Six-axis industrial robots routinely rotate, extend, and change direction at high speeds, putting substantial mechanical stress on the cables, fiber-optic lines, and pneumatic hoses that supply them. Repeated twisting, acceleration, and contact with machinery can cause conductor fatigue, insulation damage, and unexpected production downtime, tells IEEE Spectrum.
Tsubaki KabelSchlepp’s Robotrax system addresses these problems with a three-dimensional cable carrier designed specifically for complex robotic movement. At its core is a steel cable running through each chain link. Rather than allowing tensile loads to reach electrical cables and hoses, the steel element absorbs pulling forces during rapid movements and accelerations of up to 10 g. An integrated clamping component allows technicians to adjust system tension.
Robotrax uses single-piece plastic links connected through spherical snap-on joints. This geometry allows movement across three axes and radial rotation of up to plus or minus 450 degrees per meter, depending on carrier size. Internal chambers separate power cables, data lines, and fluid hoses, reducing abrasion and signal interference. Several models also allow cables to be installed without tools.
Another key component is the Pull Back Unit, an active retraction mechanism that maintains cable-carrier tension throughout the robot’s motion cycle. It reduces loose loops that could swing into the robot and cause damaging collisions.
Modular external protectors provide additional resistance to impact and abrasion while limiting the carrier’s minimum bending radius. Damaged protectors can be replaced individually instead of replacing the entire carrier.
The system can also incorporate heat shields, protective sleeves, and strain-relief clamps for environments involving welding spatter, sparks, cutting fluids, oils, paint, or abrasive dust.
By combining tensile-load management, flexible geometry, controlled retraction, and replaceable protection, the design aims to extend cable life, simplify maintenance, and reduce unplanned robot downtime.
