ROBOTRAX® System
Cable carrier for 3D movements
- Steel cable for transferring extremely high tensile forces
- Tension piece for locking the chain links
- Type with toolless opening swivel crossbars and divider module available
- Open design
– Fast cable laying as the cables are simply pressed in
– Easy checking of all cables - Special plastic for long service life
- Protective covers or heat shields made from different materials are available for different environmental conditions
- Quick-release bracket for fixing and continuation
- Strain relief with LineFix clamps
- Protection against hard impacts, excessive abrasion and premature wear as well as limitation of the bending radius through protector
Features
- Suitable for three-dimensional swivel and rotation movements
- Ideal for a long service life of the cables:
– The bending radius does not fall below the minimum when using protectors
– The cables can be separated in three chambers - Also ideal for turntables
Swiveling crossbars and divider module (R140X)
Active return mechanism with the PBU pull back unit (R040 – R100)
Fast cable laying by simply pressing in the cables (R040 – R100)
Strain relief for secure fixing of the cables
R040
- Inner height [hi]: 10 mm
- Inner widths [Bi]: 27 mm
- Pitch [t]: 21.5 mm
- Bending [KR]: 70 [75] mm
R056
- Inner height [hi]: 14 mm
- Inner widths [Bi]: 39 mm
- Pitch [t]: 32 mm
- Bending [KR]: 90 [105] mm
R075
- Inner height [hi]: 22 mm
- Inner widths [Bi]: 52 mm
- Pitch [t]: 40 mm
- Bending [KR]: 125 [140] mm
R085
- Inner height [hi]: 24 mm
- Inner widths [Bi]: 54 mm
- Pitch [t]: 40 mm
- Bending [KR]: 130 [170] mm
R100
- Inner height [hi]: 31 mm
- Inner widths [Bi]: 64 mm
- Pitch [t]: 40 mm
- Bending [KR]: 130 [175] mm
R140x
- Inner height [hi]: 48 mm
- Inner widths [Bi]: 74 mm
- Pitch [t]: 50 mm
- Bending [KR]: 125 [225] mm
| Type | hi [mm] | Bi [mm] | t [mm] | KR [mm] |
|---|---|---|---|---|
| R040 | 10 | 27 | 21.5 | 70 [75] |
| R056 | 14 | 39 | 32 | 90 [105] |
| R075 | 22 | 52 | 40 | 125 [140] |
| R085 | 24 | 54 | 40 | 130 [170] |
| R100 | 31 | 64 | 40 | 130 [175] |
| R140x | 48 | 74 | 50 | 125 [225] |
Design principle
Pitch
21.5 – 40 mm
Inner heights
10 – 31 mm
Inner widths
27 – 64 mm
Bending radii
70 – 130 mm
Chain links single part
The basic structure of ROBOTRAX® consists of plastic links. These have spherical snap-on connections on both sides. This allows the individual links to be snapped together to form a cable carrier.
Protectors ensure that the bending radius does not fall below the minimum in any direction. The links can be rotated in the radial direction (see table values). The cables can be separated in three chambers.
Dimensions
| Type | t [mm] | KR [mm] | Radial rotation possible on 1 m length [°] | d* [mm] | Number of links per m | Additional load ≤ [kg/m] |
|---|---|---|---|---|---|---|
| R040 | 21.5 | 70 [75] | ± 450 | 2 – 8.5 | 47 | 0.7 |
| R056 | 32 | 90 [105] | ± 300 | 2 – 11 | 31 | 1.1 |
| R075 | 40 | 125 [140] | ± 215 | 3 – 18 | 25 | 4 |
| R085 | 40 | 130 [170] | ± 215 | 3 – 20 | 25 | 5 |
| R100 | 40 | 130 [175] | ± 215 | 3 – 27 | 25 | 6 |
Values in [ ] apply when using protectors
*We recommend a maximum cable diameter of 70 % of the highest specified value
CALCULATING THE CABLE CARRIER LENGTH
Cable carrier length LK: LK ≈ n x t
Order example
* Type 010: cables are simply pressed in
Pitch
50 mm
Inner height
48 mm
Inner width
74 mm
Bending radius
125 mm
Chain links with crossbars
The basic construction is similar to the ROBOTRAX® types with single part design. Swiveling crossbars with snap locks make it easy to open and safely close the cable carrier. In addition, the three chambers can be divided horizontally and vertically by a divider module for precisely separating cables and hoses.
Dimensions and order
| Type | t [mm] | KR [mm] | Radial rotation possible on 1 m length [°] | d1 [mm] | d2 [mm] | d3 [mm] | Number of links per m | Additional load ≤ [kg/m] |
|---|---|---|---|---|---|---|---|---|
| R140X | 50 | 125 [225] | ± 200 | 42 | 18 | 15 | 20 | 10 |
Values in [ ] apply when using protectors
CALCULATING THE CABLE CARRIER LENGTH
Cable carrier length LK: LK ≈ n x t
Order example
* Type 030: Outside opening crossbars
Mounting kit
Fast movements of the robot arms generate high accelerations and therefore high tensile forces on the cable carrier. To transfer these tensile forces, ROBOTRAX® has a hole at the center of each chain link through which the steel cable is pulled. This steel cable takes on the function of force transmission.
The steel cable is fixed with a clamping piece on one side. ROBOTRAX® permits accelerations up to 10 g. The clamping piece can be used to easily set the chain links to the desired tension and adjust them at any time.
Long service life of the cables and hoses:
The forces are primarily transmitted by the cable carrier and not by cables and hoses.
The mounting set consists of steel cable, clamping and tension piece for up to 5 m cable carrier length.
Quick-release brackets
The ROBOTRAX® is fixed and continued with quickrelease brackets which are attached with screws. The quick-release brackets fit on any chain link of the respective size. This means the fixing points can be individually adjusted to the motion sequence.
Locking bolt:
100% recyclable, cost-effective locking bolt, optimized for installation space and environment. The bolt can be assembled and disassembled without tools. (Also available as a screwed version)
Dimensions
| R040 | R056 | R075 | R085 | R100 | R140X | |
|---|---|---|---|---|---|---|
| h1 [mm] | 54 | 70 | 86 | 105 | 120 | 164 |
| l1 [mm] | 15 | 22 | 28 | 30 | 32 | 50 |
| l2 [mm] | – | – | – | – | – | 20 |
| b1 [mm] | 82 | 86 | 110 | 133 | 150 | 197.4 |
| b2 [mm] | 50 | 63 | 82 | 96 | 112 | 158 |
| b3 [mm] | 36 | 48 | 64 | 72 | 70 | 70 |
| b4 [mm] | 18 | 24 | 32 | 36 | 35 | 35 |
| b5 [mm] | – | – | – | – | – | 32 |
| Screws | 2xM4 | 2xM4 | 2xM6 | 2xM8 | 2xM8 | 4xM8 |
System components
Heat shield/protective cover
Heat shield: The heat shield made from aluminumcoated textile fibers protects the ROBOTRAX® system and inserted cables against flying sparks, weld spatter and radiated heat.
Protective cover: The protective cover made from coated polyester protects against aggressive cutting fluids, hydraulic oils, fine dust and paint spatter.
Strain relief for cable ties
(available for all types)
For secure fixing of the cables.
The strain relief can be used on either end.
Strain relief LFR
(for types R075, R085, R100 and R140X)
Secure cable fixing, gentle on the cables.
Multi-layer cable fixing is also possible with double and triple LineFix® clamps. Several systems can be installed in sequence.
LineFix® strain reliefs – see here.
PBU pull back unit
(for types R040, R056, R075, R085 and R100)
PBU: With fast movement sequences and large work envelopes, the relatively long carriers knock against the robot arm. The repeated impact significantly reduces the service
life of the cable carrier and the cables within, and the entire system can fail. Downtimes cause high costs and problems in the manufacturing process – so they have to be avoided.
- Compact design: fewer interfering contours and lower risk of collision
- Maximum flexibility for cable carrier routing
- No maintenance on the retraction element required
- Standard mounting for KUKA, ABB and FANUC
PBU is available for new robots, regardless of size, manufacturer, type or application, as well as retrofits and upgrades for existing workcells. It can be mounted vertically, horizontally or upside down. The extension length of the LSH 3 is 350 mm.
| R040 | R056 | R075 | R085 | R100 | |
|---|---|---|---|---|---|
| HZ [mm] | 187 | 187 | 221 | 221 | 268 |
| Typ | Tensile forces [N] |
|---|---|
| PBU Light | 40 |
| PBU Standard | 80 |
| PBU Heavy | 110 |
Protector
The service life of the cable carriers and cables is significantly reduced by impact during fast movement sequences and in large work envelopes. The Protector protects the cable carrier against hard impacts, excessive abrasion and premature wear, while also acting as a limitation for the smallest bending radius. Downtimes are minimized. Not the entire cable carrier has to be replaced, but only the Protector in some cases.
Turntable for quick-release bracket
One additional degree of freedom on the attachments points. When mounted on a turntable, the quick-release bracket can rotate as well, to offer increased flexibility during complex robot movements.
Dimensions
| R040 | R056 | R075 | R085 | R100 | R140X | |
|---|---|---|---|---|---|---|
| A [mm] | 57 | 65 | 82 | 96 | 112 | 96 |
| B [mm] | 57 | 57 | 57 | 70 | 70 | 70 |
| C [mm] | 43 | 43 | 43 | 75 | 75 | 70 |
| D [mm] | 43 | 43 | 43 | 45 | 45 | 20 |
| E [mm] | 36 | 48 | 64 | 72 | 70 | – |
| F [mm] | – | – | – | – | – | 8 |
| H [mm] | 25 | 25 | 25 | 34 | 34 | 43 |
| d1 [mm] | M6 | M6 | M6 | M6 | M6 | M8 |
| d2 [mm] | M4 | M4 | M6 | M8 | M8 | – |
| d3 [mm] | – | – | – | – | – | 14 |
| d4 [mm] | – | – | – | – | – | 20 |
Set consists of
Coil spring for quick-release bracket
If the quick-release bracket is mounted on a coil spring, it can move elastically in all directions, deflect in 3 dimensions and spring back.
Dimensions
| R040 | R056 | R075 | R085 | R100 | |
|---|---|---|---|---|---|
| A [mm] | 52 | 64 | 82 | 96 | 112 |
| B [mm] | 36 | 48 | 64 | 72 | 70 |
| C [mm] | 5 | 5 | 6.5 | 8.5 | 8.5 |
| D [mm] | 26 | 30 | 34 | 34 | 34 |
| L [mm] | 110 150 – – – – – | 110 150 – 190 – – – | – – 165 – 230 315 465 | – – 165 – 230 315 465 | – – 165 – 230 315 465 |
Cobot holder
(for types R040 and R056)
The ROBOTRAX® cobot holder was specially developed for sizes R040 and R056 as well as for corrugated tubes from the FIPLOCK® series (23-48). As a high-quality solution for industrial use, the sturdy steel straps offer non-slip support up to 100 N centrifugal force and thus ensure the trouble-free function of the cobot and the attached cables and hoses in continuous operation. It can be mounted on various surfaces and on diameters between 50-130 mm. The anti-twist design, an easily accessible lock and a protective rubber profile provide additional safety and support.
The cobot holder is versatile - from handling and quality assurance, assembly and laboratory automation to logistics, medical technology and service robotics - and ensures precision, safety and efficiency.
| R040 Order no. Set | R040 Order no. Set | |
|---|---|---|
| Set for Ø 50-70 mm | 60552 | 60556 |
| Set for Ø 70-90 mm | 60553 | 60557 |
| Set for Ø 90-110 mm | 60554 | 60558 |
| Set for Ø 110-130 mm | 60555 | 60559 |
Set consists of
