Flexible cable guidance for assembly robots in the automotive industry

Profile

• What was needed: triflex energy supply systems
• Requirements: reliable energy supply system that also flexibly follows complex movements in all axes; movements mean strong twisting, yet the energy supply system must not tear or buckle; in addition, simple assembly and the price-performance ratio were important to the customer.
• Industry: automotive industry
• Success for the customer: for all eleven robots, the triflex R offers high flexibility and cable protection for complex movements, this also increases the service life; it is also impact-resistant, dirt-repellent, tough, abrasion-resistant and swarf-resistant; the modular design enables cost-saving assembly and disassembly

Different movement sequences of the robots. They are used for handling heavy parts or for screwing processes.

Problem

LSW Maschinenfabrik GmbH supplies turnkey assembly systems for the automotive industry and its suppliers worldwide. The company develops, plans, designs and manufactures computer-controlled automation equipment and transfer lines for the rational assembly of power train components such as engines, cylinder heads, gearboxes, axes and steering systems. In doing so, the company supports all project phases - from the idea of a new unit over the entire service life of the production plant. The all-round support includes on-site staff training as well as preventive maintenance and servicing or the possibility of remote diagnosis. This service package is intended to be the guarantee that LSW's customers benefit from its knowledge over the entire service life of the assembly lines.
For a customer from the automotive supply industry, LSW designed and built two assembly lines for a front-axis and a rear-axis gearbox, including an assembly robot.
The requirements that a robot places on an energy supply system are obvious. It must reliably follow every movement. In this particular application, for example, there are complicated movements that go in all axes. The energy supply system is strongly twisted by the various axis movements. Therefore, it must be ensured that it does not tear or buckle even at extreme points. But the ease of assembly and the price-performance ratio also played an important role for LSW Maschinenfabrik GmbH.

Solution

After the product presentation and a test setup, LSW decided to replace the usual system with the triflex R energy supply systems. They are currently proving their worth with all eleven robots.
There are a number of technical reasons in favour of the multi-dimensionally moving energy supply system specifically for robotic applications. It offers high flexibility and cable protection for complex movements even in the 6th axis. A twist of up to approx. +/- 380° per metre in the longitudinal axis is possible and limited by a clear stop-dog. This supports guidance of the cables around difficult geometries and extends the service life through defined minimum bend radii. The trailer principle ("ball and socket" connection, similar to the trailer coupling on a car) enables high tensile force absorption, which means smooth movements in all axes with a tested tensile force of up to 2 340 N.
The energy supply system is impact-resistant, dirt-repellent, robust, abrasion-resistant and swarf-resistant. Small bend radii and the small pitch ensure space-saving installation. Assembly and disassembly are simple. Thanks to its modular design, the triflex can be easily shortened or extended. External stop-dogs ensure high strength. 
A universal assembly kit allows the energy supply system to be individually adapted to any movement sequence. When ordering, you don't need to know much about the movement sequence; the actual adjustment takes place during installation.

Different movement sequences of the robots. They are used for handling heavy parts or for screw fastening processes.

High flexibility in complicated movement sequences.