB has developed a dedicated application through which operators can easily view these parameters, consult logs, and take action based on the system’s actual condition.

From the start of the project, Renault’s technical team showed an open, co-creation-oriented attitude, which enabled smooth, coordinated work at every stage. Based on a detailed analysis of the robot model, SUMCAB designed custom mechanical structures tailored to the arm’s specific mounting points. These ensured robust fastening of the SUMOTEX™ package and efficient routing of the assembly, capable of withstanding fast, repetitive rotations without compromising integrity.

Finally, customized electrical and pneumatic adjustments were carried out to ensure full integration with the plant’s technical ecosystem. From calibrating airflow to implementing compatible sensors and connectors, every decision was made in close coordination with Renault’s teams, ensuring a harmonious, functional implementation aligned with the plant’s quality standards.

The Results

Thanks to the new energy supply system with textile protection and active monitoring, unplanned stoppages due to cable breakage were completely eliminated. Continuous, safe, incident-free operation was achieved.

• 100% reduction in camera cable breakages.
• Elimination of unexpected line stoppages.
• Increased dresspack service life (estimated x3).
• Savings in intervention and spare-parts costs.
• Useful predictive insights for planned maintenance.

The solution was very positively received by Renault’s team, who highlighted SUMCAB’s adaptability, fast execution, and technical support throughout every phase of the project. Renault’s team’s strong willingness to share operational challenges, collaborate closely, and trust innovative proposals was key to achieving this shared success.

This case shows how SUMCAB not only supplies components, but also acts as a strategic technology partner. By integrating advanced mechanics, intelligent sensors, and cloud connectivity, the company has helped Renault operate while minimizing risk and maximizing efficiency.

The model implemented can be easily replicated on other robotic manufacturing lines, both within the automotive sector and in other industries. In an environment where every second counts, anticipating incidents is no longer just a competitive advantage—it is a new standard of operational excellence, and this collaboration between Renault and SUMCAB has clearly demonstrated it.