Flexible cable guidance for assembly robots in the automotive industry

triflex® R multidimensional cable carriers allow complex movements of the assembly robots

Robots form the backbone of modern turnkey assembly lines, especially in the automotive industry. These robots operate under demanding conditions and often perform the most physically intensive tasks on the line. To keep pace with these requirements, the machines depend on energy‑supply systems, also known as robot dresspacks, that can move freely in multiple dimensions. These systems must deliver maximum flexibility, withstand continuous dynamic loads, and support long service life across every axis of motion. At the same time, they need to be fast to install, easy to service, and engineered to handle the constant motion profiles that automated manufacturing demands.

Profile

What was needed: triflex® R robot dresspacks

Requirements: The application demanded an energy‑supply system that could reliably track complex, multi‑axis motion without sacrificing durability. The movements involved significant torsion, yet the system needed to resist tearing and buckling from continuous mechanical stress. At the same time, the customer placed high value on fast, simple assembly and a competitive price‑performance balance.

Industry: automotive production

Success for the customer: for all eleven robots, triflex® R provided high flexibility and cable protection during complex movements. This cable management system also increases the service life as it is also impact-resistant, dirt-repellent, tough, abrasion-resistant and chip-resistant. The modular design enabled cost-saving assembly and disassembly as individual pieces can be replaced and cables can be installed from the sides.

Learn more about triflex® R

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. This includes engines, cylinder heads, gearboxes, axes and steering systems. In doing so, the company supports all project phases starting from the concept of a new unit throughout 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 ensures that LSW’s customers can rely on the company’s expertise throughout the entire lifespan of their assembly lines. It’s designed not just as support, but as a long‑term partnership that keeps the equipment performing at its best from day one to end of life.

LSW designed and built two assembly lines for a customer in the automotive supply industry for a front‑axis gearbox and a rear‑axis gearbox, each equipped with an assembly robot.

Robots place demanding requirements on an energy‑supply system. This system must follow every motion reliably, even when the robot executes complex, multi‑axis movements. These movements introduce significant torsion, so the energy‑supply system must resist tearing and buckling even at extreme positions. LSW Maschinenfabrik GmbH also prioritized fast, straightforward installation and a strong price‑performance ratio when selecting the components.

Solution

After a product presentation and a test setup, LSW decided to replace the previous cable management system with triflex® R dresspacks, which are currently proving their value for all eleven robots.

There are several technical advantages that make triflex® R the ideal multidimensional energy‑supply system for robotic applications. The design provides high flexibility and reliable cable protection, even during complex movements on the sixth axis. It can handle twists of approximately ±380° per meter along the longitudinal axis, that are controlled by an integrated stop‑dog. This allows the cables to move cleanly around tight or irregular geometries while maintaining defined minimum bend radii, thus preventing costly damage that would otherwise reduce the service life, and provides additional strength.

The system uses a “ball‑and‑socket” connection, similar to a vehicle trailer hitch. This design absorbs high tensile forces and enables smooth, unrestricted movement across all axes (including the sixth). The system has been tested to handle tensile forces up to 2,340 N.

The dresspack is impact‑resistant, dirt‑repellent, robust, abrasion‑resistant, and chip‑resistant. Small bend radii and a compact pitch support space‑saving installation. Assembly and disassembly are straightforward. Thanks to its modular construction, the triflex® R system can be shortened or extended with ease and individual segments can be changed instead of needing to replace the entire system.

A universal mounting kit makes it possible to adapt the energy‑supply system to virtually any movement profile. The customer doesn’t need detailed knowledge of the robot’s motion sequence when ordering since fine‑tuning happens during installation.

After a product presentation at our company, a complex movement was simulated in a test setup in the igus test laboratory. Their flexibility appealed to us so much that we replaced our earlier system with them. Now, all eleven robots are equipped with the triflex® R energy supply systems. And they prove themselves in everyday life. All the tests and experiments conducted so far satisfy us.