New Rotary Module from Igus Maximum Freedom of Movement for Industrial Robots

The new twisterchain module from igus simplifies the energy supply on the first and last axis of an industrial robot—without any channel systems and with reduced installation effort. The new self-supporting twisterchain solves two problems: the energy supply on the first axis of compact articulated arm robots and on the fifth axis of palletizing robots.

Compact articulated arm robots for industry still pose challenges for designers when it comes to energy supply. This is because there are hardly any suitable solutions on the market for the fast rotational movements along the first axis and the limited space available. igus is now closing this gap with a new self-supporting energy chain from the twisterchain series. At the same time, it also solves a second problem: the energy supply along the fifth axis of palletizing robots. Here too, many designers have so far experimented with their own solutions.

Compact industrial robots such as the KR Agilus from Kuka or the Fanuc LR Mate can be found everywhere in industry. They screw, glue, assemble and perform pick-and-place tasks. But as established as the robots are, one problem has always existed. "There are no suitable rotary modules on the market for the cable routing at the foot of the small robots, which rotate 360 degrees and follow the movement," says Matthias Meyer, Head of the triflex e-chains and Robotics business unit at igus. The reason for this is often the connector plate for the power supply on the back of the robot, which is in the way of the rotary modules. "This is why many designers still resort to makeshift solutions, such as hanging hoses that drag across the floor and wear out quickly." To solve this problem, igus is now launching a self-supporting twisterchain cable carrier onto the market. The rotary module lies in an arc around the robot base—on the floor or on a raised base. The fixed point is attached to the base, the driver side slightly higher on the first axis. When the robot rotates, the energy chain gradually lifts upwards and moves to a new level. "This means we can rotate 360° around the base of the robot for the first time without colliding with the connector contour," says Matthias Meyer. Improvised solutions are no longer necessary, significantly increasing the reliability of compact industrial robots.

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Fifth Axis Safely Guided By Palletizing Robots

With the new self-supporting twisterchain, igus is also addressing a second problem: cable routing on the fifth axis of palletizing robots. In many cases, these robots guide the cables through the robot arm. But only up to the fourth axis. "Suitable solutions for the rotary movement on the fifth axis have also been lacking to date. Designers often make do with corrugated hoses, which move in an uncontrolled manner and can collide with the tool," says Matthias Meyer. The self-supporting twisterchain can also be used here for greater safety. The specially developed design makes it possible for the power and data cables on the fifth axis to follow the 360-degree rotations of the tool. The controlled and defined movement across two planes prevents the cables from colliding with the robot arm or tool. "The system therefore offers maximum freedom of movement for applications with extended rotation angles and ensures permanently reliable energy supply even with highly dynamic movement profiles," says Matthias Meyer.

Quick Installation And Easy Retrofitting

The new twisterchain variant can be installed quickly. "As the solution is self-supporting, we only need two connection points on the robot. Expensive guide troughs and complicated alignments are superfluous," emphasizes Matthias Meyer. The e-chains can also be adapted to different cable assignments thanks to a flexible internal layout with removable shelves. Another advantage: the energy chains can be opened on the inside radius so that users can insert the cables from the outside. Matthias Meyer: "This is a major advantage over hoses, where the cables have to be threaded through. Different connector sizes are always a limiting factor here." The system has an adjustable pre-tension for precise adaptation to every application. This can be precisely adjusted to the cable weight and required angle of rotation—a decisive advantage for the fine-tuning of robots and machines that require maximum repeat accuracy and stability.