{"id":25174,"date":"2021-04-14T13:53:32","date_gmt":"2021-04-14T13:53:32","guid":{"rendered":"https:\/\/www.machinery.world\/?p=25174"},"modified":"2021-04-14T13:53:32","modified_gmt":"2021-04-14T13:53:32","slug":"robots-in-the-factory-of-the-future-opportunities-and-challenges-for-cable-manufacturers","status":"publish","type":"post","link":"https:\/\/machinery.world\/index.php\/2021\/04\/14\/robots-in-the-factory-of-the-future-opportunities-and-challenges-for-cable-manufacturers\/","title":{"rendered":"Robots in the factory of the future: opportunities and challenges for cable manufacturers"},"content":{"rendered":"

I<\/span>ndustrial robots\u00a0<\/span><\/span>are pervasive in manufacturing and their applications<\/span>\u00a0<\/span>are increasing\u00a0<\/span><\/span>all the time<\/span>. But\u00a0<\/span><\/span>with\u00a0<\/span><\/span>constant<\/span>\u00a0<\/span><\/span>multi-axis\u00a0<\/span><\/span>movements, the cables that supply robot<\/span>s<\/span>\u00a0<\/span>are subjected to extreme levels of stress<\/span>,\u00a0<\/span><\/span>pos<\/span>ing a\u00a0<\/span><\/span>challenge for manufacturers of cables and\u00a0<\/span><\/span>other<\/span>\u00a0<\/span><\/span>connecting components.<\/span><\/p>\n

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The International Federation of\u00a0<\/span><\/span>Robotics<\/span><\/a>\u00a0<\/span>predicts that by 2020 more than 1.7 million industrial robots will be working in factories worldwide.\u00a0<\/span><\/span>R<\/span>obots\u00a0<\/span><\/span>move\u00a0<\/span><\/span>continuously\u00a0<\/span><\/span>in multiple axes\u00a0<\/span><\/span>and must be<\/span>\u00a0<\/span>supplied with data and energy\u00a0<\/span><\/span>by cables\u00a0<\/span><\/span>without interruption,\u00a0<\/span><\/span>so<\/span>\u00a0<\/span>the<\/span>se<\/span>\u00a0<\/span>cables<\/span>\u00a0<\/span>need\u00a0<\/span><\/span>careful\u00a0<\/span><\/span>consideration<\/span>.<\/span><\/p>\n

F<\/span>or applications where\u00a0<\/span><\/span>robot cables<\/span><\/a>\u00a0<\/span>are subjected to torsional stress<\/span>, the<\/span>\u00a0<\/span>cables<\/span>\u00a0<\/span>have to be\u00a0<\/span><\/span>designed<\/span>\u00a0<\/span>and manufactured in a completely different way to cables for linear motion.\u00a0<\/span><\/span>Linear cables<\/span>\u00a0<\/span>must be as compact and as closely braided as possible and have an outer jacket extruded at high pressure<\/span>,<\/span>\u00a0<\/span><\/span>which creates a<\/span>\u00a0<\/span>special “hardness”\u00a0<\/span><\/span>that\u00a0<\/span><\/span>enables the cable to follow the motion pattern of the energy chain.<\/span><\/p>\n

I<\/span>n contrast<\/span>,<\/span>\u00a0<\/span><\/span>r<\/span>obot cables<\/span><\/a>\u00a0<\/span>need force-compensating elements, loose braiding elements, different slip<\/span>–<\/span>planes and completely different shield<\/span>ing<\/span>\u00a0<\/span>concepts in order to ensure they function correctly after several million\u00a0<\/span><\/span>torsional\u00a0<\/span><\/span>movements. This is because the\u00a0<\/span><\/span>cables<\/span><\/a>\u00a0<\/span>used in\u00a0<\/span><\/span>robot technology<\/span><\/a>\u00a0<\/span>have to repeatedly change<\/span>\u00a0<\/span><\/span>direction.\u00a0 For example, the diameter of the braid structure can actually change with\u00a0<\/span><\/span>the\u00a0<\/span><\/span>torsion angle.\u00a0<\/span><\/span>Cable<\/span><\/a>\u00a0<\/span>specialist\u00a0<\/span><\/span>igus<\/span><\/a>\u00a0<\/span><\/span>build<\/span>s\u00a0<\/span><\/span>damping elements and torsional<\/span>\u00a0<\/span><\/span>force absorbing\u00a0<\/span><\/span>layers<\/span>\u00a0<\/span><\/span>into the core groups,\u00a0 to offset the forces acting on the cores.<\/span><\/p>\n

The requirements for the shielded\u00a0<\/span><\/span>robot<\/span><\/a>\u00a0<\/span><\/span>cables are especially high.\u00a0<\/span><\/span>G<\/span>liding elements\u00a0<\/span><\/span>are placed\u00a0<\/span><\/span>above and below the shields<\/span>\u00a0<\/span><\/span>i<\/span>n order to ensure that\u00a0<\/span><\/span>excessive\u00a0<\/span><\/span>forces\u00a0<\/span><\/span>are not placed\u00a0<\/span><\/span>on the shield wires. These elements ensure that the shield can move freely in relation to the overall braiding as well as the outer jacket. The shield structure is designed\u00a0<\/span><\/span>to distribute<\/span>\u00a0<\/span>force<\/span>s<\/span>\u00a0<\/span>and has damping elements in the direction of th<\/span>e<\/span>\u00a0<\/span>force redistribution. This “soft” mode of construction gives the entire cable the necessary freedom of movement,\u00a0<\/span><\/span>reduces tensile and compressive forces, and prevent<\/span>s<\/span>\u00a0<\/span><\/span>the\u00a0<\/span><\/span>shutdown of a\u00a0<\/span><\/span>robot<\/span><\/a>\u00a0<\/span>or\u00a0<\/span><\/span>machine due to a premature conductor breakage.\u00a0<\/span><\/span><\/p>\n

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Optimum protection for robot cables with the energy chain<\/span><\/p>\n

Using<\/span>\u00a0<\/span><\/span>expertise<\/span>\u00a0<\/span>gained over more than 50-years in this area, the jacket materials have been optimally matched to the plastic of the\u00a0<\/span><\/span>triflex<\/span>\u00a0<\/span>R robot energy chain<\/span><\/a>, reducing abrasion and wear to a minimum.\u00a0<\/span><\/span>For example<\/span>,<\/span>\u00a0<\/span><\/span>t<\/span>he\u00a0<\/span><\/span>triflex<\/span>\u00a0<\/span>R<\/span><\/a>\u00a0<\/span>TRCF is a closed energy tube based on the three-chamber principle: all three chambers of the TRCF can be opened and closed independently of each other. The supply hose is placed in one of the three chambers of the energy tube and is therefore protected against deformation<\/span>,<\/span>\u00a0<\/span>mak<\/span>ing<\/span>\u00a0<\/span>the energy supply process reliable whatever the axial position of the robot.<\/span><\/p>\n

The main feature that ensures reliable and operationally<\/span>–<\/span>safe guidance of robot\u00a0<\/span><\/span>cables<\/span><\/a>\u00a0<\/span>and hoses is compliance with the minimum bending radii.\u00a0<\/span><\/span>C<\/span>ost-intensive plant failures<\/span>\u00a0<\/span>can occur if these are not followed<\/span>. The technical design of the igus\u00a0<\/span><\/span>triflex<\/span>\u00a0<\/span>R<\/span><\/a>\u00a0<\/span>ensures that the prescribed minimum bending radius is adhered to whatever the working position of the\u00a0<\/span><\/span>robot<\/span><\/a>\u00a0<\/span><\/span>\u2013\u00a0<\/span><\/span>a circumferential outer stop prevents\u00a0<\/span><\/span>the\u00a0<\/span><\/span>cable<\/span><\/a>\u00a0<\/span><\/span>bending below the minimum bending radius.<\/span><\/p>\n

Moreover, the modular design of the\u00a0<\/span><\/span>igus\u00a0<\/span><\/span>triflex<\/span>\u00a0<\/span>R<\/span><\/a>\u00a0<\/span>ensures that a torsion angle of approx. +-10\u00b0 per chain link is not exceeded. This has the advantage that torsional stress on the cables is distributed along their whole length and not only at one end, which is the case with other systems. The defined minimum bending radius of the\u00a0<\/span><\/span>triflex<\/span>\u00a0<\/span>R robot<\/span><\/a>\u00a0<\/span>energy supply system guarantees process reliability<\/span>,<\/span>\u00a0<\/span>especially in\u00a0<\/span><\/span>robot<\/span><\/a>\u00a0<\/span>applications with supply hoses\u00a0<\/span><\/span>and in<\/span>\u00a0<\/span>flow punch bolting. This is because a kink in the supply hose interrupts the power supplied to the screws on the tool and the process is disrupted.<\/span><\/p>\n

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Multiple t<\/span>ests\u00a0<\/span><\/span>allow<\/span>\u00a0<\/span>plann<\/span>ed<\/span>\u00a0<\/span>reliability and reduce<\/span>d<\/span>\u00a0<\/span>costs<\/span><\/p>\n

igus<\/span><\/a>\u00a0<\/span>has repeatedly set new standards with its range of\u00a0<\/span><\/span>chainflex<\/span><\/a>\u00a0<\/span>moving\u00a0<\/span><\/span>cables<\/span><\/a>\u00a0<\/span><\/span>for<\/span>\u00a0<\/span><\/span>automation and robot technology<\/span>\u00a0<\/span><\/span>for more than 25 years<\/span>. It is regarded as a leading company for special cables, available from stock, for continuous motion in applications involving energy chains and torsional stress.\u00a0<\/span><\/span>igus<\/span><\/a>\u00a0<\/span><\/span>in Cologne\u00a0<\/span><\/span>has a 3,800 m2 test laboratory, the world’s largest lab for dynamic\u00a0<\/span><\/span>cables<\/span><\/a>. Here, igus twists the chainflex CFROBOT cables millions of times while continuously measuring core resistance in different test set-ups.<\/span><\/p>\n

The\u00a0<\/span><\/span>biggest<\/span>\u00a0<\/span>challenge in the tests is that it is difficult to reproduce every conceivable application that involves torsion over the service life of the product. Wh<\/span>ile\u00a0<\/span><\/span>service life limits can be dependably predicted in the case of linear travel in energy chains<\/span>,<\/span>\u00a0<\/span>due to fixed parameters and known ambient-influences, robot applications are usually much more complex. In particular, the sequence of movements\u00a0<\/span><\/span>the robot will follow\u00a0<\/span><\/span>is often not\u00a0<\/span><\/span>known<\/span>\u00a0<\/span>during the planning phase. For the\u00a0<\/span><\/span>cable<\/span><\/a>\u00a0<\/span>supplier, it is therefore\u00a0<\/span><\/span>very<\/span>\u00a0<\/span>importan<\/span>t<\/span>\u00a0<\/span>to test, test and test again.<\/span><\/p>\n

All the\u00a0<\/span><\/span>test\u00a0<\/span><\/span>results of are recorded in a database at igus.\u00a0<\/span><\/span>W<\/span>ith\u00a0<\/span><\/span>igus\u2019s<\/span><\/a>\u00a0<\/span>decades-long experience in plastics technology<\/span>,<\/span>ig<\/span>us<\/span><\/a>\u00a0<\/span><\/span>can offer<\/span>\u00a0<\/span>a 36-month guarantee on the mechanical specifications of the chainflex cables,\u00a0<\/span><\/span>allowing\u00a0<\/span><\/span>the mechanical engineering processes\u00a0<\/span><\/span>to\u00a0<\/span><\/span>be precisely planned. If a CFROBOT cable failed when used for the purpose described in the catalogue, igus w<\/span>ill<\/span>\u00a0<\/span>supply a new cable immediately and free of charge. Users can order cables of one metre and longer<\/span>, which\u00a0<\/span><\/span>will be delivered within 24 hours. The advantage of the CFROBOT series for\u00a0<\/span><\/span>robot<\/span><\/a>\u00a0<\/span>manufacturers and users is that they do not have to depend on expensive, special\u00a0<\/span><\/span>cables<\/span><\/a>\u00a0<\/span>with long delivery times but\u00a0<\/span><\/span>they\u00a0<\/span><\/span>can select from a standard range of products which has been specially developed for torsion applications and includes over 100 types of robot\u00a0<\/span><\/span>cables<\/span><\/a>,<\/span>\u00a0<\/span>all available from stock.\u00a0<\/span><\/span><\/p>\n

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Predictive Maintenance: Industry 4.0 gets trouble-free motion<\/span><\/p>\n

The “smart plastics”<\/span><\/a>\u00a0<\/span><\/span>products\u00a0<\/span><\/span>from\u00a0<\/span><\/span>igus<\/span><\/a>\u00a0<\/span>provide a glimpse into the future of robotic cables.<\/span><\/p>\n

Under the name\u00a0<\/span><\/span>\u201c<\/span>isense<\/span>\u201d<\/span>,\u00a0<\/span><\/span>igus<\/span><\/a>\u00a0<\/span><\/span>products\u00a0<\/span><\/span>carr<\/span>y<\/span>\u00a0<\/span><\/span>different\u00a0<\/span><\/span>sensors that detect the condition of igus components such as cables or energy chains. They measure<\/span>,<\/span>\u00a0<\/span>among other things<\/span>,\u00a0<\/span><\/span>wear during the operation and\u00a0<\/span><\/span>will\u00a0<\/span><\/span>alert the user\u00a0<\/span><\/span>with<\/span>enough\u00a0<\/span><\/span>notice\u00a0<\/span><\/span>to plan\u00a0<\/span><\/span>a\u00a0<\/span><\/span>repair or replacement.<\/span><\/p>\n

By networking with the icom communication module, data is transmitted to an intelligent system. The module can be connected to all igus specific sensors. Once the measured values from a sensor have been transferred to the icom module, they\u00a0<\/span><\/span>have to<\/span>\u00a0<\/span>be “interpreted”, i.e. understood in order to generate instructions from the\u00a0<\/span><\/span>module<\/span>. So far, this has been possible via connection to the igus cloud. Due to the increasing importance of IT security, however, many companies are increasingly relying on develop<\/span>ing<\/span>\u00a0<\/span>of their own SCADA systems, which is why\u00a0<\/span><\/span>igus<\/span><\/a>\u00a0<\/span>has now advanced its data concentrator\u00a0<\/span><\/span>module\u00a0<\/span><\/span>into\u00a0<\/span><\/span>icom.plus<\/span>. With the new module, the customer can integrate the data in the way\u00a0<\/span><\/span>that best suits their equipment. With the online connection of icom.plus,\u00a0<\/span><\/span>the\u00a0<\/span><\/span>service life statement\u00a0<\/span><\/span>of smart plastic products\u00a0<\/span><\/span>is\u00a0<\/span><\/span>continu<\/span>ally<\/span>\u00a0<\/span><\/span>connected<\/span>\u00a0<\/span><\/span>to<\/span>\u00a0<\/span>the\u00a0<\/span><\/span>igus<\/span><\/a>\u00a0<\/span>cloud to enable maximum system runtimes with minimal failure risk.\u00a0<\/span><\/span><\/p>\n

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The data in the cloud draws on the 10 billion test cycles of energy chains and cables performed in the company’s own 3,800<\/span>m<\/span>2<\/span>\u00a0<\/span><\/span>test laboratory, and thanks to machine learning and\u00a0<\/span><\/span>artificial intelligence<\/span>,\u00a0<\/span><\/span>igus<\/span><\/a>\u00a0<\/span>can provide precise information on the durability of the solutions used and inform the user about a necessary replacement before<\/span>\u00a0<\/span>it is needed<\/span>.<\/span><\/p>\n

https:\/\/www.igus.co.uk\/<\/a><\/p>\n

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 <\/p>\n<\/div>\n

\u00a0<\/span><\/p>\n","protected":false},"excerpt":{"rendered":"

Industrial robots\u00a0are pervasive in manufacturing and their applications\u00a0are increasing\u00a0all the time. But\u00a0with\u00a0constant\u00a0multi-axis\u00a0movements, the cables that supply robots\u00a0are subjected to extreme levels of stress,\u00a0posing a\u00a0challenge for manufacturers of cables and\u00a0other\u00a0connecting components. \u00a0 The International Federation of\u00a0Robotics\u00a0predicts that by 2020 more than… Continue Reading →<\/a><\/p>\n","protected":false},"author":1,"featured_media":25175,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[4],"tags":[],"class_list":["post-25174","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-news"],"_links":{"self":[{"href":"https:\/\/machinery.world\/index.php\/wp-json\/wp\/v2\/posts\/25174","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/machinery.world\/index.php\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/machinery.world\/index.php\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/machinery.world\/index.php\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/machinery.world\/index.php\/wp-json\/wp\/v2\/comments?post=25174"}],"version-history":[{"count":1,"href":"https:\/\/machinery.world\/index.php\/wp-json\/wp\/v2\/posts\/25174\/revisions"}],"predecessor-version":[{"id":25176,"href":"https:\/\/machinery.world\/index.php\/wp-json\/wp\/v2\/posts\/25174\/revisions\/25176"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/machinery.world\/index.php\/wp-json\/wp\/v2\/media\/25175"}],"wp:attachment":[{"href":"https:\/\/machinery.world\/index.php\/wp-json\/wp\/v2\/media?parent=25174"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/machinery.world\/index.php\/wp-json\/wp\/v2\/categories?post=25174"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/machinery.world\/index.php\/wp-json\/wp\/v2\/tags?post=25174"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}