What is robotic cable management?
Cables are essential for robotics. Information is constantly being relayed between the computer to the equipment. Poor choices in cable management can result in tangled and corkscrewed cables, complete breaks that cause downtime, lost revenue, and ultimately, damaged reputations.
The problem lies in restrictive cable management systems that try to keep the cables static. These industrial wirings don’t take into account the constant twisting that robots undertake. Since they weren't built to turn 360 degrees or 180 degrees, robotic applications raise the risk that one of the wires or the shield itself will break.
Using one, long restrictive cable package prevents movement in sync with the robot, some technicians bind cables with too many dress packs – protective coverings on cables and hoses – cable ties, and even duct tape. They’re attempting to minimise tangling and interference with the machine by creating cable protection, but instead, they’re creating issues.
On the other hand, flexible wires and proper cable management – which includes flexible cable protection – allow the robotic section free range of movement while eliminating risks that the cables may restrict the equipment.
Cables - the basics:
Cables that connect the robot tool to the robot controller typically have two functions:
- Transmit electricity
- Establish communications between the devices
Your goal when it comes to cable management is to place cables so that they’re able to go through as many cycles as the robot in a seamless manner. For that to happen, you must do three things:
- Work with the cable’s natural curvature
- Don’t pinch the cable
- Segment the cables
Think of a six-axis robot as three separate segments, like this:
- The sixth-to-third axis
- The third-to-second axis
- The second-to-first axis
Each segment should feature a minimal dress pack, along with strain relief with service loops, and a cable junction box that holds and protects the electrical connector that join the cables. Strain relief cables specially designed to handle torsional movement are crucial to avoid cable failure and keep machines up and running for as long as possible.
The junction box is likewise crucial. Improperly housed cables will wear prematurely or fail in other ways, causing a delay in production. Unhoused cables can sag and fall into the work area, becoming a health and safety risk or becoming tangled within the moving parts of the machinery.
For the best results
Segmenting your cables gives optimum control over cable design, allowing you to reduce the amount of cable management equipment needed. With better control and less strain, your cables will have a longer life.
From the sixth-to-third axis
Use strain-relief cables on the sixth axis, which is the moving end, with a one- to two-foot service loop. You’ll want to protect cables and hoses with a modular, multi-axis cable carrier. You should also segment cables at the third axis and install a junction box for quick diagnostics and cable replacement.
Third-to-second axis
Use strain-relief cables on the third axis with a one- to two-foot service loop, and a modular, multi-axis cable carrier. Segment cables and install a junction box at the second axis.
Second-to-first axis
Install strain-relief cables on the second axis with a one- to two-foot service loop. Use a multi-axis, reverse-bend cable carrier to protect and guide cables and hoses rotating around the robot. Finally, segment cables and install a junction box at the first axis.
At a glance: cable management
|
Recommended |
Reason why |
| Slit harness wrap, also called rapid cable wrap | A spiral cable wrap that bundle cables together and is flexible enough to adapt to any installation location |
| Flexible cable conduit | A type of cable protector sleeve that also bundles cables, but with added protection by providing an isolated housing |
| Spiral cable glands | Flexible wire cover used as a fixed point where wires enter a different location (wall, electric cable junction box etc.), providing protection against excessive bending |
| Multi slot cable glands | Keeps wires apart at end nodes to avoid friction wear or interference |
| Cable entry systems | Separates wires when passing into a power cable junction box or control box |
| Flexible cable duct | Organises and protects cables |
| Braided cable sleeving | Protects wires while conforming to irregular shapes |
| Wire cable clamp | Defines the route for the cables while providing support |
| Cable hole grommets | Resists vibrations while providing insulation and structural support for cables |
| Cable ties | From nylon cable ties to stainless steel cable ties, use these to bundle, protect and organise your cables |
You’ll also need fasteners
Nylon is an excellent solution for robotics. It’s a lightweight material providing insulation and corrosion resistance.
|
Recommended |
Reason why |
| Rivets | Acts as a permanent fastener with enhanced performance |
| Nuts | Anti-vibration properties that prevent loosening |
| Screws | Lightweight and conforms to irregular surfaces |
| Washers | Anti-loss lip for pre-assembly |
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Questions?
Email us at sales@essentracomponents.co.uk or speak to one of our experts for further information on the ideal solution for your application 0345 528 0474.