Product Catalogue Robot Technology. A company of the Group.

Transcription

1 Product Catalogue Robot Technology A company of the Group

2 Contents Robotec Systems GmbH Solutions for all robot applications 4 Solution 1: Energy conduit system with R-TecBox 5 Module overview Mini-clip series NW 36 8 Mini-clip series NW System holder NW 70 (hose fastening) 12 System holder NW 70 (train relief) 14 R-TecBox 70/56 and 48/36 16 Spring pack 18 Pipe clamp 20 Fastening elements and accessories System holder 24 Half shell / central jaw 25 Articulated piece 26 Ball joint 27 Strain relief 28 Swivel bearing 30 Clamping clips Clamping clip / spring pack (axis 4) 32 Clamping clip with tube (axis 6) 33 Adapter plate 34 Pipe clamp 34 Protector / impact protection 36 Flared section and accessories Flared section 40 Spring guide 41 Precision tubes 44 Plug-in hoses and accessories Plug-in hose 46 Hose nozzle / bulkhead fitting 47 Cable sheath Cable sheath type EW-HY/EWX-HY 52 Solution 2: Energy conduit system with spring guide 51 Add-on parts System holder / clamping clip 54 Middle jaw / combi jaw 55 Articulated piece 56 Ball joint 57 Strain relief 58 Swivel bearing 59 Clamping clip / pipe clamping piece / adapter plate 60 Protector 61 Hose and spring guide 62 Compression spring 63 Cable sheath 65 Cables for robot applications 67 Primary cables 68 Control cables 70 Cables for BUS systems: Robot bus cables / FO data cables / FO supply cables 72 Pre-assembled special cables: ROBOFLEX recycle 74 Edition 12/2012 3

3 Robotec Systems GmbH: Solutions for all robot applications Irrespective of whether you need dresspacks, robot support, special cables for robots or preassembled cables, Robotec Systems has got a team of specialised employees available, who can help you with their many years of experience. From development through to prototyping, final assembly and on-the-spot service, Robotec Systems is the partner for leading car makers and their component suppliers. The Robotec Systems GmbH company based in Kamp- Lintfort (with ideal transport links between the conurbations of the Ruhr and the left bank of the lower Rhine) was founded in April It has developed into one of the leading companies in Europe for robot dresspacks and their attachment systems, special cables for robots, pre-assembled cables, driver technology, controllers for measurement technology as well as media systems such as air and water hoses. Since moving into the newly built production and administration building in July 2002, Robotec Systems has opened up new possibilities by setting up a development department and robot test areas. As a result, the company can offer individual solutions in response to customers' increased requirements. In July 2012, Robotec Systems GmbH became a wholly owned subsidiary of HELUKABEL GmbH based in Hemmingen, Baden Württemberg. Achieve freedom of movement through fastening elements: There s nothing else like it for robotics and automation! Ingenious support components give the robot the necessary freedom of movement for a fast working speed and precise repeat accuracy with a long service life. Universally applicable fastening elements for all commonly used robots can be combined into individual designs to provide the hydraulic, pneumatic and electrical components of the dresspacks with the attachment points they need. Special cable sheaths for complex robot applications withstand the extreme loadings and movements. Specially modified materials and special hose geometries guarantee the best protection and durability. Our services: Design Working out various solution concepts with regard to all the possibilities and your wishes. Development Our specialists develop individual dresspacks and equip them with the corresponding cables, media hoses and connectors. Prototyping On request, we produce prototypes that can be checked in test installations for function and service life Documentation If required, we undertake the documentation of the dresspacks including drawings. Installation/optimisation Our installation team can install the dresspacks on request. Repair/maintenance In case of damage, we can repair or renew the dresspacks on request. We are also please to handle ongoing and preventative maintenance. Spare parts Having a suitable stock guarantees high levels of availability and short delivery times. 4

4 Solution 1 Energy conduit system with R-TecBox 5

5 Contents Solution 1: Energy conduit system with R-TecBox Module overview Mini-clip series NW 36 8 Mini-clip series NW System holder NW 70 (hose fastening) 12 System holder NW 70 (train relief) 14 R-TecBox 70/56 and 48/36 16 Spring pack 18 Pipe clamp 20 Fastening elements and accessories System holder 24 Half shell / central jaw 25 Articulated piece 26 Ball joint 27 Strain relief 28 Swivel bearing 30 Clamping clips Clamping clip / spring pack (axis 4) 32 Clamping clip with tube (axis 6) 33 Adapter plate 34 Pipe clamp 34 Protector / impact protection 36 Flared section and accessories Flared section 40 Spring guide 41 Precision tubes 44 Plug-in hoses and accessories Plug-in hose 46 Hose nozzle / bulkhead fitting 47 Cable sheath Cable sheath type EW-HY/EWX-HY 52 6

6 Module overview 7

7 Module overview Mini-clip series NW 36 System holder with half shell for installing a corrugated hose NW 36. 1) System holder 2) Half shell (hose rotating radially) System holder with ball joint for installation of a fixed corrugated hose NW 36. 1) System holder 3) Ball joint (hose fixed) System holder with ball joint and strain relief for cables for installation of a fixed corrugated hose NW 36. 1) System holder 3) Ball joint (hose fixed) 5) Strain relief System holder with ball joint for installation of a sliding corrugated hose NW 36. 1) System holder 4) Ball joint (hose sliding) System holder on swivel bearing. 1) System holder 6) Swivel bearing with adapter plate 8

8 Mini-clip series NW 36 Sample applications for installation of cable protection conduits with nominal width 36. The ball joint remains swivelling in the system holder and thus adjusts to the movements of the cable protection conduits. As a result, tensions in the cable guidance can be avoided or reduced. No. Type Order no. Material Colour PU pce. Remarks 1 System holder NW POM Black 1 2 Half shell NW POM Black 1 3 End jaw NW POM Black 1 4 Flared section NW POM Black 1 5 Strain relief as blank PVC Black 10 6 Swivel bearing with adapter plate Steel Silver/black 1 7 Adapter plate Steel Black 1 powder-coated 8 Spring end piece NW POM Black 1 9 Swivel bearing Steel Silver 1 9

9 Module overview Mini-clip series NW 48 System holder with half shell for installing a corrugated hose NW 48. 1) System holder 2) Hose ring (hose rotating radially) System holder with ball joint for installation of a fixed corrugated hose NW 48. 1) System holder 3) Ball joint (hose fixed) System holder with ball joint and strain relief for cables and installation of a fixed corrugated hose NW 48. 1) System holder 3) Ball joint (hose fixed) 5) Strain relief System holder with ball joint for installation of a sliding corrugated hose NW 48. 1) System holder 4) Ball joint (hose sliding) System holder on swivel bearing. 1) System holder 6) Swivel bearing with adapter plate 10

10 Mini-clip series NW 48 Sample applications for installation of cable protection conduits with nominal width 48. The ball joint remains swivelling in the system holder and thus adjusts to the movements of the cable protection conduits. As a result, tensions in the cable guidance can be avoided or reduced. No. Type Order no. Material Colour PU pce. Remarks 1 System holder NW POM Black 1 2 Half shell NW POM Black 1 3 End jaw NW POM Black 1 4 Flared section NW POM Black 1 5 Strain relief as blank PVC Black 10 6 Swivel bearing with adapter plate Steel Silver/black 1 7 Adapter plate Steel Black 1 powder-coated 8 Spring end piece NW POM Black 1 9 Swivel bearing Steel Silver 1 11

11 Module overview System holder NW 70 (hose fastening) System holder with half shell for installing a corrugated hose NW 70. 1) System holder 2) Half shell (hose rotating radially) System holder with swivelling articulated piece for installing a corrugated hose NW 70 1) System holder 4) Articulated piece System holder with swivelling articulated piece and strain relief for installing a corrugated hose NW 70 at the same time as securing the cables 1) System holder 3) Strain relief 4) Articulated piece System holder on swivel bearing with ball bearing. Can be swivelled through ) System holder 5) Swivel bearing with adapter plate 12

12 System holder NW 70 (hose fastening) Combination examples of the system holder for installing dresspacks in nominal width 70. The different combination possibilities with the system holder enable you to find the ideal solution for the application. No. Type Order no. Material Colour PU pce. Remarks 1 System holder NW PA Black 10 2 Half shell NW PA Black 10 3 Strain relief cable star PVC Black 10 4 Extractable articulated piece PA Black 1 5 Swivel bearing with adapter plate Steel Silver 1 13

13 Module overview System holder NW 70 (train relief) System holder with strain relief for securing the installed cables 1) System holder 3) Strain relief System holder with strain relief for securing the installed cables 1) System holder 2) Strain relief System holder with strain relief for securing the installed cables 1) System holder 4) Strain relief System holder on ball bearing can rotate ) System holder 5) Swivel bearing with adapter plate 14

14 System holder NW 70 (train relief) Combination examples of the system holder for installing dresspacks in nominal width 70. The different combination possibilities with the system holder enable you to find the ideal solution for the application. No. Type Order no. Material Colour PU pce. Remarks 1 System holder NW PA Black 10 2 Strain relief cable star 1/ PVC Black 10 3 Strain relief cable star 1/ PVC Black 10 4 Cable star holder PA Black 1 5 Swivel bearing with adapter plate Steel Silver 1 6 Strain relief blank PA/TPE Black 10 7 Adapter plate Steel Black 1 powder-coated 8 Swivel bearing Steel Silver 1 15

15 Module overview R-TecBox 70/56 and 48/36 R-TecBox closed and open: 1) R-TecBox R-TecBox and base plate, individually and in working position Accessories and spare parts for R-TecBox: 3) Strain relief holder Base plates Base plate ABB (2.1) Base plate FANUC (2.2) Base plate KUKA (2.3) R-TecBox R-TecBox 48/36 R-TecBox 70/56 16

16 R-TecBox 70/56 and 48/36 With the R-TecBox, Robotec Systems has succeeded in creating a new system for optimum guidance of the energy packs from axis 3 to axis 6 on industrial robots. The energy pack is guided securely, effectively with low-wear in the specially produced housing. The integrated spring return system is unique. No. Type Order no. Material Colour PU pce. Remarks 1 R-TecBox PP + GF Black 1 2 Base plates 2.1 Base plate A3 ABB 6600/6650* Steel Black 1 powder-coated 2.2 Base plate A3 Fanuc R2000* Steel Black 1 powder-coated 2.3 Base plate A3 Kuka KR * Steel Black 1 powder-coated 3 Strain relief holder PA Black 1 Spare parts for R-TecBox 70/56 4 Tension spring Steel Silver 1 5 Spring cup R-TecBox Al Silver 4 6 Spring holder R-TecBox Al Silver 1 7 Slider R-TecBox POM Black 1 8 Threaded pin M 12 x Steel Black 4 powder-coated Spare parts for R-TecBox 48/36 9 R-TecBox PP + GF Black 1 10 Slider R-TecBox SL 36 EWX POM Black 1 11 Slider R-TecBox SL 48 EWX POM Black 1 12 Spring holder R-TecBox Al Silver 1 * For additional robots / robot types on request 17

17 Module overview Spring pack Spring pack as flexible attachment possibility on axis 4. 1) Clamping clip 2) Spring pack 5) System holder 7) Base plate Spring pack as flexible attachment possibility on axis 4. 1) Clamping clip 2) Spring pack 3) Swivel bearing with adapter plate 5) System holder Spring pack as flexible attachment possibility on axis 4. 1) Clamping clip 2) Spring pack 4) Swivel bearing 6) Flared section 18

18 Spring pack The clamping clip allows the spring pack to be secured on axis 4. The spring element permit the dresspack freedom of movement. The spring element compensates for changes in length and also avoids or minimises stresses on the dresspack. No. Type Order no. Material Colour PU pce. Remarks 1.1 Clamping clip D227 without tube Steel Black 1 powder-coated 1.2 Clamping clip D243 without tube Steel Black 1 powder-coated 1.3 Clamping clip D305 without tube Steel Black 1 powder-coated 1.4 Clamping clip D238 without tube Steel Black 1 powder-coated 2.1 Spring pack Steel Black 1 powder-coated 2.2 Spring pack Steel Black 1 powder-coated 3 Swivel bearing with adapter plate Steel Silver/black 1 4 Individual swivel bearing Steel Silver System holder NW POM Black System holder NW POM Black System holder NW PA Black Flared section Al Black Flared section PA Black 1 7 Base plate Steel Black 1 powder-coated 8 Holding plate for spring pin Steel Black 1 powder-coated 19

19 Module overview Pipe clamp Pipe clamp for rigid attachment of corrugated hoses. 1) Pipe clamp 2) Base plate 4) System holder 5) Precision tube straight Pipe clamp with swivel bearing for flexible attachment of corrugated hoses. 1) Pipe clamp 3) Swivel bearing with adapter plate 4) System holder 5) Precision tube straight Pipe clamp for rigid attachment of corrugated hoses. 1) Pipe clamp 2) Base plate 4) System holder 6) Precision tube 90 Pipe clamp for flexible attachment of corrugated hoses. 1) Pipe clamp 3) Swivel bearing with adapter plate 4) System holder 6) Precision tube 90 20

20 Pipe clamp The pipe clamps are required for attaching the precision tubes. The mounting flange is used for holding the swivel bearing and the base plate. No. Type Order no. Material Colour PU pce. Remarks 1.1 Pipe clamp D Al Silver Pipe clamp D Al Silver 1 2 Base plate Steel Black 1 powder-coated 3 Swivel bearing with adapter plate Steel Silver/black System holder NW PA Black System holder NW PA Black System holder NW PA Black Precision tube straight 5.1 Precision tube straight 40x Steel Silver 1 galvanized 5.2 Precision tube straight 40x Steel Silver 1 galvanized 5.3 Precision tube straight 40x Steel Silver 1 galvanized 6 Precision tube 90 angled Ø Precision tube angled 400x Steel Silver 1 galvanized 6.2 Precision tube angled 500x Steel Silver 1 galvanized 7. Precision tube 90 angled Ø Precision tube angled 400x Steel Silver 1 galvanized 21

21 22

22 Fastening elements and accessories 23

23 Single component System holder One-piece system holder made from plastic. Simple opening and closing by knuckle joint lock. Ideal for quick installation and removal of dresspacks. No. Type Order no. Material Colour PU pce. Remarks 1 System holder NW POM Black 1 2 System holder NW POM Black 1 3 System holder NW PA Black 10 24

24 Half shell / central jaw The half shell/middle jaw is required for installing cable sheaths in the system holder. The dresspack remains swivelling in the system holder. No. Type Order no. Material Colour PU pce. Remarks 1 Half shell NW POM Black 1 2 Half shell NW POM Black 1 3 Half shell NW PA Black 10 25

25 Single component Articulated piece The 2-piece articulated piece offers a length compensation of approx. 30 mm. The hose connection piece can be swivelled approx. 15 in all directions, thus adapting to the movements of the dresspack. No. Type Order no. Material Colour PU pce. Remarks 1 Articulated piece POM Black 1 2 Articulated piece PA Black 1 26

26 Ball joint The ball joint is used for holding a dresspack in the system holder. This allows the conduit adequate freedom of movement, because it can rotate approx. 22 all directions once installed in the system holder. The cable sheath is guided in the flared piece in such a way as to allow it to slide. No. Type Order no. Material Colour PU pce. Remarks 1 End jaw NW POM Black 1 2 End jaw NW POM Black 1 3 Flared section NW POM Black 1 4 Flared section NW POM Black 1 27

27 Single component Strain relief Strain relief for securing the cables in the dresspack. The cables can easily be installed in the elastic cable star. No. Type Order no. Material Colour PU pce. Remarks Strain relief pre-assembled 1 Strain relief pre-assembled 1/ PVC Black 10 2 Strain relief pre-assembled 1/ PVC Black 10 Strain relief as blank for self-assembly 3 Strain relief 36 blank* TPE outer sheath Black 1 4 Strain relief 48 blank* TPE outer sheath Black 1 5 Strain relief 70 blank* TPE outer sheath Black 10 * On request, we pre-assemble the blank according to your specifications 28

28 Swivel bearing 29

29 Swivel bearing The swivel bearing can rotate 360 and is mounted on ball bearings. No. Type Order no. Material Colour PU pce. Remarks 1 Swivel bearing with adapter plate Steel Silver/black 1 2 Adapter plate Steel Black 1 powder-coated 3 Individual swivel bearing Steel Silver 1 30

30 Clamping clips 31

31 Single component Clamping clip / spring pack (axis 4) The clamping clip provides an attachment point on axis 4. The appropriate spring pack, can create a flexible attachment point for the dresspack. No. Type Order no. Material Colour PU pce. Remarks 1 Clamping clip D227 without tube Steel Black 1 powder-coated 2 Clamping clip D243 without tube Steel Black 1 powder-coated 3 Clamping clip D305 without tube Steel Black 1 powder-coated 4 Clamping clip D238 without tube Steel Black 1 powder-coated 5 Spring pack Steel Black 1 powder-coated 6 Spring pack Steel Black 1 powder-coated 7 Base plate Steel Black 1 powder-coated 32

32 Clamping clip with tube (axis 6) The clamping provides an attachment point to axis 6. Further attachment elements can be mounted on the clamping clip as required. No. Type Order no. Material Colour PU pce. Remarks 1 Clamping clip D115 with tube D Steel Black 1 angled, burnished 2 Clamping clip D115 with tube D Steel galvanized 1 angled, galvanized 3 Clamping clip D125 with tube D Steel galvanized 1 angled, galvanized 4 Clamping clip D125 with tube D Steel Black 1 angled, burnished 5 Clamping clip D160 with tube D Steel galvanized 1 angled 6 Clamping clip D160 with tube D Steel galvanized 1 angled, without notch 7 Clamping clip D172 with tube D Steel Black 1 angled, burnished 8 Clamping clip D190 with tube D Steel galvanized 1 straight, galvanized 9 Clamping clip D190 with tube D Steel galvanized 1 angled, galvanized 10 Clamping clip D190 with tube D Steel Black 1 angled, burnished 11 Clamping clip D200 with tube D Steel Black 1 angled, burnished 12 Clamping clip D220 with tube D Steel galvanized 1 angled, galvanized 13 Clamping clip D250 with tube D Steel galvanized 1 angled, galvanized 14 Clamping clip D227 without tube Steel Black 1 powder-coated 15 Clamping clip D243 without tube Steel Black 1 powder-coated 16 Clamping clip D305 without tube Steel Black 1 powder-coated 17 Clamping clip D238 without tube Steel Black 1 powder-coated 33

33 Single component Adapter plate The base plate is used as an adapter for system holders. The 16 part split allows to install the system holders at an angle of 22.5 in each case. The mounting holes are matched to the pipe clamp and swivel bearing. No. Type Order no. Material Colour PU pce. Remarks 1 Base plate A6 (DH-RK 40-32) Steel Black 1 powder-coated 2 Base plate A6 (DH-RK 40-32) Steel Black 1 powder-coated Pipe clamp The pipe clamp enables clamping clips and precision tubes to be connected to other components. Clamping on the entire circumference of the tube. With holding flange for swivel bearing and base plate. No. Type Order no. Material Colour PU pce. Remarks 1 Pipe clamp D Al Silver 1 2 Pipe clamp D Al Silver 1 3 Pipe clamp D Al Silver 1 4 Pipe clamp D Al Silver 1 34

34 Protector / impact protection 35

35 Single component Protector / impact protection Protector with screw-on configuration as impact protection for cable conduits. 1) Protector / impact protection high design Protector with slide locking and locking screw as impact protection for cable sheaths. 2) Protector / impact protection low design 36

36 Protector / impact protection The protectors, also referred to as impact protection, protect the dresspack against impacts and abrasion. This means the service life of the dresspacks is significantly increased. Low configuration with slide locking and locking screw High configuration with screw attachment No. Type Order no. Material Colour PU pce. Remarks Tall configuration Design 1 Impact protection PA Black 10 high 2 Impact protection PA Red 10 high 3 Impact protection PA Green 10 high Low configuration for cable sheaths with standard corrugation type EW-xx Design 4 Impact protection PA Black 10 low 5 Impact protection PA Black 10 low 6 Impact protection PA Black 10 low Low configuration for cable sheaths with standard corrugation type EWX-xx Design 7 Impact protection PA Black 10 low 8 Impact protection PA Black 10 low 9 Impact protection PA Black 10 low Low configuration for cable sheaths with standard corrugation type EWX-xx and Design standard corrugation EW-xx 10 Impact protection PA Black 10 low 11 Impact protection PA Grey 10 low 37

37 38

38 Flared section and accessories 39

39 Single component Flared section Flared section for guidance and spring return of dresspacks. Made from aluminium or hard-wearing plastic. Aluminium variant with plastic coating for improved sliding properties Plastic variant with safety clips for a safe connection No. Type Order no. Material Colour PU pce. Remarks 1 Flared section Al Black 1 2 Flared section PA Black 1 40

40 Spring guide The compression spring with appropriate end piece is used as length compensation for dresspacks, for example on axis 3 or axis 4 of an articulated arm robot. A flared section and a protector are required for this. The protector sets the spring travel. The dresspack can thus adapt to the movements of the robot arm and compensate for resulting changes in length. No. Type Order no. Material Colour PU pce. Remarks Spring end piece 1 Spring end piece NW POM Black 1 Sliding 2 Spring end piece NW POM Black 1 Sliding 3 Spring end piece NW POM Black 1 Fixed 4 Spring end piece NW PA Black 1 Divisible Compression spring 4 Compression spring NW 36, L Spring steel Silver 1 5 Compression spring NW 48, L Spring steel Silver 1 6 Compression spring NW 70, L Spring steel Silver 1 7 Compression spring NW 70, L Spring steel Silver 1 41

41 42

42 Precision tubes 43

43 Single component Precision tube Different precision tubes are available as extension. These can be combined with the pipe clamps. No. Type Order no. Material Colour PU pce. Remarks 1 Precision tube straight 1.1 Precision tube straight 40x Steel Silver 1 galvanized 1.2 Precision tube straight 40x Steel Silver 1 galvanized 1.3 Precision tube straight 40x Steel Silver 1 galvanized 2 Precision tube 90 angled Ø Precision tube angled 400x Steel Silver 1 galvanized 2.2 Precision tube angled 500x Steel Silver 1 galvanized 3 Precision tube 90 angled Ø Precision tube angled 400x Steel Silver 1 galvanized 44

44 Plug-in hoses and accessories 45

45 Single component Plug-in hose C Reinforced, double-layer, self-clamping polyurethane hoses for industrial applications. These hoses have been designed especially for equipping robots and machine components, and are particularly suitable as a conduit for water, air and various gases. Free of substances that impair paint adhesion Silicone-free, UV-resistant, cold-flexible Resistant to oils, oxygen, ozone, acids and dilute alkalis Temperature range -40 to +80 C Type Order no. Material Colour Ø inside mm Ø inside inch max. operating min. burst pressure pressure bar bar PU pce. Plug-in hose DN PUR Black 6.4 1/ Plug-in hose DN PUR Black 9.5 3/ Plug-in hose DN PUR Black / Plug-in hose DN PUR Green 6.4 1/ Plug-in hose DN PUR Green 9.5 3/ Plug-in hose DN PUR Green / Plug-in hose DN PUR Red 6.4 1/ Plug-in hose DN PUR Red 9.5 3/ Plug-in hose DN PUR Red / Plug-in hose DN PUR Blue 6.4 1/ Plug-in hose DN PUR Blue 9.5 3/ Plug-in hose DN PUR Blue / Plug-in hose DN PUR Grey 9.5 3/

46 Hose nozzle / bulkhead fitting Hose nozzle for installation of the media hoses. The media hose is pushed onto the plug-in nipple as far as the stop and is self-locking. There is no need for an additional hose clip for applications up to max. operating pressure of the media hoses. Type Order no. Thread connection Hose connection Version PU pce. Remarks Hose nozzle M12-G1/ M12x1.5 G 1/4" straight 10 ÜM Hose nozzle M14-G3/ M14x1.5 G 3/8" straight 10 ÜM Hose nozzle M16-G3/ M16x1.5 G 3/8" straight 10 ÜM Hose nozzle M20-G1/ M20x1.5 G 1/2" straight 10 ÜM Hose nozzle M22-G1/ M22x1.5 G 1/2" straight 10 ÜM Hose nozzle M14-G3/ M14x1.5 G 3/8" straight 10 MT Hose nozzle M16-G3/ M16x1.5 G 3/8" straight 10 MT Hose nozzle M22-G1/ M22x1.5 G 1/2" straight 10 MT Hose nozzle M16-G3/ M16x1.5 G 3/8" angled ÜM Hose nozzle M22-G1/ M22x1.5 G 1/2" angled ÜM Hose nozzle M16-G3/ M16x1.5 G 3/8" angled ÜM Hose nozzle M22-G1/ M22x1.5 G 1/2" angled ÜM Hose nozzle G1/4-G1/ G 1/4" G 1/4" straight 10 ÜM Hose nozzle G3/8-G3/ G 3/8" G 3/8" straight 10 ÜM Hose nozzle G1/2-G1/ G 1/2" G 1/2" straight 10 ÜM Hose nozzle G3/8-G3/ G 3/8" G 3/8" straight 10 MT Hose nozzle G1/2-G1/ G 1/2" G 1/2" straight 10 MT Hose nozzle G3/8-G3/ G 3/8" G 3/8" angled ÜM Hose nozzle G1/2-G1/ G 1/2" G 1/2" angled ÜM 47

47 Single component Hose nozzle / bulkhead fitting Hose nozzle G1/4-G1/ G 1/4" G 1/4" angled ÜM Hose nozzle G3/8-G3/ G 3/8" G 3/8" angled ÜM Hose nozzle G1/2-G1/ G 1/2" G 1/2" angled ÜM Bulkhead fitting M16-M M16x1.5" M16x1.5" straight 10 MT Bulkhead fitting M22-M M22x1.5" M22x1.5" straight 10 MT Bulkhead fitting G3/8-G3/ G 3/8" G 3/8" straight 10 MT Bulkhead fitting G1/2-G1/ G 1/2" G 3/8" straight 10 MT 48

48 Cable protection conduit 49

49 Single component Cable protection conduit type EW-HY / EWX-HY C, intermittently 180 C HB Cable protection conduit for medium to heavy-duty mechanical loadings and the highest flexibility. Ideal for robot applications at higher ambient temperatures. Applications: Robots Handling systems In cable carriers Temperature range -50 to +160 C, intermittently 180 C Type Order no. Material Colour Ø inside mm Bending Ø outside radius mm static Bending radius dynamic PU pce. Remarks EW-HY TPE outer sheath Black EW-HY TPE outer sheath Black EW-HY TPE outer sheath Black EW-HY TPE outer sheath Black EW-HY TPE outer sheath Black EW-HY TPE outer sheath Black EWX-HY TPE outer sheath Black high corrugation EWX-HY TPE outer sheath Black high corrugation EWX-HY TPE outer sheath Black high corrugation EWX-HY TPE outer sheath Black high corrugation EWX-HY TPE outer sheath Black high corrugation EWX-HY TPE outer sheath Black high corrugation EWX-HY TPE outer sheath Black high corrugation 50

50 Solution 2 Energy conduit system with spring guide 51

51 Contents Solution 2: Energy conduit system with spring guide 27 Add-on parts System holder / clamping clip 54 Middle jaw / combi jaw 55 Articulated piece 56 Ball joint 57 Strain relief 58 Swivel bearing 59 Clamping clip / pipe clamping piece / adapter plate 60 Protector 61 Hose and spring guide 62 Compression spring 63 Cable sheath 65 52

52 Add-on parts 53

53 Single component System holder / clamping clip One-piece system holder / clamping clips made from plastic with and without metal closure. Ideal for quick installation and removal of dresspacks. Type Order no. Material Colour Clamping clip Clamping clip; NW 29K PA Black 1 Clamping clip; NW 36S PA Black 1 Clamping clip; NW 52M PA Black 1 Clamping clip; NW 70M PA Black 1 Clamping clip; NW 70K PA Black 1 PU pce. Remarks Type Order no. Material Colour System holder System holder reinforced, NW PA Black 1 System holder reinforced, NW PA Black 1 System holder reinforced, NW PA Black 1 PU pce. Remarks 54

54 Single component Middle jaw / combi jaw Two-piece plastic jaws for installing the corrugated tubes in the clamping clips and for fixing the strain reliefs. Type Order no. Material Colour PU pce. Remarks Middle jaws; NW PA Black 1 matching clamping clip; NW 29K Middle jaws; NW PA Black 1 matching clamping clip; NW 29K Middle jaw; NW 36 / PA Black 1 matching clamping clip; NW 36S Middle jaw; NW 36 / PA Black 1 matching clamping clip; NW 52M Combi jaw; NW PA Black 1 matching clamping clip; NW 52M Middle jaws; NW PA Black 1 Combi jaws; NW PA Black 1 matching clamping clip; NW 70M clamping clip; NW 70K matching clamping clip; NW 70M clamping clip; NW 70K 55

55 Single component Articulated piece The multi-piece articulated pieces permit movements of the dresspack up to 30 in circular tracks on the end of the dresspack. Type Order no. Material Colour PU pce. Remarks NW36 Ball joint jaws NW PA Black 1 Protector NW PA Black 1 Cable star NW TPE outer sheath Black 1 Dummy plug 7.5 mm TPE outer sheath Black 2 Dummy plug 10.0 mm TPE outer sheath Black 1 Dummy plug 22.0mm TPE outer sheath Black 1 Hose clip, mm Alu natural 1 Clamping clip NW PA Black 1 NW52 Ball joint jaws NW PA Black 1 Protector NW PA Black 1 Cable star NW TPE outer sheath Black 1 Dummy plug 10.0 mm TPE outer sheath Black 1 Dummy plug 12.5mm TPE outer sheath Black 2 Dummy plug 19.5mm TPE outer sheath Black 2 Hose clip, 40-60mm Alu natural 1 Clamping clip NW PA Black 1 56

56 Single component Ball joint The ball joint is used for holding a dresspack in the system holder. This allows the dresspack adequate freedom of movement, because it can move approx. 22 in all directions when in the installed system holder. The globe variant additionally absorbs torsion from the corrugated hose. Type Order no. Material Colour PU pce. Remarks NW36 Ball joint jaws NW PA Black 1 matching clamping clip NW 52M Protector NW PA Black 1 NW52 Ball joint jaws NW PA Black 1 matching clamping clip NW 70M Protector NW PA Black 1 NW70 Connection element NW PA Black 1 matching clamping clip NW 70M Globe NW PA Black 1 57

57 Single component Strain relief Strain relief for securing the cables in the dresspack. The cables can easily be installed in the elastic cable star. Unoccupied bushings are sealed tight with the dummy plug. Type Order no. Material Colour PU pce. Remarks Cable star Cable star, NW23, bk, blind TPE outer sheath Black 1 dummy Cable star, NW29, bk, blind TPE outer sheath Black 1 dummy Cable star, NW36, bk, blind TPE outer sheath Black 1 dummy Cable star, NW36, bk, drilling pattern TPE outer sheath Black 1 1 x 6.0 / 2 x 7.5 / 1 x 10.0 / 1 x 22.0 Cable star, NW52, bk, drilling pattern TPE outer sheath Black 1 1 x 10.0 / 2 x 12.5 / 2 x 19.0 Cable star, NW70, bk, drilling pattern TPE outer sheath Black 1 4 x 14.0 / 4 x 19.0 / 1 x 28.0 Dummy plug Dummy plug 7.5 mm TPE outer sheath Black 1 Dummy plug 10.0mm TPE outer sheath Black 1 Dummy plug 12.5mm TPE outer sheath Black 1 Dummy plug 14.0mm TPE outer sheath Black 1 Dummy plug 19.5mm TPE outer sheath Black 1 Dummy plug 22.0mm TPE outer sheath Black 1 Dummy plug 28.0mm TPE outer sheath Black 1 Hose clip Hose clip, NW23, mm ALU natural 1 Hose clip, NW29, mm ALU natural 1 Hose clip, NW36, mm ALU natural 1 Hose clip, NW52, mm ALU natural 1 Hose clip, NW70, mm ALU natural 1 58

58 Single component Swivel bearing Swivel bearing made from plastic with multiple holder for system holder / clamping clip or rotating fork. Type Order no. Material Colour PU pce. Remarks Rotating flange NW52, bk PA Black 1 Rotating flange NW70, bk PA Black 1 59

59 Single component Clamping clip / pipe clamping piece / adapter plate The clamping clip provides attaching an attachment point to axis 6. The pipe clamping piece and the adapter plate can be used for mounting all system holders/clamping clips and articulated end pieces. Type Order no. Material Colour PU pce. Remarks Clamping clip Clamping clip D Steel Black 1 powder-coated Clamping clip D Steel Black 1 powder-coated Clamping clip D100 with tube D Steel Black 1 powder-coated Clamping clip D115 with tube D Steel Black 1 powder-coated Clamping clip D125 with tube D Steel Black 1 powder-coated Clamping clip D160 with tube D Steel Black 1 angled 20, powder-coated Clamping clip D190 with tube D Steel Black 1 powder-coated Clamping clip D200 with tube D Steel Black 1 angled 20, powder-coated Clamping clip D250 with tube D Steel Black 1 powder-coated Pipe clamping piece FLR 34/ Alu natural 1 Adapter plate Adapter plate Alu natural 1 60

60 Single component Protector The protectors protect the dresspack against impacts and abrasion, which significantly increases the service life of the dresspacks. Type Order no. Material Colour PU pce. Remarks Protector, NW 23, bk PA Black 1 Protector, NW 29, bk PA Black 1 Protector, NW 36, bk PA Black 1 Protector, NW 52, bk PA Black 1 Protector, NW 70, bk PA Black 1 61

61 Single component Hose and spring guide The protectors protect the dresspack against impacts and abrasion, which significantly increases the service life of the dresspacks. Type Order no. Material Colour PU pce. Remarks Spring holder, NW 23/ PA Black 1 Spring holder, NW 36/ PA Black 1 Spring holder, NW 36/ PA Black 1 Sliding jaws; NW PA Black 1 Sliding jaws; NW PA Black 1 Flared jaw; NW PA Black 1 Flared jaw; NW PA Black 1 Spring holder NW PA Black 1 matching clamping clip; NW 29K / matching clamping clip; NW 36S / matching clamping clip; NW 52M / matching clamping clip; NW 52M / matching clamping clip; NW 70M / matching rotating fork; NW 70 / matching rotating fork; NW 70 / matching clamping clip; NW 70M / Rotating fork with rotating flange Rotating flange NW PA Black 1 Rotating fork; NW PA Black 1 62

62 Single component Compression spring Compression springs for all available nominal widths in various levels of hardness and lengths. This allows an individual response to the fill level of the dresspack. Type Order no. Material Colour PU pce. Remarks Compression spring 23 Compression spring 23 Compression spring 29 Compression spring 29 Compression spring 29 Compression spring 36 Compression spring 36 Compression spring 36 Compression spring 52 Compression spring 52 Compression spring Spring steel natural Spring steel natural Spring steel natural Spring steel natural Spring steel natural Spring steel natural Spring steel natural Spring steel natural Spring steel natural Spring steel natural Spring steel natural 1 Size: 400, classification: light matching: Spring holder, NW 23/29 / Size: 600, classification: light matching: Spring holder, NW 23/29 / Size: 410, classification: light matching: Spring holder, NW 23/29 / Size: 400, classification: light matching: Spring holder, NW 36/36 / Size: 600, classification: medium matching: Spring holder, NW 36/36 / Size: 400, classification: light matching: Spring holder, NW 36/52 / Size: 400, classification: medium matching: Spring holder, NW 36/52 / Size: 600, classification: medium matching: Spring holder, NW 36/36 / Size: 450, classification: light matching: Spring flared section; NW 70 / or spring holder NW70 / Size: 1000, classification: medium matching: Spring flared section; NW 70 / or spring holder NW70 / Size: 1000, classification: reinforced matching: Spring flared section; NW 70 / or spring holder NW70 /

63 Single component Compression spring Compression spring 70 Compression spring 70 Compression spring 70 Compression spring Spring steel natural Spring steel natural Spring steel natural Spring steel natural 1 Size: 450 classification: medium, matching: Spring flared section; NW 70 / or spring holder NW70 / Size: 550 classification: medium, matching: Spring flared section; NW 70 / or spring holder NW70 / Size: 1000, classification: medium, matching: Spring flared section; NW 70 / or spring holder NW70 / Size: 1000, classification: reinforced matching: Spring flared section; NW 70 / or spring holder NW70 /

64 Single component Cable sheath Cable protection conduit made from PUR and polyamide. Extremely flexible, resistant to impacts and notches, suitable for all robot applications. Type Order no. Material Colour Ø inside mm Ø outside mm Bending radius static Bending radius dynamic PU pce. PU corrugated tube, NW 23G standard PU corrugated tube, NW 29G standard PU corrugated tube, NW 36G standard PU corrugated tube, NW 52G standard PU corrugated tube, NW 52G reinforced PA corrugated tube, NW 52G PU corrugated tube, NW 70G standard PU corrugated tube, NW 70G reinforced PA corrugated tube, NW 70G PU Black On request PU Black On request PU Black On request PU Black On request PU Black On request PA Black On request PU Black On request PU Black On request PA Black On request 65

65 HELUKABEL GmbH Leading manufacturer and supplier of cables and wires Fully automatic logistics centre Redefining logistics in the cable business HELUKABEL has Europe's largest and most modern fully automatic distribution centre for cables and wires. A large proportion of the more than 33,000 articles is held in stock in Hemmingen, near Stuttgart. The automated high-bay warehouse accommodates 16,600 pallet locations. The most modern conveyor and control technology achieves a high level of automation which accelerates the material flow and guarantees that numerous order items are brought together on schedule. At present, the logistics centre is being expended by a further 23,900 locations, to 40,500 pallet locations. In addition, 33,400 new locations are being created in the fully automatic small parts warehouse and 610 locations in the heady load warehouse. The expansion is planned to come into operation during the first quarter of Facts and figures 23,900 pallet locations 33,400 locations in the small parts warehouse 610 locations in the heavy load warehouse 2 km conveyor line for pallets 9,000 truck loads excavated ( 64,000 m³) 215,210 m³ converted volume 9,305 m² area under cover 1,100 tonnes reinforced steel Completion/start-up in 1st quarter 2013 Cables and Wires made in Germany Cable production at the Windsbach factory 66 Since 1988, HELUKABEL has been producing more than 340,000 km of wire annually in its own factory in Windsbach, to a high standard. More than 150 highly qualified employees are specialised in manufacturing a large variety of high-specification cables. The cable factory is regarded as a centre of excellence in the business areas of automation, data technology, building systems technology and renewable energies. We manufacture cables and wires from a wide range of materials in more than 10,000 m 2 of production space and meet every possible expectation on modern cable production. HELUKABEL offers its customers products to practically every standard and regulation. Our range is rounded out by special cables produced to customer requirements. Facts and figures 150 employees 10,000 m² production area 340,000 km of wire Fire testing equipment Drag chain test equipment Test tower for wind power cables Torsion test system Scrape off equipment In-house test centre The HELUKABEL dynamic test centre has numerous test and inspection stations.

66 Cables for robot applications 67

67 Primary cables Robot primary cable Cable design Internal conductor Special conductor Strand class VI (super-fine wire) Highly flexible Core insulation TPM or PUR Core identification Black cores with continuous white numberingk PE conductor green/yellow Core stranding With very short lay length, reeled around a filler element in one layer for design reasons. Outer sheath Special PUR Cable properties PUR self-extinguishing and flame retardant according to IEC / EN Oil-resistant acc. to VDE 0472 Halogen-free Based on EN Silicone-free The materials used in manufacture are free of silicone and cadmium, as well as of substances that impair paint wetting Lead-free Based on EU Directive (RoHS) 2002/95/EC Advantages Extremely high resilience to mechanical loads For extreme loadings High flexibility, even at very low temperatures Application Primary cables for the most extreme applications. These robot cables are absolutely torsion-loadable and are highly resistant to flexural stresses. They are particularly suitable for automated production processes with 3D movements, such as occur in the automotive industry, general engineering and plant construction. 68

68 Robot primary cable Technical data Nominal voltage: U 0 /U: 600 V/1,00 V Insulation resistance: min. 100 MΩ x km Temperature range when moving: 40 C to +80 C max. conductor temp. Temperature range static: 50 C to +80 C max. conductor temp. Minimum bending radius flexing: 10 x Cable diameter Minimum bending radius static: 5 x Cable diameter Designation: Order no. Colour Ø in CU Weight Minimum bending Remarks mm: kg/km: kg/km: radius (mm): Primary cable 1x25 mm² Black Primary cable 1x25 mm² bk/gnye Primary cable 1x35 mm² Black Primary cable 3x16 mm² Orange Primary cable 3x25 mm² Yellow Primary cable 3x35 mm² Orange Primary cable 3x50 mm² Orange Dimensions and specifications may be changed without prior notice. 69

69 Control cables Robot control cable / motor cable / sensor cable / EMZ cable Cable design Internal conductor Special conductor Strand class VI (super-fine wire) Highly flexible Core insulation TPM or PUR Core identification for design reasons Core stranding Wires stranded with optimum lay lengths, low-torsion stranding with matching short lay lengths by one filling element Innen sheath TPM Screening Tin-plated copper braid Optical covering > 80% Outer sheath Special PUR Cable properties PUR self-extinguishing and flame retardant according to IEC / EN Oil-resistant acc. to VDE 0472 Halogen-free Based on EN Silicone-free The materials used in manufacture are free of silicone and cadmium, as well as of substances that impair paint wetting Lead-free Based on EU Directive (RoHS) 2002/95/EG Advantages Extremely high resilience to mechanical loads For extreme loadings High flexibility, even at very low temperatures Application Robot cables for the most extreme applications. These robot cables are absolutely torsion-loadable and are highly resistant to flexural stresses. They are particularly suitable for automated production processes with 3D movements, such as occur in the automotive industry, general engineering and plant construction. 70

70 Robot control cable / motor cable / sensor cable / EMZ cable Technical data Nominal voltage: U 0 /U: 300 V/500 V Test voltage: 3,000 V Insulation resistance: min. 100 MΩ x km Temperature range when moving: 30 C to +80 C max. conductor temp. Temperature range static: 40 C to +80 C max. conductor temp. Minimum bending radius flexing: 10 x Cable diameter Minimum bending radius static: 5 x Cable diameter Designation: Art no.: Ø in CU Weight Minimum bending Remarks mm: kg/km: kg/km: radius (mm): Control cable 2x0.5+(2x0.5) mm² Control cable 13x0.5+3x1.0+(2x0.5) mm² Control cable 6x0.75+(3x0.75) mm² Control cable 5x1.0+(2x1.0) mm² Control cable 7x1.0+(2x1.0) mm² Control cable 16x1.0+(2x1.0) mm² Control cable 17x1.0+(2x1.0) mm² Control cable 23x1.0+(2x1.0) mm² Control cable 24x1.0+(2x1.0) mm² Control cable 3x(2x0.75)+17x0.75 mm² Control cable 2x(3x0.5)+3x0.5+2x4x0.5+2x0.5 mm² Control cable 22x0.75+5x(2x0.75) mm² Control cable (2x2x0.5)+3x3x0.5+5x3x1.0 mm² Control cable (2x1.0)+(3x1.0)+1x1.0 mm² Motor cable (4x2.5+(2x2x0.75)) mm² Motor cable (4x2.5+2x1.0) mm² Sensor cable 4x(2x0.25) mm² Sensor cable 8x(2x0.25) mm² EMZ cable [(4x2x0.25)+(5x1.5)+2x(2x0.5)+(5x0.5)] mm² EMZ cable [(4x0.75)+(5x0.5)+2x(2x0.5)+(4x2x0.25)] mm² EMZ cable [(4x2x0.25)+2x(2x0.5)+(5x2.5)+(5x0.5)] mm² Wire colour spiralled EMZ cable [(4x2x0.25)+2x(2x0.5)+(5x2.5)+(5x0.5)] mm² Wire colour plain Dimensions and specifications may be changed without prior notice. 71

71 Cables for BUS systems Robot bus cables Cable design Internal conductor Special conductor Strand class VI (super-fine wire) Highly flexible Core insulation TPM or PUR Core identification Coloured wires PE conductor green/yellow Core stranding Wires stranded with optimum lay lengths, low-torsion stranding with matching short lay lengths by one filling element Screening Tin-plated copper braid Optical covering > 90% Outer sheath Special PUR Cable properties Flame-retardant acc. to HD or IEC and VW1/ FT1 acc. to C-UL Oil-resistant acc. to VDE 0472 Halogen-free in accordance with DIN VDE 0475 Part 815 Silicone-free The materials used in manufacture are free of silicone and cadmium, as well as of substances that impair paint wetting Lead-free Based on EU Directive (RoHS) 2002/95/EC Advantages Extremely high resilience to mechanical loads For extreme loadings High flexibility, even at very low temperatures Application Robot bus cables for the most extreme applications. These robot cables are absolutely torsion-loadable and are highly resistant to flexural stresses. They are particularly suitable for automated production processes with 3D movements, such as occur in the automotive industry, general engineering and plant construction. 72

72 Robot bus cables Technical data Nominal voltage: 1.0 mm 2 : U 0 /U: 450 V/750 V Test voltage: 0.25 mm 2 : 1.5 kv, 1.0 mm 2 : 2.5 kv Insulation resistance: min. 100 MΩ x km Temperature range when moving: 20 C to +60 C max. conductor temp. Temperature range static: 40 C to +70 C max. conductor temp. Minimum bending radius flexing: 10 x Cable diameter Minimum bending radius static: 5 x Cable diameter Type Order no. Ø in CU Weight Minimum bending Remarks mm: kg/km: kg/km: radius (mm): Interbus cable 5x(2x0.25)+2x(2x1.0)+1.0 mm² Multibus cable 1x(2x0.34)+2x(2x0.25)+ 2x(2x0.34)+2x(2x1.0)+1.0 mm² Dimensions and specifications may be changed without prior notice. FO data cable and FO supply cables Type Order no. Ø in CU Weight Minimum bending Remarks mm: kg/km: kg/km: radius (mm): FO data cable 2P 980/ Profinet-FO Supply cable 5x1.5 mm² Dimensions and specifications may be changed without prior notice. 73