Product Catalogue Robot Technology6 Strain relief blank 82951628 PA/TPE Black 10 ... Base plate FANUC (2.2) R-TecBox 48/36 Module overview. 17 R-TecBox 70/56 and 48/36 With the R-TecBox,

www.robotec-systems.de

Product CatalogueRobot Technology

A company of the Group

3

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 8Mini-clip series NW 48 10System holder NW 70 (hose fastening) 12System holder NW 70 (train relief) 14R-TecBox 70/56 and 48/36 16Spring pack 18Pipe clamp 20

Fastening elements and accessories System holder 24Half shell / central jaw 25Articulated piece 26Ball joint 27Strain relief 28

Swivel bearing 30

Clamping clips Clamping clip / spring pack (axis 4) 32Clamping clip with tube (axis 6) 33Adapter plate 34Pipe clamp 34

Protector / impact protection 36

Flared section and accessories Flared section 40Spring guide 41

Precision tubes 44

Plug-in hoses and accessories Plug-in hose 46Hose 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 54Middle jaw / combi jaw 55Articulated piece 56Ball joint 57Strain relief 58Swivel bearing 59Clamping clip / pipe clamping piece / adapter plate 60Protector 61Hose and spring guide 62Compression spring 63Cable sheath 65

Cables for robot applications 67

Primary cables 68Control cables 70Cables for BUS systems: Robot bus cables / FO data cables / FO supply cables 72Pre-assembled special cables: ROBOFLEX recycle 74

Contents

Edition 12/2012

4

Robotec Systems GmbH: Solutions for all robot applications

Irrespective of whether you need dresspacks, robot support, special cables for robots or pre-assembled 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 1998. 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:

DesignWorking out various solution concepts with regard to all the possibilities and your wishes.

DevelopmentOur specialists developindividual dresspacks and equip them with the corresponding cables, media hoses and connectors.

PrototypingOn request, we produce prototypes that can be checked in test installations for function and service life

DocumentationIf required, we undertake the documentation of the dresspacks including drawings.

Installation/optimisationOur installation team can install the dresspacks on request.

Repair/maintenanceIn case of damage, we can repair or renew the dresspacks on request. We are also please to handle ongoing and preventative maintenance.

Spare partsHaving a suitable stock guarantees high levels of availability and short delivery times.

5

Solution 1Energy conduit system with R-TecBox

6

Solution 1: Energy conduit system with R-TecBoxModule overview Mini-clip series NW 36 8

Mini-clip series NW 48 10System holder NW 70 (hose fastening) 12System holder NW 70 (train relief) 14R-TecBox 70/56 and 48/36 16Spring pack 18Pipe clamp 20

Fastening elements and accessories System holder 24Half shell / central jaw 25Articulated piece 26Ball joint 27Strain relief 28

Swivel bearing 30

Clamping clips Clamping clip / spring pack (axis 4) 32Clamping clip with tube (axis 6) 33Adapter plate 34Pipe clamp 34

Protector / impact protection 36

Flared section and accessories Flared section 40Spring guide 41

Precision tubes 44

Plug-in hoses and accessories Plug-in hose 46Hose nozzle / bulkhead fitting 47

Cable sheath Cable sheath type EW-HY/EWX-HY 52

Contents

7

Module overview

8

Mini-clip series NW 36

System holder with half shell for installing a corrugated hose NW 36.1) System holder2) Half shell

(hose rotating radially)

System holder with ball joint for installation of a fixed corrugated hose NW 36.1) System holder3) 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 holder3) Ball joint (hose fixed)5) Strain relief

System holder with ball joint for installation of a sliding corrugated hose NW 36.1) System holder4) Ball joint (hose sliding)

System holder on swivel bearing.1) System holder6) Swivel bearing with adapter plate

Module overview

9


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 36 82951008 POM Black 1

2 Half shell NW 36 82951408 POM Black 1

3 End jaw NW 36 82951248 POM Black 1

4 Flared section NW 36 82951258 POM Black 1

5 Strain relief as blank 82951608 PVC Black 10

6 Swivel bearing with adapter plate 82952214 Steel Silver/black 1

7 Adapter plate 82952212 Steel Black 1 powder-coated

8 Spring end piece NW 36 82952418 POM Black 1

9 Swivel bearing 82952210 Steel Silver 1

10


System holder with half shell for installing a corrugated hose NW 48.1) System holder2) Hose ring (hose rotating radially)

System holder with ball joint for installation of a fixed corrugated hose NW 48.1) System holder3) 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 holder3) Ball joint (hose fixed)5) Strain relief

System holder with ball joint for installation of a sliding corrugated hose NW 48.1) System holder4) Ball joint (hose sliding)

System holder on swivel bearing.1) System holder6) Swivel bearing with adapter plate

Module overview

11


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.






5 Strain relief as blank 82951610 PVC Black 10



8 Spring end piece NW 48 82952420 POM Black 1


12

System holder NW 70 (hose fastening)

System holder with half shell for installing a corrugated hose NW 70.1) System holder2) Half shell

(hose rotating radially)

System holder with swivelling articulated piece for installing a corrugated hose NW 701) System holder4) 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 cables1) System holder3) Strain relief4) Articulated piece

System holder on swivel bearing with ball bearing. Can be swivelled through 360°.1) System holder5) Swivel bearing with adapter plate

Module overview

13

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.


1 System holder NW 70 82951014 PA Black 10

2 Half shell NW 70 82951414 PA Black 10

3 Strain relief cable star 82951624 PVC Black 10

4 Extractable articulated piece 82951214 PA Black 1

5 Swivel bearing with adapter plate 82952214 Steel Silver 1

14

System holder NW 70 (train relief)

System holder with strain relief for securing the installed cables1) System holder3) Strain relief



System holder on ball bearing can rotate 360°.1) System holder5) Swivel bearing with adapter plate

Module overview

15

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.



2 Strain relief cable star 1/1 82951614 PVC Black 10

3 Strain relief cable star 1/2 82951624 PVC Black 10

4 Cable star holder 82951646 PA Black 1

5 Swivel bearing with adapter plate 82952214 Steel Silver 1

6 Strain relief blank 82951628 PA/TPE Black 10



16

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

Base plate ABB (2.1)

Base plates

R-TecBox

Accessories and spare parts for R-TecBox:3) Strain relief holder

Base plate KUKA (2.3)

R-TecBox 70/56

Base plate FANUC (2.2)

R-TecBox 48/36

Module overview

17

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.


1 R-TecBox 70 82950000 PP + GF Black 1

2 Base plates

2.1 Base plate A3 ABB 6600/6650* 82953051 Steel Black 1 powder-coated

2.2 Base plate A3 Fanuc R2000* 82953040 Steel Black 1 powder-coated

2.3 Base plate A3 Kuka KR 150-240* 82950012 Steel Black 1 powder-coated

3 Strain relief holder 82951646 PA Black 1

Spare parts for R-TecBox 70/56

4 Tension spring 82952430 Steel Silver 1

5 Spring cup R-TecBox 70 82952432 Al Silver 4

6 Spring holder R-TecBox 82952426 Al Silver 1

7 Slider R-TecBox 70 82950005 POM Black 1

8 Threaded pin M 12 x 50 82952428 Steel Black 4 powder-coated

Spare parts for R-TecBox 48/36

9 R-TecBox 36-48 82950009 PP + GF Black 1

10 Slider R-TecBox SL 36 EWX 82950001 POM Black 1

11 Slider R-TecBox SL 48 EWX 82950003 POM Black 1

12 Spring holder R-TecBox 36-48 82950018 Al Silver 1

* For additional robots / robot types on request

18

Spring pack

Spring pack as flexible attachment possibility on axis 4.1) Clamping clip2) Spring pack5) System holder7) Base plate

Spring pack as flexible attachment possibility on axis 4.1) Clamping clip2) Spring pack3) Swivel bearing with adapter plate5) System holder

Spring pack as flexible attachment possibility on axis 4.1) Clamping clip2) Spring pack4) Swivel bearing6) Flared section

Module overview

19

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.


1.1 Clamping clip D227 without tube 82952650 Steel Black 1 powder-coated




2.1 Spring pack 125 82952690 Steel Black 1 powder-coated

2.2 Spring pack 250 82952694 Steel Black 1 powder-coated


4 Individual swivel bearing 82952210 Steel Silver 1

5.1 System holder NW 48 82951010 POM Black 1

5.2 System holder NW 36 82951008 POM Black 1

5.3 System holder NW 70 82951014 PA Black 10

6.1 Flared section 82952414 Al Black 1

6.2 Flared section 83692005 PA Black 1

7 Base plate 82952620 Steel Black 1 powder-coated

8 Holding plate for spring pin 82953210 Steel Black 1 powder-coated

20

Pipe clamp

Pipe clamp for rigid attachment of corrugated hoses.1) Pipe clamp2) Base plate4) System holder5) Precision tube straight

Pipe clamp with swivel bearing for flexible attachment of corrugated hoses.1) Pipe clamp3) Swivel bearing with adapter plate4) System holder5) Precision tube straight

Pipe clamp for rigid attachment of corrugated hoses.1) Pipe clamp2) Base plate4) System holder6) Precision tube 90°

Pipe clamp for flexible attachment of corrugated hoses.1) Pipe clamp3) Swivel bearing with adapter plate4) System holder6) Precision tube 90°

Module overview

21

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.


1.1 Pipe clamp D32 82952610 Al Silver 1

1.2 Pipe clamp D40 82952612 Al Silver 1






5. Precision tube straight

5.1 Precision tube straight 40x1000 82952810 Steel Silver 1 galvanized



6 Precision tube 90° angled Ø 40

6.1 Precision tube angled 400x250 83952830 Steel Silver 1 galvanized


7. Precision tube 90° angled Ø 30


22

23

Fastening elements and accessories

24





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.

Single component

25




3 Half shell NW 70 82951414 PA Black 10

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.

26


1 Articulated piece 56 82951216 POM Black 1

2 Articulated piece 70 82951214 PA Black 1

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.

Single component

27






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.

28


Strain relief pre-assembled

1 Strain relief pre-assembled 1/1 82951614 PVC Black 10

2 Strain relief pre-assembled 1/2 82951624 PVC Black 10

Strain relief as blank for self-assembly

3 Strain relief 36 blank* 82951608 TPE outer sheath Black 1



* On request, we pre-assemble the blank according to your specifications

Strain relief

Strain relief for securing the cables in the dresspack. The cables can easily be installed in the elastic cable star.

Single component

29

Swivel bearing

30

Swivel bearing

The swivel bearing can rotate 360° and is mounted on ball bearings.




3 Individual swivel bearing 82952210 Steel Silver 1

31

Clamping clips

32

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.

Single component


1 Clamping clip D227 without tube 82952650 Steel Black 1 powder-coated




5 Spring pack 125 82952690 Steel Black 1 powder-coated

6 Spring pack 250 82952694 Steel Black 1 powder-coated


33

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.


1 Clamping clip D115 with tube D32 82952629 Steel Black 1 angled, burnished

2 Clamping clip D115 with tube D32 82952631 Steel galvanized 1 angled, galvanized



5 Clamping clip D160 with tube D32 82952628 Steel galvanized 1 angled

6 Clamping clip D160 with tube D32 82952630 Steel galvanized 1angled, without notch


8 Clamping clip D190 with tube D32 82921444 Steel galvanized 1 straight, galvanized










34

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.

Single component


1 Base plate A6 (DH-RK 40-32) 82952620 Steel Black 1 powder-coated

2 Base plate A6 (DH-RK 40-32) 82952092 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.


1 Pipe clamp D30 82952616 Al Silver 1




35

Protector / impact protection

36


Protector with screw-on config-uration 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

Single component

37



Tall configuration Design

1 Impact protection 70 82951814 PA Black 10 high

2 Impact protection 70 82951824 PA Red 10 high

3 Impact protection 70 82951844 PA Green 10 high

Low configuration for cable sheaths with standard corrugation type EW-xx Design

4 Impact protection 36 82691062 PA Black 10 low



Low configuration for cable sheaths with standard corrugation type EWX-xx Design




Low configuration for cable sheaths with standard corrugation type EWX-xx and standard corrugation EW-xx

Design


11 Impact protection 70 82951814 PA Grey 10 low

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

38

39

Flared section and accessories

40

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

Single component


1 Flared section 82952414 Al Black 1

2 Flared section 82692005 PA Black 1

41


Spring end piece

1 Spring end piece NW 36 82952418 POM Black 1 Sliding

2 Spring end piece NW 48 82952420 POM Black 1 Sliding

3 Spring end piece NW 70 82852424 POM Black 1 Fixed

4 Spring end piece NW 70 83692014 PA Black 1 Divisible

Compression spring

4 Compression spring NW 36, L 600 82952442 Spring steel Silver 1




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.

42

43

Precision tubes

44


1 Precision tube straight









Precision tube

Different precision tubes are available as extension. These can be combined with the pipe clamps.

Single component

45

Plug-in hoses and accessories

46

Type Order no. Material Colour Ø inside mm

Ø inside inch

max. operating pressure bar

min. burst pressure bar

PU pce.

Plug-in hose DN6 82929299 PUR Black 6.4 1/4 24.0 95.0 50



Plug-in hose DN6 82929298 PUR Green 6.4 1/4 24 95.0 50

Plug-in hose DN10 82929242 PUR Green 9.5 3/8 20.0 81.0 50

Plug-in hose DN13 82929262 PUR Green 12.5 1/2 20.0 81.0 50

Plug-in hose DN6 82929297 PUR Red 6.4 1/4 24 95.0 50

Plug-in hose DN10 82929244 PUR Red 9.5 3/8 20.0 81.0 50

Plug-in hose DN13 82929264 PUR Red 12.5 1/2 20.0 81.0 50

Plug-in hose DN6 82929294 PUR Blue 6.4 1/4 24 95.0 50

Plug-in hose DN10 82929246 PUR Blue 9.5 3/8 20.0 81.0 50

Plug-in hose DN13 82929266 PUR Blue 12.5 1/2 20.0 81.0 50

Plug-in hose DN10 82929248 PUR Grey 9.5 3/8 20.0 81.0 50

Plug-in hose

-40 – 80 °C

Single component

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

47

Type Order no. Thread connection

Hose connection Version PU pce. Remarks

Hose nozzle M12-G1/4 82929090 M12x1.5 G 1/4" straight 10 ÜM





Hose nozzle M14-G3/8 82929070 M14x1.5 G 3/8" straight 10 MT



Hose nozzle M16-G3/8-45 82929030 M16x1.5 G 3/8" angled 45° 10 ÜM




Hose nozzle G1/4-G1/4 82929094 G 1/4" G 1/4" straight 10 ÜM



Hose nozzle G3/8-G3/8 82929042 G 3/8" G 3/8" straight 10 MT

Hose nozzle G1/2-G1/2 82929052 G 1/2" G 1/2" straight 10 MT

Hose nozzle G3/8-G3/8-45 82929034 G 3/8" G 3/8" angled 45° 10 ÜM


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.

48

Hose nozzle / bulkhead fitting

Single component




Bulkhead fitting M16-M16 82956013 M16x1.5" M16x1.5" straight 10 MT

Bulkhead fitting M22-M22 82956012 M22x1.5" M22x1.5" straight 10 MT

Bulkhead fitting G3/8-G3/8 82956010 G 3/8" G 3/8" straight 10 MT

Bulkhead fitting G1/2-G1/2 82956011 G 1/2" G 3/8" straight 10 MT

49

Cable protection conduit

50


Ø outside mm

Bending radius static

Bending radius dynamic

PU pce. Remarks

EW-HY-21 83121056 TPE outer sheath Black 21.7 28.0 49.0 109.0 50






EWX-HY-21 83121258 TPE outer sheath Black 19.8 28.1 49.0 11.0 50 high corrugation







Cable protection conduit type EW-HY / EWX-HY

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

-50 – 160 °C, intermittently 180 °C

HB

Single component

51

Solution 2Energy conduit system with spring guide

52

Solution 2: Energy conduit system with spring guide 27

Add-on parts System holder / clamping clip 54Middle jaw / combi jaw 55Articulated piece 56Ball joint 57Strain relief 58Swivel bearing 59Clamping clip / pipe clamping piece / adapter plate 60Protector 61Hose and spring guide 62Compression spring 63Cable sheath 65

Contents

53

Add-on parts

54

Type Order no. Material Colour PU pce. Remarks

System holder

System holder reinforced, NW 23 99775 PA Black 1



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.

Single component


Clamping clip

Clamping clip; NW 29K 902001 PA Black 1

Clamping clip; NW 36S 940626 PA Black 1

Clamping clip; NW 52M 902205 PA Black 1

Clamping clip; NW 70M 902207 PA Black 1

Clamping clip; NW 70K 902208 PA Black 1

55


Middle jaws; NW 23 902002 PA Black 1 matching clamping clip; NW 29K

Middle jaws; NW 29 902009 PA Black 1 matching clamping clip; NW 29K

Middle jaw; NW 36 / 36 940627 PA Black 1 matching clamping clip; NW 36S

Middle jaw; NW 36 / 52 902211 PA Black 1 matching clamping clip; NW 52M

Combi jaw; NW 52 902213 PA Black 1 matching clamping clip; NW 52M

Middle jaws; NW 70 902214 PA Black 1matching clamping clip; NW 70M clamping clip; NW 70K

Combi jaws; NW 70 902223 PA Black 1matching clamping clip; NW 70M clamping clip; NW 70K

Middle jaw / combi jaw

Two-piece plastic jaws for installing the corrugated tubes in the clamping clips and for fixing the strain reliefs.

Single component

56


NW36

Ball joint jaws NW36 902007 PA Black 1

Protector NW36 902232 PA Black 1

Cable star NW36 902005 TPE outer sheath Black 1

Dummy plug 7.5 mm 902006 TPE outer sheath Black 2


Dummy plug 22.0mm 902003 TPE outer sheath Black 1

Hose clip, 32-50 mm 902849 Alu natural 1

Clamping clip NW 52 902205 PA Black 1

NW52

Ball joint jaws NW52 902251 PA Black 1


Cable star NW52 902237 TPE outer sheath Black 1




Hose clip, 40-60mm 902315 Alu natural 1

Clamping clip NW 70 902207 PA Black 1

Articulated piece

The multi-piece articulated pieces permit movements of the dresspack up to 30° in circular tracks on the end of the dresspack.

Single component

57


NW36

Ball joint jaws NW36 902007 PA Black 1 matching clamping clip NW 52M


NW52

Ball joint jaws NW52 902251 PA Black 1 matching clamping clip NW 70M


NW70

Connection element NW70 942551 PA Black 1 matching clamping clip NW 70M

Globe NW70 942550 PA Black 1

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.

Single component

58


Cable star

Cable star, NW23, bk, blind 902263 TPE outer sheath Black 1 dummy



Cable star, NW36, bk, drilling pattern 902005 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 902237 TPE outer sheath Black 1 1 x 10.0 / 2 x 12.5 / 2 x 19.0

Cable star, NW70, bk, drilling pattern 902240 TPE outer sheath Black 1 4 x 14.0 / 4 x 19.0 / 1 x 28.0

Dummy plug








Hose clip

Hose clip, NW23, 16-27 mm 902842 ALU natural 1





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.

Single component

59


Rotating flange NW52, bk 902255 PA Black 1

Rotating flange NW70, bk 902252 PA Black 1

Swivel bearing

Swivel bearing made from plastic with multiple holder for system holder / clamping clip or rotating fork.

Single component

60

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.

Single component


Clamping clip

Clamping clip D50 902798 Steel Black 1 powder-coated

Clamping clip D63 902294 Steel Black 1 powder-coated

Clamping clip D100 with tube D34 941470 Steel Black 1 powder-coated



Clamping clip D160 with tube D34 941104 Steel Black 1 angled 20°, powder-coated


Clamping clip D200 with tube D34 941090 Steel Black 1 angled 20°, powder-coated


Pipe clamping piece

FLR 34/32 941472 Alu natural 1

Adapter plate

Adapter plate 941471 Alu natural 1

61

Protector

The protectors protect the dresspack against impacts and abrasion, which significantly increases the service life of the dresspacks.

Single component


Protector, NW 23, bk 902229 PA Black 1





62

Hose and spring guide

The protectors protect the dresspack against impacts and abrasion, which significantly increases the service life of the dresspacks.

Single component


Spring holder, NW 23/29 942001 PA Black 1matchingclamping clip; NW 29K / 902001

Spring holder, NW 36/36 940628 PA Black 1matching clamping clip; NW 36S / 940626

Spring holder, NW 36/52 902016 PA Black 1matching clamping clip; NW 52M / 902205

Sliding jaws; NW 52 902219 PA Black 1matching clamping clip; NW 52M / 902205

Sliding jaws; NW 70 902220 PA Black 1matching clamping clip; NW 70M / 902207

Flared jaw; NW 70 902226 PA Black 1matching rotating fork; NW 70 / 902224

Flared jaw; NW 70 902227 PA Black 1matching rotating fork; NW 70 / 902224

Spring holder NW70 942000 PA Black 1matching clamping clip; NW 70M / 902207

Rotating fork with rotating flange

Rotating flange NW 70 902252 PA Black 1

Rotating fork; NW 70 902224 PA Black 1

63

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.

Single component


Compression spring 23

902539 Spring steel natural 1Size: 400, classification: light matching: Spring holder, NW 23/29 / 942001








940610 Spring steel natural 1Size: 600, classification: medium matching: Spring holder, NW 36/36 / 940628








902371 Spring steel natural 1Size: 450, classification: light matching: Spring flared section; NW 70 / 902227 or spring holder NW70 / 942000


902374 Spring steel natural 1Size: 1000, classification: medium matching: Spring flared section; NW 70 / 902227 or spring holder NW70 / 942000


902369 Spring steel natural 1Size: 1000, classification: reinforced matching: Spring flared section; NW 70 / 902227 or spring holder NW70 / 942000

64


940213 Spring steel natural 1Size: 450 classification: medium, matching: Spring flared section; NW 70 / 902227 or spring holder NW70 / 942000


902124 Spring steel natural 1Size: 550 classification: medium, matching: Spring flared section; NW 70 / 902227 or spring holder NW70 / 942000


902370 Spring steel natural 1Size: 1000, classification: medium, matching: Spring flared section; NW 70 / 902227 or spring holder NW70 / 942000


902379 Spring steel natural 1Size: 1000, classification: reinforced matching: Spring flared section; NW 70 / 902227 or spring holder NW70 / 942000

Compression spring

Single component

65


Ø outside mm

Bending radius static

Bending radius dynamic

PU pce.

PU corrugated tube, NW 23G standard

99764 PU Black 21.5 28.3 40 100 On request







PU corrugated tube, NW 52G reinforced


PA corrugated tube, NW 52G

902127 PA Black 52.0 62.8 125 300 On request



PU corrugated tube, NW 70G reinforced


PA corrugated tube, NW 70G

902013 PA Black 70.0 82.5 150 350 On request

Cable sheath

Cable protection conduit made from PUR and polyamide. Extremely flexible, resistant to impacts and notches, suitable for all robot applications.

Single component

66

HELUKABEL® GmbH Leading manufacturer and supplier of cables and wires

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 m2 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.

In-house test centre

The HELUKABEL® dynamic test

centre has numerous test and

inspection stations.

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

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

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 2013.

Redefining logistics in the cable business

Cable production at the Windsbach factory

Cables and Wires – made in Germany

www.helukabel.de

Fully automatic logistics centre

67

Cables for robot applications

68

Robot primary cable

Primary cables

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 automa-ted production processes with 3D movements, such as occur in the automotive industry, general engineering and plant construction.

• Extremely high resilience to mechanical loads

• For extreme loadings• High flexibility, even at very

low temperatures

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

PUR self-extinguishing and flame retardant• according to IEC 60332-1 / EN 50265-2-1

Oil-resistant• acc. to VDE 0472

Halogen-free• Based on EN 50267-2-1

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

Cable design

Application

Cable properties Advantages

69

Robot primary cable

Technical data

Nominal voltage: U0/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 82854001 Black 10.8 238.0 278.0 108.0

Primary cable 1x25 mm² 82854002 bk/gnye 10.8 238.0 278.0 108.0

Primary cable 1x35 mm² 82854003 Black 11.8 332.0 371.0 118.0

Primary cable 3x16 mm² 82851010 Orange 21.4 460.8 721.0 214.0

Primary cable 3x25 mm² 82854005 Yellow 22.3 720.0 965.0 223.0



Dimensions and specifications may be changed without prior notice.

70

Robot control cable / motor cable / sensor cable / EMZ cable

Control cables

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 automa-ted production processes with 3D movements, such as occur in the automotive industry, general engineering and plant construction.



low temperatures



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%


PUR self-extinguishing and flame retardant• according to IEC 60332-1 / EN 50265-2-1


Halogen-free• Based on EN 50267-2-1



Lead-free• Based on EU Directive (RoHS) 2002/95/EG

Cable design

Application


71

Robot control cable / motor cable / sensor cable / EMZ cable

Technical data

Nominal voltage: U0/U: 300 V/500 V

Test voltage: 3,000 V






Designation: Art no.: Ø in CU Weight Minimum bending Remarks


Control cable 2x0.5+(2x0.5) mm² 82851001 8.0 32.0 72.0 80.0

Control cable 13x0.5+3x1.0+(2x0.5) mm² 82851002 12.7 102.0 186.0 127.0








Control cable 3x(2x0.75)+17x0.75 mm² 82851019 15.8 185.0 333.0 158.0

Control cable 2x(3x0.5)+3x0.5+2x4x0.5+2x0.5 mm² 82853010 11.4 108.0 91.6 114.0

Control cable 22x0.75+5x(2x0.75) mm² 82851013 17.0 265.0 430.0 170.0

Control cable (2x2x0.5)+3x3x0.5+5x3x1.0 mm² 82851020 13.6 126.0 253.0 136.0

Control cable (2x1.0)+(3x1.0)+1x1.0 mm² 82853007 10.2 89.0 145.0 102.0

Motor cable (4x2.5+(2x2x0.75)) mm² 82859009 13.0 197.0 275.0 104.0

Motor cable (4x2.5+2x1.0) mm² 82859019 12.3 147.0 250.0 123.0

Sensor cable 4x(2x0.25) mm² 82859010 11.6 86.0 190.0 116.0

Sensor cable 8x(2x0.25) mm² 82859018 12.0 90.0 220.0 120.0

EMZ cable [(4x2x0.25)+(5x1.5)+2x(2x0.5)+(5x0.5)] mm²

82852002 16.3 274.0 456.0 163.0

EMZ cable [(4x0.75)+(5x0.5)+2x(2x0.5)+(4x2x0.25)] mm²

82852003 17.4 221.0 388.0 174.0

EMZ cable [(4x2x0.25)+2x(2x0.5)+(5x2.5)+(5x0.5)] mm²

82852004 20.0 328.0 547.0 200.0Wire colour spiralled

EMZ cable [(4x2x0.25)+2x(2x0.5)+(5x2.5)+(5x0.5)] mm²

82852005 20.0 328.0 546.0 200.0Wire colour plain


72

Robot bus cables

Cables for BUS systems

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 automa-ted production processes with 3D movements, such as occur in the automotive industry, general engineering and plant construction.



low temperatures



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%


Flame-retardant• acc. to HD 405.1 or IEC 332-1 and VW1/

FT1 acc. to C-UL


Halogen-free• in accordance with DIN VDE 0475

Part 815



Lead-free• Based on EU Directive (RoHS)

2002/95/EC

Cable design

Application


73

Robot bus cables

Type Order no. Ø in CU Weight Minimum bending Remarks


Interbus cable 5x(2x0.25)+2x(2x1.0)+1.0 mm²

82853001 13.6 120.0 220.0 136.0

Multibus cable 1x(2x0.34)+2x(2x0.25)+ 2x(2x0.34)+2x(2x1.0)+1.0 mm²

82853003 14.7 139.0 258.0 147.0

FO data cable and FO supply cables

Type Order no. Ø in CU Weight Minimum bending Remarks


FO data cable 2P 980/1000 82859015 8.0 - 55.0 40.0

Profinet-FO 82859032 8.0 - 51.0 40.0

Supply cable 5x1.5 mm² 82859013 9.9 68.2 133.2 148.5

Nominal voltage: 1.0 mm2: U0/U: 450 V/750 V

Test voltage: 0.25 mm2: 1.5 kV, 1.0 mm2: 2.5 kV








Technical data

74

ROBOFLEX recycle

For more information, refer to www.robotec-systems.de/roboflex

Pre-assembled special cables

• Approval: UL/cUL approved• Manufacture based on VDE• Temperature range: fixed installation: -40 °C to +120 °C flexible: -30 °C to +120 °C• Nominal voltage: 300 V• Test voltage: 2000 V• Minimum bending radius: approx. 7.5 cable diameters (for flexible application)• Traversing speed: max. 3.3 m/s for 5 m of horizontal traverse path length• Acceleration: max. 5 m/s² • Flexing and torsion cycles: min. 10 million • Torsional stress: +/- 360 °/m

• Highly oil resistant• In accordance with VDE 0473 Part 811-2-1• Good resistance to acids, alkalis and solvents• Not cross-linked• Weld spatter resistant• Recyclable• Halogen-free• Silicone and cadmium-free• Free of substances harmful to paint adhesion • Very high mechanical load capacity• Abrasion-resistant• Wear-resistant• Highly flexible• UV-resistant• ROHS-compliant• CE-compliant

• Bare copper stranded wire, 42 x 0.10 mm • Core insulation polyester, bk, bu, bn • Cores stranded in layers• Sheath, special mix• Weld spatter resistant, matt, low-adhesion, flame retardant and self-extinguishing (acc. to VDE 0472 Part 804 test type B, IEC 60332-1)• Sheath colour: black Design (3-pin) Wire colours bn, bu, bkOD 5.2 +/-0.2 mmDesign (4-pin)Wire colours bn, bu, bk, whOD 5.5 +/-0.2 mmDesign (5-pin)Wire colours bn, bu, bk, wh, gyOD 6.0 +/-0.2 mm

• IP67• A-coded

ROBOFLEX recycle Pre-assembled special cables

ROBOFLEX recycle M12 socket pre-assembled on one side 3-pin, 4-pin and 5-pin

ROBOFLEX recycle M12 4-pin + PE pre-assembled on one side

ROBOFLEX recycle M12 pre-assembled on both sides 3-pin, 4-pin and 5-pin

ROBOFLEX recycle M12 4-pin + PE pre-assembled on both sides

ROBOFLEX recycle M12 plug pre-assembled on one side 3-pin, 4-pin and 5-pin

ROBOFLEX recycle M8 socket pre-assembled on one side 3-pin and 4-pin

ROBOFLEX recycle M8 pre-assembled on both sides 3-pin and 4-pin

ROBOFLEX recycle M8 plug pre-assembled on one side 3-pin and 4-pin

ROBOFLEX recycle M12 shielded pre-assembled on one side 3-pin, 4-pin and 5-pin

ROBOFLEX recycle M12 shielded pre-assembled on both sides 3-pin, 4-pin and 5-pin

ROBOFLEX recycle M12 on M12 twin cables pre-assembled on one side 3-pin

ROBOFLEX recycle M12 on M12 twin cables pre-assembled on both sides 3-pin

ROBOFLEX recycle 3x0.34 mm², 4x0.34 mm², 5x0.34 mm² shielded and unshielded per metre length

Technical data Structure Properties

Notes


Documents

Product Catalogue Robot Technology6 Strain relief blank 82951628 PA/TPE Black 10 ... Base plate FANUC (2.2) R-TecBox 48/36 Module overview. 17 R-TecBox 70/56 and 48/36 With the R-TecBox,