New, trending markets where robots are making inroads include the production of fuel cells for hydrogen-powered cars, batteries for the transportation sector, and solar cells for the energy sector. Robots working in these fields can withstand extremely harsh conditions, such as moving under high accelerations in continuous 24/7 operation and performing acrobatic movements with their six axes. Torsion and limited installation space can pose a challenge for cable protection systems. This is because they must function reliably even under high dynamic forces while remaining lightweight and compact. These requirements also affect the cables that supply data, fluids, and power to the robot and its tools. Therefore, cables and their protection systems need to be durable, maintenance-free, safe, and securely routed. Furthermore, these cable protection systems should only represent a small additional load for the robot, they must be quick to install and easy to maintain in the worst case scenario.

Corrugated tubes made of optimized polymers are used in most six-axis robot applications to guide and protect cables. These tubes are lightweight, cost-effective, and offer good mechanical protection for the cables, even against dust. However, they also have drawbacks: if a single cable fails, the entire system must be replaced. Quick replacement of individual cables is not possible because the connectors can only be used after the cable has already been routed through the protective tube. Maintenance costs are high due to system failures. Another disadvantage is that protective cables do not guarantee a defined minimum bend radius. Therefore, the minimum bend radius of the cables may fall short at any point during operation, potentially leading to cable damage and failure. On the other hand, robotic cables are designed to withstand torsional loads: typically, the standard is ±180 degrees over a length of one meter. However, the protective tubes are designed to prevent twisting. The resulting torsional load is absorbed solely by a swivel joint on the robot's sixth axis, which is only a few centimeters long. This leads to cable overload, eventually causing them to break and the system to stop.

Three-dimensional cable carriers are an alternative to corrugated tubing. Although a cable carrier is more expensive than corrugated tubing, it offers several advantages. Its minimal bending radius prevents damage to cables and tubing from excessive bending. Since the robot head, in particular, is subjected to strong twisting and turning movements, the defined twist limit is of paramount importance. Each link in the chain has a twist stop of approximately 10 degrees, allowing cables to be safely bent over a greater distance. The cable carrier also offers users greater adjustability compared to corrugated tubing, as its modular design allows it to be lengthened or shortened to suit the application. This means that cable carrier systems can be quickly adapted when new robots are acquired.

To guide cables and tubes with the correct bend radii within the robot, users rely on retraction systems, which ensure the cable carrier system remains as close as possible to the robotic arm. Retraction systems prevent the power supply from interfering with or blocking the robot's movements, even highly dynamic ones. In the worst-case scenario, loops could damage the cable carrier, the cables, and the tubes inside, leading to machine failure. Retraction systems require space, but current robots can no longer accommodate this.

For the long-lasting and safe operation of robots, cable carriers as a cable guidance system, in combination with a retraction system, are a good solution, despite the higher initial costs. The cables can be replaced quickly during maintenance, which ultimately has a positive economic impact on the long-term energy supply concept. Cable carrier systems offer the user the added advantage of simply connecting the cable system to their robot. Ideally, the solutions should come from the same supplier.