Hybrid cable solutions to define Automation

Cables are the backbone of Industrial automation sector. The last two decades have witnessed developments in automation technology that is changing the nature of manufacturing industry today. The increased penetration of technology among Cable manufacturers in India has gained a competitive advantage for players in the manufacturing world. This evolution has generated a demand for hybrid and single-cable solutions that are compact and light and use minimal space and promise high speed.

Characteristics of cables for robotics and handling in automation:

Robots today are seen working alongside people across sectors be it lifting heavy loads or accurately apply paint over and over with exact precision. Their movement sequences look like highly choreographed routines featuring extreme bending and rotary motions, demanding the highest levels of flexibility, stability, and durability from all the components, integrated cables, and cable systems used. The failure of just one component brings the entire production line to a standstill, causing losses running into millions.

Key Applications:

●     3D-Applications of all kinds

●     Industrial and Lightweight Robots

●     Industrial Communication

●     Factory Automation

●     Sensor Technology

●     Identification Systems

●     Palettisers

●     Mechatronic Systems

●     Intelligent Imaging Technologies

●     Handling Systems

Cables:

Power control and data network (copper + Fiber cables) are special cables for corresponding assemblies. Most of the requests for the type of cable emanates from customer groups like, system integrators, machine maintenance firms, and robot manufacturers that have different product requirements. System integrators specialize in setting up production lines on behalf of production companies. These companies usually request unique assemblies such as a customized configuration of standard parts. Additionally, machine maintenance firms are responsible for the maintenance and servicing of machines. Their main role is to be able to source important replacement parts from an extensive product portfolio as fast as possible, as any delay can lead to downtimes causing financial losses.

Challenges:

As robots are in constant motion there is a need for them to have stringent uptime requirements. Cables and connectors should keep pace and evolve to work with precision in the automation industry and must meticulously deploy cables to ensure no high-cost production failures.

The challenge faced by robot manufacturers with exceptionally challenging applications is industry always prefers for “off-the-shelf’ products which may not deliver the solution required. Each robot type carries out different movement sequences and is constructed in a different way.

• Lack of tailored solutions

There’s a strong pressure on robot component suppliers to supply high-quality customized products as standard cables if used in complex areas might result in problems in existing robot and production systems.

• Lack of flexibility and stability

There’s a requirement for cables to be highly flexible and have a small bending radius. Cables should be able to withstand high torsional loads especially, in stud welding machines in the automotive manufacturing industry. The stud welding machine is automatically positioned by the robot and sets the studs for wiring harness assembly in the body shells. This requires the highest levels of flexibility and stability in cables used for greater efficiency and precision for better execution of movements and system productivity.

• Space limitation

To avoid restrictions on the robot's movements, various cables are required to be laid over the robot axes in the smallest of spaces to assemble all necessary components, i.e. the welding cable, the data network and signal cable, air and protective gas conduits, in an outer sheath. This has led to a demand for cables with smaller customized cross-section cables for easy adaptation and use.

• Creation of Electro Magnetic Compatibility (EMC)

There is a challenge for the creation of EMC for robotic cables, as copper braiding reduces the flexibility of the cable and impacts the life of the product. It is particularly tricky to achieve the high bending radius and torsional strength requirements to combine all components in a complex hybrid cable system for the robot.

• Lack of complete connectivity solutions

Of course, no system is complete without connecting all the individual components, and for this, the industry requires a reliable partner who lives up to customer requirements. Plug and play solutions like LAPP’s ÖLFLEX® CONNECT is a one-stop solution that saves manufacturers the time and effort in sourcing individual components and then integrating separately. 

Future of Automation:

Robotics in automation is used across segments like machine tools, textile, oil & gas to scale up production and define efficiencies. They are used not only by the big leading players but also by small and medium-sized enterprises in the sector.

As systems are becoming mobile, affordable and flexible to help fast and easier reprogramming, making an interesting prospect for small and medium-sized to stir up high production volumes. Megamarket players like Google, acquiring nine robotics companies last year promises cutting-edge innovative solutions in the segment.

Against this backdrop, market experts are predicting technological developments to fuel the growth of new commercial market potential for robotics.

These futuristic factories represent the absolute pinnacle of technological expansion and manufacturing development, which is here to stay and grow. Greater intelligence will be required to manufacture cables for automated machines in near future.

Therefore, Cable manufacturers in India have to be more focused on the quality and service life of the cables, while making cabling decisions for automation. Thus, it is important to select appropriate power and control cable for smooth and reliable operations.