Cable Protection for Palletizing Robots Increases Service Life

Packaging system robots rely on triflex® R cable routing with retraction system

Palletizing robots are subjected to continuous multidirectional movement, creating significant challenges for cable and hose routing. Power, data, and pneumatic lines must be reliably guided through complex motions and rotations without twisting, snagging, or experiencing premature wear

. Traditional solutions such as corrugated tubing may provide basic protection, but they often struggle to withstand constant rotary movement over the long term, increasing the risk of cable failures and costly unplanned downtime.

To ensure reliable media guidance throughout the robot's full range of motion, a German packaging manufacturer selected the igus® triflex R® energy supply system. The modular solution safely guides cables around every robot axis, delivering the durability and operational reliability required for fully automated palletizing applications.

Profile

What was needed: triflex® R dress pack with triflex® RS universal module, twisterchain®
Requirements: The energy supply system should permanently protect all cables under continuous operation of the palletizing robot and also be able to withstand torsional movements.
Industry: Packaging
Success for the customer: With the triflex® e-chain® including retraction module, safety and durability of the cables are guaranteed. Expensive plant downtimes are a thing of the past.

Learn more about triflex® R

packaging systems relies on triflex® R cable routing with retraction system

Problem

Transnova-RUF offers solutions for end-of-line packaging and palletizing tasks from planning and construction to commissioning. The range includes individual compact machines for top and side loading or picker systems for fast pick & place applications. In addition, robot systems for picking, palletizing and depalletizing tasks for packaging systems are being developed, where the specialist integrates more than 200 robots per year into machine environments.

When handling cartons, buckets, sacks, plastic cushions, and other packaging materials, everything must be highly flexible and reliable. This was also the case for a new project in which a packaging system with a length of approx. 60 m for the packaging of film rolls was equipped with nine robot systems for handling. Since each film roll is manufactured specifically to order and differs in length, thickness, weight and sometimes material, the robots must work particularly flexibly. The respective packaging weight of the containers is between 2 kg and 60 kg, the conveyor speed is approx. 40 m/min. 20 rolls per minute can be packed.

The high performance of the system as well as the continuous operation seven days a week led to considerations of the correct cable routing of the palletizing robot. This is because a corrugated hose cannot keep up with the strong rotational movements in axes 3 to 6.

The high risk of torsion entails risks such as the rupture of the hose and thus also line damage. As a result, the entire plant would come to a standstill and lead to high downtime costs.

Solution

The multi-axis triflex® R energy supply system (TRE 60.B) is now used on the palletizing robot in the film packaging system. The compact triflex® RS universal module, which is also installed, ensures that the dress pack is always guided close to the robot arm. It pulls the dress pack towards it when the robot arm retracts, preventing loops from forming.

Limit stops ensure defined freedom of movement creating additional protection. There are also integrated spring rods to guide the system safely. A twist of approx. +/- 10° per chain link in the longitudinal axis is possible. And a defined radius prevents the cable from kinking or being damaged.

Another benefit is that triflex R is designed for the quick insertion, replacement or removal of the various cables. An improved connection principle enables even greater stability and thus further increases machine and system availability.

In addition, the dress pack can be easily shortened or extended thanks to its modular design. The connection of the triflex R system works via the housing pad connection, similar to a trailer coupling. This increases the bending radius load capacity by a factor of four and compensates for even greater torsional forces.

On the first axis of this robot, a twisterchain® system is used to guide the cables with a rotary movement of 180°, although a rotation of up to 360° is possible with this e-chain®.,

The triflex® R dress pack is designed for fast insertion of the different cables.

Components for the multidimensionally movable energy supply system from the modular system.

On the first axis, a "twisterchain" guides the cables. Here it is used with a rotary movement of 180°.

The compact "triflex® RS" retraction system is used on axles 4 to 6. With this universal module, the dress pack is always guided parallel to the robot arm in a space-saving manner.