International automation expert for machine-integrated robots, Keba Industrial Automation, uses its latest demonstrator to highlight the opportunities of creating a digital twin of an industrial robot. To illustrate the corresponding applications, an industrial robot with a versatile tool simulator was set up. Just as in practical application, a multicore cable had to move along with this tool simulator, reliably and safely guided in the robot work envelope even at the highest travel speeds.

Kabelschlepp Metool provided support for planning and configuration of the ROBOTRAX cable carrier, which is flexible in three dimensions and was optimized specifically for use on industrial robots. Reliable cable guiding in different robot positions and at high speeds was achieved with the PBU pull back unit. The Austrian distributor for Kabelschlepp Metool provided support for the practical optimisation.

“The cable carrier system impressed us with its easy installation and versatile fastening options,” explains Michael Garstenauer, product manager for robotics at Keba Industrial Automation. “In combination with the pull back unit, reliable pretension is ensured along the complete demonstration paths.”

The dreaded knocking of the energy chain against the robot is prevented even at the highest speeds while retaining full freedom of movement. The result is a thoroughly reliable overall solution that is suitable for long-term use.

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The moving gantry units are controlled using feed drives, with one installed on each side of the gantry. Thanks to this modular overhead gantry concept, the robotics solutions can cover large working areas. The Cimcorp systems are used in production and distribution centres in over 40 countries on six continents.

To reduce the handling and picking times in intralogistics, the systems have to move reliably with high speeds and accelerations. This is where cable carriers from Kabelschlepp Metool come into play. They ensure reliable and safe movement of the cables and hoses while taking the complex parameters into account. The long travel lengths of the gantry units are equipped with a gliding hybrid MC0650 cable carrier: the combination of a plastic cable carrier and an RS aluminium profile offers maximum stability and reliability. In addition, Cimcorp use special OFFROAD glide shoes that reduce wear on the cable carrier.

The media required for controlling the 3D shuttle units, which act as grippers for goods and products, are reliably guided with cable carriers from the BASIC LINE series, depending on their size. In this case, Cimcorp uses the UNIFLEX Advanced 1455 and 1555 cable carriers.

“We are pleased to have Kabelschlepp Metool as a partner by our side,” says Mika Laine, product manager for gantry robots at Cimcorp. “In all these years, there were hardly any problems with the cable carriers. And when something did not go quite as planned, the service was fast and good.”

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With fast movement sequences and large work envelopes typical in robotics applications, the relatively long carriers can knock against the robot arm. The PBU prevents this by keeping the cable carrier tensioned. This means that there is no premature wear, the service life is extended and expensive downtimes are avoided. The compact design of the unit results in fewer protruding contours and a lower risk of collisions. The maximum flexibility for the guiding of the cable carrier is still ensured.

Kabelschlepp says the PBU has proven successful in a variety of different applications. It can be used on robots regardless of size, manufacturer and type and is also suitable for retrofitting and modernizing existing production cells. Standard fasteners for robots from Kuka, ABB and Fanuc are available. The pull back unit can be installed vertically, horizontally or overhead; the extension length is 350 mm. The PBU is available for the ROBOTRAX types R040, R056, R075, R085 and R100. The pull back unit requires no maintenance.

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Conventional cable carriers feature jointed links that form polygons in curved sections due to their pitch: during operation, this effect can cause vibration, wear, and – naturally – noise. QUANTUM’s design avoids this ‘polygon effect’ entirely: depending on the form factor, its pitch can be over 50 percent smaller than in comparable link chains. Curved sections are near-perfect curves that avoid vibrations that could cause wear in the upper run. This smooth-running operation is achieved by the one-part side band, whose reduced noise emissions of just 31 dB(A) also make QUANTUM one of the quietest cable carrier systems on the market.

The QUANTUM cable carrier system also features many other clever design details, such as separate stay systems that can be opened both inwards and outwards, with variable widths and a wide range of options for height separation, as well as strain reliefs, and length connectors are important elements of this intelligent and flexible cable routing. The driver connection can also be moved laterally and rotated by up to ±30°. The system also facilitates a degree of 3D motion, so there is no need for extra carriers to handle moderate multi-axis movement. A high load capacity as well as superior functional reliability and durability is also assured by quality materials such as aluminium and technical plastics for the stays, plus extruded steel cables in the profile support floor. The system is designed for acceleration of up to 300 m/s² and operating speeds of up to 40 m/s.

“From extensive testing and experience in the field, we know that our aluminium stays significantly reduce wear on cables while increasing their service life,” comments Thomas Ameis, senior technical expert at Kabelschlepp Metool. QUANTUM is not only UV-stable but also has excellent resistance to both coolants and lubricants. The system is ideally suited to applications in the clean room, microchip assembly, and semiconductor applications, but is also deployed together with handling/assembly systems, robots and instruments, and in pick-and-place, printing, and textile machinery. Users can choose from four form factors to match their specific application.

Quickfinder, the intuitive online tools facilitate orientation in the extensive product portfolio.

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The ‘free-standing’ flat cable system is based on Kabelschlepp’s progressive cable carrier technology. It is a flat cable system in accordance with ISO cleanroom class 2 which, for example, can be used in the manufacturing of infusion bags or in laboratory sorting systems. The wide temperature range from -10°C to +80°C additionally expands the area of application. The internal support elements allow travel lengths of up to 3m and speeds of up to 2m per second. The support elements act as reliable guides which can be moved in one direction along the intended bending radius, ensuring reliable guiding of cables and hoses.

For smooth running, the system moves along the minimum bending radius of the cables, while a small pitch reduces noise and vibrations during operation. This results in a noise level below 38 dB(A). The independent structure prevents the breaking of cables and hoses. The design is particularly space saving and lightweight; the system can easily be integrated into systems. Overall, this solution allows for reduced dust and noise generation in cleanrooms, contributing to lowering total costs.

Flat cable systems are often used in cleanrooms because they cause almost no unwanted contaminates and dust. These solutions, however, cause problems such as sagging or unwanted movements, in particular for travel lengths over 500mm. Not so with the Flatveyor: the high-performance cable system is based on innovative cable carrier technology and experience and can therefore master the challenges in cleanrooms.

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The model of the UNIFLEX Advanced cable carriers features an inner height of 56 mm and inner widths of 100 to 250 mm – enough space for applications with numerous cables and hoses. The four-part chain links are designed so that the separate parts require only a minimum of storage volume, which simplifies logistics and saves resources. The new cable carrier type with bending radii from 90 to 340 mm runs very smoothly thanks to the short pitch of 77.5 mm. The low-torsion design ensures a sturdy cable carrier body with low wear and a long service life. To protect the environment, Kabelschlepp Metool manufactures this cable carrier with up to 35 % recycled regranulate.

The cable routing can be used with or without pretension as well as unsupported and gliding on extended travel lengths. High speeds and acceleration are also possible.

As for all items from the UNIFLEX Advanced series, this size also allows for fast, simple and easy installation of cables and hoses: The crossbars can be opened and closed quickly – with just two steps in each case. A simple screwdriver is the only tool required. Particularly convenient: the crossbar remains attached to the chain link even when open. If necessary, the crossbar can be released from the chain link with a simple twist.

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German integrator KUK-Automation has been providing robot integration services to customers for many years. “KUK supports users across all industries with the commissioning and setup of robot systems,” André Röttger, managing director of KUK-Automation. The company offers the entire range of services from one single source to provide best possible customised automation technology – from planning and implementation to customer service.

In the field of robotics, KUK takes on the planning, design and manufacturing of robot cells for handling, separation and assembly tasks. Robots from ABB, Kuka, Mitsubishi and Fanuc are used. Services include project engineering, switchgear manufacturing, system installation and software creation. “We design manual workstations or robot gripper systems, for example,” explains Röttger. “Whether small or large robots, they are always integrated perfectly into the existing production plants.” This is ensured by virtual real time simulations and by test installations at the KUK workshops. The KUK engineers also optimise the setup and the motion programs of the robots and configure the control systems.

To minimise downtime, KUK uses ROBOTRAX cable carriers from Tsubaki Kabelschlepp, which are designed to ensure maximum freedom of movement for the robots. “Undamaged cables are a prerequisite for uninterrupted operation of the robots,” says Röttger. “This area of application also entails special requirements which ROBOTRAX can fully meet.”

Werner Eul, product manager for cable carrier systems at Tsubaki Kabelschlepp, explains: “The ROBOTRAX system consists of the cable carrier and special accessories. This allows us to really meet all the challenges which arise in this special area of application with 3D movements.”

The ROBOTRAX cable carrier itself is designed especially for use in industrial robots. It consists of individual plastic links with spherical clip connections on both sides which support the three-dimensional swivel and circular movements of the machines. The forces are not only transmitted through the ball joints, but also through a steel cable at the centre of the cable carrier, making it suitable for extremely high towing forces and accelerations.

Röttger explains the benefits: “The steel cable design creates very high strength in the cable carrier. Additionally, the manoeuvrability of the ROBOTRAX can be adjusted individually. The robust cable carrier supports the robot movements in the best possible way and features a very long service life in continuous operation.”

The cable carrier is easily fixed to the robot with quick release brackets. They can be attached to any chain link and can be individually adapted to the movement of the machine. KUK also uses the ‘Pull-Back Unit’. This is an active pull-back mechanism which additionally extends service life and decreases downtime. The device keeps the cable carrier under tension, preventing unwanted contact between the cable carrier and the robot to protect the cables inside. “In measuring robotics in particular, it is very important that the cable carrier is not in the way and is always kept taut,” Röttger explains. “This also protects the very expensive 3D sensor in the long term.”

Another component of the ROBOTRAX system is the Protector stroke system which is available for all sizes. During fast movements and in large work envelopes it protects against hard impact, excessive abrasion and premature wear. It also limits the smallest bending radius. Downtime is minimised as only the Protector rather than the entire cable carrier has to be replaced in case of damage.

The collaboration between KUK-Automation and Tsubaki Kabelschlepp has now developed further, with KUK providing detailed feedback and making suggestions for improvement which are then used in the further development of the cable carriers.

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