Sectional type torsion-resistant drag chain flat cable and manufacturing method thereof

Abstract

The invention relates to the technical field of power cables, in particular to a sectional type anti-torsion drag chain flat cable and a manufacturing method thereof.The sectional type anti-torsion drag chain flat cable comprises at least two strip-shaped components, each strip-shaped component comprises at least two functional units and a protective layer extruded outside the functional units, and the strip-shaped components are constructed to be strip-shaped components extending in the length direction; and the protective layers of all the strip-shaped parts are constructed to have the same outer contour shape. According to the invention, the standardized functional units and the split type sheath adopt a hot-melting reversible bonding modular design, so that hundreds of traditional finished cable models can be simplified into limited standard unit and sheath specifications, meanwhile, a user can perform field model selection and assembly according to actual requirements, the delivery cycle is shortened from several weeks to several days, and the production efficiency is greatly improved. And more importantly, when a certain core wire is damaged or needs to be subjected to function upgrading, maintenance can be completed only by locally heating, prying the sheath and replacing a corresponding unit, so that the maintenance cost is reduced.

Description

Technical Field

[0001] This invention relates to the field of power cable technology, and more specifically to a segmented anti-torsion drag chain flat cable and its manufacturing method. Background Technology

[0002] As core equipment in modern intelligent manufacturing, industrial robots rely heavily on their pipeline systems (i.e., cables, air pipes, and other energy and signal transmission components) as key parts connecting the control cabinet and the end effector. In practical applications, the arm length of the same model of industrial robot is usually standardized, thus the required drag chain cable length is essentially fixed. However, the functions of the end effectors installed on robots vary greatly depending on the operating scenario. For example, spot welding robots require large-section power cables and water pipes, handling robots require pneumatic and vacuum pipelines, and assembly robots require high-density signal and data cables.

[0003] In existing technologies, drag chain cables generally adopt an integrated molding structure. The internal core configuration of the cable is fixed once production is complete and cannot be adjusted according to changes in end-effectors. When production processes are improved to add new functions or a core wire breaks due to fatigue, users must replace the entire cable. This not only requires disassembling the entire drag chain system but also results in a large number of cables being scrapped. Because drag chain cables are highly susceptible to fatigue damage during high-speed reciprocating motion, once a single core wire breaks, the integral extrusion structure cannot achieve local repair, requiring users to disassemble the entire drag chain system for a complete replacement, leading to prolonged production line downtime. Furthermore, existing drag chain flat cables are prone to helical stress in the internal core wires during frequent twisting, causing sheath wear, especially during robot reciprocating motion and frequent movement, which can easily lead to cracking. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings of existing drag chain flat cables. Firstly, it proposes a technical solution: a segmented anti-torsion drag chain flat cable, comprising: At least two strip-shaped components, each strip-shaped component comprising at least two functional units and a protective layer extruded over the functional units, the strip-shaped components being configured as strip-shaped members extending along the length direction, and the protective layers of all the strip-shaped components being configured to have the same outer contour shape; The sheath component includes a first sheath and a second sheath that can be joined together. On the side where the first sheath and the second sheath are joined together, a plurality of first positioning parts and second positioning parts are provided respectively. The first positioning parts and the second positioning parts extend along the length direction of the sheath component, so that after the first sheath and the second sheath are joined together, a positioning space for accommodating and limiting the strip component is formed between the first sheath and the second sheath. The strip component is covered with a first hot-melt adhesive layer, and the strip component is configured to be independently prefabricated and continuously produced. The inner surfaces of the first and second sheaths are provided with a second hot melt adhesive layer in at least a portion of the area. The second hot melt adhesive layer and the first hot melt adhesive layer on the surface of the strip component placed in the positioning space can be fused together under heating and pressure conditions, so that multiple strip components are encapsulated and fixed in the sheath component. By combining different types and numbers of strip components, a drag chain flat cable with a predetermined functional combination can be formed. Among them, multiple strip-shaped components are arranged in a straight line along the width direction of the sheath component.

[0005] Preferably, the functional unit includes at least one of the following types: A power transmission unit, comprising at least one multi-strand stranded conductor; The signal control unit includes at least one twisted-pair shielded wire pair; The data communication unit has impedance-matched differential pairs inside. A fluid transport unit with flexible internal pipe walls; Filling units, including solid or foamed fillers; Furthermore, the outer contour of the strip component is racetrack-shaped, consisting of two parallel straight edges and two semi-circular arc edges.

[0006] Preferably, the protective layer includes a protective tube independently disposed on the outer wall of a single functional unit and a flexible buffer layer that simultaneously covers two protective tubes, and the first hot melt adhesive layer is disposed on the surface of the flexible buffer layer. The flexible buffer layer is embedded with a tensile core, which is arranged along the axial direction of the two protective tubes.

[0007] Preferably, the first hot melt adhesive layer and the second hot melt adhesive layer include a thermoplastic hot melt adhesive layer, which is configured to be solid at room temperature and have sliding properties, be able to melt and flow when heated to a predetermined temperature, and solidify to form an adhesive after cooling.

[0008] Preferably, the first positioning part is a first protrusion structure constructed on the inner wall of the first sheath, and the second positioning part is a second protrusion structure constructed on the inner wall of the second sheath. The cross-sectional shape of the first protrusion structure and the second protrusion structure is semi-circular, and the interior of the second protrusion structure is provided with a cavity. The second hot-melt adhesive layer includes strip-shaped adhesive portions distributed along the length of the sheath component in the first protrusion structure, the second protrusion structure, and the inner walls of the first and second sheaths, with at least four of the strip-shaped adhesive portions provided in each positioning space.

[0009] Preferably, the first sheath has at least one buffer portion for providing elastic deformation when the cable is bent, and the second sheath has at least one reinforcing portion including reinforcing ribs arranged periodically along the length of the cable to resist deformation of the sheath components in the width direction.

[0010] Preferably, the buffer portion includes a plurality of hole structures, the reinforcing ribs are mesh-like reinforcing ribs, and along the length direction of the cable, there are a first reinforcing region, a second reinforcing region and a third reinforcing region, the strength of the first reinforcing region and the third reinforcing region is higher than the strength of the second reinforcing region.

[0011] A second aspect of this invention provides a technical solution: a method for manufacturing the above-mentioned segmented anti-torsion drag chain flat cable, comprising the following steps: Step S1: Prefabricate strip components. Select at least two functional units according to functional requirements, extrude a protective layer on the outside of the functional units, and form a first hot melt adhesive layer on the surface of the protective layer to make strip components with the same outer contour shape, and roll them up for later use. Step S2: Prefabricate the sheath component by extrusion molding or injection molding to prepare the first sheath and the second sheath respectively, and form a second hot melt adhesive layer on at least a portion of the inner surface of the first sheath and the second sheath. Step S3: Based on the functional requirements of the target cable, select the required type and quantity of strip components from the prefabricated strip components, and place the selected strip components into the first positioning part of the first sheath in sequence, so that each strip component is arranged in a straight line along the width direction of the first sheath. Step S4: Cover the first sheath with the second sheath and align them with each other, so that the second positioning part of the second sheath is aligned with each strip component; Step S5: Apply pressure and heat to the laminated structure of the first sheath and the second sheath. The heating temperature is controlled at a temperature that melts the first hot melt adhesive layer and the second hot melt adhesive layer but is below the softening temperature of the internal functional unit of the strip component, so that the first hot melt adhesive layer and the second hot melt adhesive layer fuse together. Step S6: Cooling under pressure to solidify the molten hot melt adhesive layer, encapsulating and fixing multiple strip components between the first and second sheaths to form a segmented anti-torsion drag chain flat cable.

[0012] Preferably, in step S2, the method of preparing the first sheath and the second sheath includes at least one of the following: Extrusion molding method: The thermoplastic elastomer material is extruded by an extruder, and after extrusion, a periodically distributed texture structure is formed on the inner surface of the first and second sheaths. The texture structure includes at least one of pits, microgrooves or protrusions. Co-extrusion molding method: Two or more extruders are used to co-extrude through a composite die. While extruding the base material layer of the first or second sheath, a continuously distributed fiber woven mesh is pre-embedded inside the base material layer to form a reinforcing part. Injection molding method: The first sheath and the second sheath are prepared separately by injection molding process, so that the inner surfaces of the first sheath and the second sheath form a periodically distributed texture structure, the texture structure including at least one of pits, microgrooves or protrusions.

[0013] Preferably, it also includes a repair and replacement step: when it is necessary to replace the damaged strip component, the sheath surface of the corresponding area of ​​the strip component to be replaced is locally heated to a temperature above the softening temperature of the first hot melt adhesive layer and the second hot melt adhesive layer. After the hot melt adhesive layer softens, use a tool to pry open the seam between the first and second sheaths to expose the damaged strip component. Remove the damaged strip component and insert a new strip component of the same type and specifications; Reattach the first and second sheaths, and apply pressure and heat to the repaired area again to re-fuse the heat-melt adhesive layer. Repairs were completed after cooling.

[0014] Compared with the prior art, the significant advantages of the segmented anti-torsion drag chain flat cable of the present invention are: This invention utilizes a modular design with standardized functional units and a split sheath, employing hot-melt reversible bonding. This simplifies hundreds of traditional finished cable models into a limited number of standardized units and sheath specifications. Users can select and assemble the cables on-site according to their actual needs, reducing the delivery cycle from weeks to days and significantly improving response speed. More importantly, when a core wire is damaged or requires a functional upgrade, repairs can be completed simply by locally heating and prying open the sheath to replace the corresponding unit, thus reducing maintenance costs. This invention features a sheath with partitioned reinforcing ribs providing a rigid anti-torsional skeleton, a hot-melt adhesive layer between units providing a flexible buffer interface, and an embedded tensile core to jointly bear axial loads. The combined effect of these three elements ensures uniform stress distribution when the cable is subjected to complex three-dimensional torsion, improving the bending life of the drag chain cable. The racetrack-shaped strip components, in conjunction with the positioning part design on the inner wall of the sheath, form a stable radial limit, effectively preventing internal unit misalignment or flipping during complex three-dimensional torsion. The tensile core embedded in the flexible buffer layer and the partitioned reinforced sheath components work together to form a rigid-flexible stress system. The buffer section absorbs bending compressive stress, while the reinforcing section resists torsional shear force, reducing fatigue damage to the internal conductors and extending the cable's bending life under extreme operating conditions. Attached Figure Description

[0015] The accompanying drawings are for illustrative purposes only and do not limit the scope of protection of this invention.

[0016] In the accompanying drawings, each identical or nearly identical component shown in the various figures may be denoted by the same reference numeral. For clarity, not every component is labeled in each figure. Embodiments of various aspects of the invention will now be described by way of example and with reference to the accompanying drawings.

[0017] Figure 1 This is a schematic diagram of the segmented anti-torsion drag chain flat cable shown in an embodiment of the present invention.

[0018] Figure 2 This is a schematic diagram of the cross-sectional structure of the segmented anti-torsion drag chain flat cable shown in an embodiment of the present invention.

[0019] Figure 3 This is a schematic diagram of the structure of the strip-shaped component shown in an embodiment of the present invention.

[0020] Figure 4 This is a schematic diagram showing the first sheath and the second sheath in a separated state according to an embodiment of the present invention.

[0021] Figure 5 This is a schematic diagram of the mesh-like reinforcing ribs shown in an embodiment of the present invention.

[0022] Figure 6 This is a schematic diagram showing the reinforcing part disposed on the inner wall of the second sheath, as illustrated in an embodiment of the present invention. Detailed Implementation

[0023] To better understand the technical content of this invention, specific embodiments are described below in conjunction with the accompanying drawings.

[0024] {Example 1} Combination Figures 1 to 3 As shown, the first aspect of the present invention proposes a technical solution, a segmented anti-torsion drag chain flat cable, comprising at least two strip components 10 and a sheath component 20 wrapped around the strip components 10.

[0025] It should be understood that the strip component 10, as the functional core of the cable, undertakes the transmission of media such as power, signals, data, and fluids. Its standardized design allows it to be prefabricated independently and flexibly combined. The sheath component 20, as the cable's protective and shaping structure, can precisely limit the position of the strip components through positioning parts and encapsulate multiple strip components into a single unit through a hot-melt adhesive layer. Therefore, the strip component 10 and the sheath component 20 together constitute a modular, customizable drag chain flat cable.

[0026] like Figure 1As shown, the strip member 10 includes at least two functional units 10a and a protective layer extruded outside the functional units. The strip member 10 is configured as a strip member extending along the length direction, and the protective layer of all strip members 10 is configured to have the same outer contour shape.

[0027] In an optional embodiment, a plurality of strip components 10 are arranged in a straight line along the width direction of the sheath component 20.

[0028] In this way, the straight-line arrangement ensures that the bending neutral surfaces of all strip components 10 are on the same plane. When the cable bends in the cable chain, the bending strain borne by each unit tends to be consistent, avoiding internal friction and stress concentration caused by the difference in bending radii between the inner and outer layers. Furthermore, the operator can intuitively see the arrangement sequence of all strip components, which facilitates quick positioning of the unit to be operated during assembly or maintenance.

[0029] In an optional embodiment, functional unit 10a includes at least one of the following types: The power transmission unit includes at least one multi-strand twisted conductor, which is used to provide power to robot end effectors such as welding clamps and motors, and features high flexibility and bend resistance.

[0030] The signal control unit includes at least one twisted shielded wire pair for transmitting encoder signals, switching control signals, etc. The shielding layer can effectively resist electromagnetic interference in the robot's working environment.

[0031] The data communication unit has impedance-matched differential pairs inside, such as the network cable structure suitable for Gigabit Ethernet, for transmitting high-speed data such as visual images and bus communication.

[0032] The fluid transfer unit has a flexible internal tube wall and is mainly used to transfer compressed air, vacuum, cooling water or hydraulic oil. It can directly replace external pipelines.

[0033] Filler units, including solid or foam fillers, are mainly used to occupy reserved slots and maintain the stability and flatness of the overall cable structure.

[0034] As mentioned above, different combinations of units can flexibly adapt to various needs of industrial robots: for example, a spot welding robot can choose 2 power units + 2 signal units + 1 water-conducting fluid unit; a handling robot can choose 1 power unit + 2 gas and vacuum fluid units respectively; and an assembly robot can choose 1 power unit + 4 signal units + 1 data communication unit.

[0035] Furthermore, the outer contour of the strip component 10 is racetrack-shaped, consisting of two parallel straight edges and two semi-circular arc edges.

[0036] In this way, the straight edge and the positioning groove surface of the sheath can be matched to prevent the strip component 10 from rolling or twisting misalignment inside the sheath, ensuring the positional accuracy before hot pressing. At the same time, when the cable is bent, the stress is evenly distributed along the arc, which significantly improves the bending fatigue life.

[0037] In an optional embodiment, the protective layer includes a protective tube 11 independently disposed on the outer wall of a single functional unit and a flexible buffer layer 12 that simultaneously covers two protective tubes 11, and a first hot melt adhesive layer 13 is disposed on the surface of the flexible buffer layer 12.

[0038] In an optional embodiment, the protective tube 11 is made of a slightly rigid material, such as nylon or PVC, and serves as a medium conduit for industrial robots, such as water pipes or air pipes. The flexible buffer layer 12 is made of a slightly softer material, such as silicone rubber or nitrile rubber.

[0039] It should be understood that the slightly stiffer protective tube provides rigid support for the internal functional units, resisting external compression and impact, while ensuring stable pipe diameter and constant flow when used as a fluid transmission unit, while the slightly softer flexible buffer layer absorbs mechanical stress during bending and buffers friction and collision between adjacent units.

[0040] In this way, the soft buffer layer allows the internal protective tube to slip to a certain extent when bent, avoiding the direct transfer of bending stress to the core structure of the functional unit.

[0041] Furthermore, a tensile core 122 is embedded in the flexible buffer layer 12, and the tensile core 122 is arranged along the axial direction of the two protective tubes 11.

[0042] In a cable chain system, the cable, especially the vertically suspended section, is subjected to axial tension caused by its own weight and acceleration. The tensile core 122, as an independent load-bearing element, bears the main tensile force and protects the internal conductors and signal lines from tensile damage. At the same time, the tensile core 122 is arranged along the axial direction, forming a neutral axis when the cable bends, preventing excessive axial displacement or wrinkling of the flexible buffer layer 12 and the protective tube 11.

[0043] Furthermore, the strip component 10 is configured to be independently prefabricated and continuously produced.

[0044] It should be understood that traditional cables require stocking for every functional combination, resulting in a wide variety of inventory models. In contrast, this solution only requires stocking a limited number of standardized strip components to reduce inventory costs. When delivering an order, the required units can be selected from the inventory and assembled and hot-pressed on-site or in the factory, reducing the delivery cycle from several weeks to several days.

[0045] In addition, the strip components can be independently tested for electrical performance (such as conductor resistance, insulation withstand voltage, and shielding continuity) before assembly. This avoids scrapping the entire cable due to local defects after integrated molding. At the same time, users can replace or upgrade the strip components 10 with specific functions at any time according to changes in site requirements without having to replace the entire cable.

[0046] Combination Figure 1 and Figure 3 As shown, the sheath component 20 includes a first sheath 21 and a second sheath 22 that can be joined together. On the side where the first sheath 21 and the second sheath 22 are joined together, a plurality of first positioning parts 211 and second positioning parts 221 are respectively provided. The first positioning parts 211 and the second positioning parts 221 extend along the length direction of the sheath component 20, so that after the first sheath 21 and the second sheath 22 are joined together, a positioning space for accommodating and limiting the strip component 10 is formed between the first sheath 21 and the second sheath 22. That is, the positioning space is enclosed by the positioning groove after the first sheath and the second sheath are joined together.

[0047] Specifically, in combination Figure 2 and Figure 4 As shown, after the first sheath 21 and the second sheath 22 are joined together, three positioning spaces are formed. The inner side of the first sheath 21 is divided by two first positioning parts 211 to form a first positioning groove 21a, a second positioning groove 21b and a third positioning groove 21c. The inner side of the second sheath 22 is divided by two second positioning parts 221 to form a fourth positioning groove 22a, a fifth positioning groove 22b and a sixth positioning groove 22c.

[0048] Thus, when the first sheath 21 and the second sheath 22 are engaged, the positions of the first positioning groove 21a and the fourth positioning groove 22a correspond, forming a first positioning space for positioning the first strip component 101; the positions of the second positioning groove 21b and the fifth positioning groove 22b correspond, forming a second positioning space for positioning the second strip component 102; and the positions of the third positioning groove 21c and the sixth positioning groove 22c correspond, forming a third positioning space for positioning the third strip component 103.

[0049] Furthermore, at least a portion of the inner surfaces of the first sheath 21 and the second sheath 22 are provided with a second hot melt adhesive layer.

[0050] The second hot-melt adhesive layer and the first hot-melt adhesive layer 13 on the surface of the strip component 10 placed in the positioning space can be fused together under heating and pressure, so that multiple strip components 10 are encapsulated and fixed in the sheath component 20, and a drag chain flat cable with a predetermined functional combination is formed by combining different types and numbers of strip components 10.

[0051] Thus, after the hot melt adhesive of the strip component 10 and the sheath component 20 is fused together, the originally independent strip component 10 and sheath component 20 are bonded into an inseparable whole, so that the cable can be subjected to stress in conjunction with its internal and external parts when subjected to bending and torsion.

[0052] In an optional embodiment, combined with Figure 1 , Figure 2 and Figure 4 As shown, sealing portions 23 are provided on both sides of the first sheath 21 and the second sheath 22. The sealing portions 23 include protrusions 232 on both sides of the first sheath 21 and recesses 231 on both sides of the second sheath 22.

[0053] Specifically, after the surface of the concave and convex portion 232 is coated with hot melt adhesive, when the first sheath 21 and the second sheath 22 are aligned, the concave and convex portion 232 is inserted into the recessed portion 231, so that the hot melt adhesive adheres to the two side edges of the first sheath 21 and the second sheath 22, so that the two side edges of the first sheath 21 and the second sheath 22 are tightly and firmly connected.

[0054] Furthermore, the first hot melt adhesive layer 13 and the second hot melt adhesive layer include a thermoplastic hot melt adhesive layer, which is configured to be solid at room temperature and have sliding properties, be able to melt and flow when heated to a predetermined temperature, and solidify to form an adhesive after cooling.

[0055] As an optional implementation, the first hot melt adhesive layer 13 and the second hot melt adhesive layer may be selected from one of ethylene-vinyl acetate copolymer (EVA) based hot melt adhesive, polyamide (PA) hot melt adhesive, or polyurethane (PUR) hot melt adhesive. To ensure reversible repairability, the selective softening point (ring and ball method) of the hot melt adhesive should be controlled between 80°C and 120°C to ensure that the cable maintains adhesive rigidity under normal operating conditions (typically not exceeding 70°C), while allowing it to reach a molten state using a common hot air blower during maintenance without damaging the insulation layer of the internal functional unit 10a (the insulation layer is typically heat-resistant above 150°C).

[0056] Thus, the strip component 10 has a smooth surface and low coefficient of friction at room temperature, and can be easily inserted into the positioning groove of the sheath when necessary. Even cables several meters long can be quickly assembled without lubricant. Furthermore, reheating can soften the adhesive layer, allowing the sheath to be pried open and the unit to be replaced. After cooling, it can be re-bonded to meet the needs of on-site maintenance.

[0057] In a specific embodiment, the first positioning part 211 is a first protrusion structure constructed on the inner wall of the first sheath 21, and the second positioning part 221 is a second protrusion structure constructed on the inner wall of the second sheath 22. The cross-sectional shape of the first protrusion structure and the second protrusion structure is semi-circular, and the interior of the second protrusion structure is provided with a cavity.

[0058] It should be understood that the semi-circular raised structure has a self-guiding function when the cover is closed. In this way, even if there is a slight misalignment during installation, the arc surface can guide the upper and lower sheaths to automatically align. At the same time, when the semi-circular surface contacts the arc corner of the strip component, the contact stress is evenly distributed, avoiding the indentation damage of the edge corner to the surface of the strip component.

[0059] Furthermore, the second hot-melt adhesive layer includes strip-shaped adhesive portions distributed along the length of the sheath component 20 on the inner walls of the first protrusion structure, the second protrusion structure, the first sheath 21, and the second sheath 22, with at least four strip-shaped adhesive portions provided in each positioning space.

[0060] Specifically, the four strip-shaped adhesive parts are located at the four corners of the positioning space, fixing the strip-shaped components inside the sheath from four directions. This effectively prevents the strip-shaped components from rotating axially when twisted. At the same time, the strip-shaped adhesive parts allow the sheath to be pried open by only heating the corresponding adhesive points during maintenance, without having to heat the entire cable.

[0061] Furthermore, the first sheath 21 is provided with at least one buffer portion 25, which provides elastic deformation when the cable is bent. The second sheath 22 is provided with at least one reinforcing portion 24, which includes reinforcing ribs periodically arranged along the length of the cable to resist deformation of the sheath component 20 in the width direction. The first sheath 21 serves as the inner side in the bending direction, and the second sheath 22 serves as the outer side in the bending direction. It should be understood that when the cable bends in the cable chain, the inner side is subjected to compressive stress, and the outer side is subjected to tensile stress. The inner buffer portion provides space for compressive deformation and absorbs compressive stress, while the outer reinforcing portion provides tensile resistance to resist tensile deformation.

[0062] Furthermore, the racetrack-shaped strip component 10, through its straight edge engaging with the positioning grooves (21a, 21b, 21c), effectively transmits the torsional torque to the sheath with the reinforcing portion 24, achieving rigid torsional resistance. Simultaneously, the four strip-shaped adhesive portions (second hot-melt adhesive layers) located at the corners of the positioning space form a discontinuous adhesive surface. Under extreme torsion, this non-full-circumference adhesive allows for minute shear elastic deformation between the strip component 10 and the sheath, thus preventing stress concentration at the core root. When the cable is torsioned, the outer reinforcing portion provides the main torsional rigidity, while the inner buffer portion allows for a certain degree of deformation to absorb torsional energy, achieving a significant improvement in torsional life compared to integrated extruded cables.

[0063] Optionally, the buffer portion 25 includes a plurality of perforated structures, which enable the first sheath to absorb compressive energy through deformation of the perforations when under pressure.

[0064] Optionally, the reinforcing ribs are mesh-like reinforcing ribs. The mesh structure is isotropically reinforced while retaining flexibility, resisting tension and allowing bending. The intersections of the mesh serve as stress dispersion points to prevent crack propagation.

[0065] Furthermore, in combination Figure 5 As shown, along the length of the cable, the reinforcing part 24 includes a first reinforcing region 24a, a second reinforcing region 24b, and a third reinforcing region 24c. The strength of the first reinforcing region 24a and the third reinforcing region 24c is higher than that of the second reinforcing region 24b.

[0066] Thus, the first reinforcing region 24a and the third reinforcing region 24c are located at both ends of the cable, close to the connector. These regions bear greater tensile and torsional stresses and have higher strength to provide protection. The second reinforcing region 24b is located in the middle of the cable and mainly bears uniformly distributed bending stresses. Appropriately reducing its strength can maintain overall flexibility.

[0067] In an optional embodiment, the first reinforcing region 24a and the third reinforcing region 24c extend to a range of 500mm from the cable end joints. Since torsional stress concentration is most likely to occur near the joints in the drag chain cable, increasing the density of the mesh-like reinforcing ribs can effectively prevent bulging deformation of the sheath in the width direction. The middle second reinforcing region 24b, by increasing the mesh spacing and in conjunction with the perforated buffer section 25 on the first sheath, ensures the cable's bending compliance during the drag chain's reciprocating motion.

[0068] In other embodiments, the first sheath 21 and the second sheath 22 can be formed by extrusion molding, co-extrusion molding and injection molding.

[0069] Specifically, when processed by extrusion molding, the reinforcing ribs of the reinforcing part 24 are integral raised stripes on the inner or outer wall of the sheath, which can be continuous longitudinal ribs, circumferential ribs, or spiral ribs formed by rotating the die head.

[0070] Specifically, during co-extrusion molding, the reinforcing ribs of the reinforcing part 24 are continuous fiber woven meshes embedded inside the sheath substrate. The fiber mesh itself has a grid-like structure, and after being embedded, it forms an invisible reinforcing layer inside the sheath without changing the flatness of the inner and outer surfaces of the sheath.

[0071] Specifically, during injection molding, the reinforcing ribs of the reinforcing part 24 can be designed as three-dimensional complex structures, such as X-shaped intersecting grids, honeycomb structures, variable cross-section ribs, or even metal reinforcing sheets or fiber-reinforced plastic inserts can be embedded during injection molding to achieve local ultra-high strength.

[0072] Combination Figure 6As shown, the reinforcing rib is a reinforcing structure formed on the inner wall of the sheath, consisting of alternating planar regions 241 and cross-grid regions 242. The planar regions 241 have a higher strength than the cross-grid regions 242, making the cross-grid regions 242 easier to bend, while the planar regions 241 provide the cable with torsional resistance.

[0073] In some embodiments, along the cable length direction, the first reinforcing region 24a and the third reinforcing region 24c are respectively arranged in the stress-sensitive areas near the robot base end and the end effector end (e.g., within 0.5~1m from the end). The mesh density of the reinforcing rib 24 is 20~40% higher than that of the second reinforcing region 24b, and the area ratio of the planar region 241 is larger, aiming to provide extremely high radial deformation stiffness and prevent the sheath from collapsing or twisting during high-speed swinging at the end. The middle second reinforcing region 24b retains a higher mesh ratio to maintain the cable's flexibility within the cable chain bending radius.

[0074] {Example 2} A second aspect of this invention provides a technical solution: a method for manufacturing the above-mentioned segmented anti-torsion drag chain flat cable, comprising the following steps: Step S1: Prefabricate strip component 10, select at least two functional units according to functional requirements, extrude a protective layer on the outside of the functional units, and form a first hot melt adhesive layer 13 on the surface of the protective layer to make strip component with the same outer contour shape, and roll it up for later use. Step S2: The prefabricated sheath component 20 is prepared by extrusion molding or injection molding to produce the first sheath and the second sheath respectively, and a second hot melt adhesive layer is formed on at least a portion of the inner surface of the first sheath and the second sheath. Step S3: According to the functional requirements of the target cable, select the required type and quantity of strip components 10 from the prefabricated strip components 10, and place the selected strip components 10 into the first positioning part 211 of the first sheath 21 in sequence, so that each strip component 10 is arranged in a straight line along the width direction of the first sheath 21. Step S4: Cover the first sheath 21 with the second sheath 22 and align it with the first sheath 21 so that the second positioning part 221 of the second sheath 22 is aligned with each strip component 10; Step S5: Apply pressure and heat to the laminated structure of the first sheath 21 and the second sheath 22. The heating temperature is controlled at a temperature that melts the first hot melt adhesive layer 13 and the second hot melt adhesive layer but is lower than the softening temperature of the internal functional unit of the strip component, so that the first hot melt adhesive layer 13 and the second hot melt adhesive layer are fused together. Step S6: Cooling under pressure to solidify the molten hot melt adhesive layer, and encapsulating and fixing multiple strip components between the first sheath 21 and the second sheath 22 to form a segmented anti-torsion drag chain flat cable.

[0075] Specifically, taking the preparation of drag chain flat cables for spot welding robots as an example, the specific process is as follows: First, select 2 power transmission units (for welding clamp power supply), 2 signal control units (for welding timing control), 1 fluid transmission unit (for welding clamp cooling water) and 1 filling unit (for filling voids) from the prefabricated inventory. All units have completed the protective layer coating and the first hot melt adhesive layer 13 coating.

[0076] Next, select a suitable 3-slot first protective sleeve (2.5 meters in length, matching the robot arm length), and place the three strip components 10 into the positioning slots of the first protective sleeve 21 in sequence, arranging them in a line. Then, cover and align the second protective sleeve 22, making the upper and lower protective sleeves fit together.

[0077] The entire laminated structure is fed into a continuous hot press roller assembly, with the roller temperature set at 100℃, linear speed at 1m / min, and roller pressure at 0.4MPa, causing the first and second hot melt adhesive layers to melt and fuse together. After hot pressing, the cable enters a cooling section, where it is air-cooled to room temperature under maintained pressure, allowing the hot melt adhesive to solidify and ultimately forming an integrated 3-core modular drag chain flat cable. 200mm unpressed sections are left at both ends of the cable for subsequent sheath stripping and connector assembly.

[0078] In an optional embodiment, in step S2 above, the preparation of the first sheath 21 and the second sheath 22 includes at least one of the following methods: Extrusion molding method: The thermoplastic elastomer material is extruded by an extruder, and after extrusion, a periodically distributed texture structure is formed on the inner surface of the first sheath 21 and the second sheath 22. The texture structure includes at least one of pits, microgrooves or protrusions.

[0079] As mentioned above, extrusion molding has high production efficiency and is suitable for continuous production of large batches of long-sized sheaths, but the inner surface texture structure requires subsequent processing or is formed by die head texture, which limits its complexity.

[0080] Co-extrusion molding method: Two or more extruders are used to co-extrude through a composite die. While extruding the substrate layer of the first sheath 21 or the second sheath 22, a continuously distributed fiber woven mesh is pre-embedded inside the substrate layer to form the reinforcing part 24.

[0081] As mentioned above, co-extrusion molding can directly embed a continuous fiber reinforcement layer during the extrusion process, resulting in good tensile and torsional strength, a strong bond between the reinforcement layer and the substrate, and no risk of peeling.

[0082] Injection molding method: The first sheath 21 and the second sheath 22 are prepared separately by injection molding process, so that the inner surfaces of the first sheath 21 and the second sheath 22 form a periodically distributed texture structure, the texture structure including at least one of pits, microgrooves or protrusions.

[0083] As mentioned above, injection molding offers a high degree of shape freedom and can mold complex three-dimensional structures.

[0084] Furthermore, it also includes a repair and replacement step: when it is necessary to replace the damaged strip component 10, the sheath surface of the corresponding area of ​​the strip component 10 to be replaced is locally heated to a temperature above the softening temperature of the first hot melt adhesive layer 13 and the second hot melt adhesive layer. After the hot melt adhesive layer softens, use a tool to pry open the seam between the first sheath 21 and the second sheath 22 to expose the damaged strip component 10. Remove the damaged strip component and insert a new strip component 10 of the same type and specifications; The first sheath 21 and the second sheath 22 are resealed, and pressure and heat are applied to the repair area again to re-fuse the hot melt adhesive layer. Repairs were completed after cooling.

[0085] In an optional example, during the actual repair process, the operator uses an infrared heating device to locally irradiate the joint gap between the first sheath 21 and the second sheath 22. When the surface temperature reaches approximately 100 degrees Celsius, the hot melt adhesive layer transforms into a highly elastic state. At this point, a specially designed flat wedge tool is inserted into the recess 231, allowing for non-destructive disassembly without damaging the sheath substrate. When replacing the corresponding strip component 10, the corresponding area is locally irradiated to transform the hot melt adhesive layer into a highly elastic state. Then, the strip component 10 is removed, replaced, and the sheaths are reassembled and pressure is applied. The hot melt adhesive, due to its thermal reversibility, re-establishes intermolecular forces, achieving a repaired seal that is no less than the original factory standard.

[0086] Therefore, while traditional cables require the entire cable to be scrapped if a single core wire breaks, this solution only requires local heating to replace the damaged unit, reducing maintenance costs by more than 80%. Furthermore, when new functions such as vision sensors are needed, the sheath can be pried open by local heating to insert a new data unit, replacing the original filler, thus upgrading the cable's functionality without requiring a complete replacement.

[0087] While the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the invention. Those skilled in the art can make various modifications and refinements without departing from the spirit and scope of the invention. Therefore, the scope of protection of the present invention shall be determined by the claims.

Claims

1. A segmented anti-torsion drag chain flat cable, characterized in that, include: At least two strip-shaped components (10), each strip-shaped component (10) comprising at least two functional units and a protective layer extruded over the functional units, the strip-shaped components (10) being configured as strip-shaped members extending along the length direction, and the protective layers of all the strip-shaped components (10) being configured to have the same outer contour shape; The sheath component (20) includes a first sheath (21) and a second sheath (22) that can be joined together. On the side where the first sheath (21) and the second sheath (22) are joined together, a plurality of first positioning parts (211) and second positioning parts (221) are respectively provided. The first positioning parts (211) and the second positioning parts (221) extend along the length direction of the sheath component (20), so that after the first sheath (21) and the second sheath (22) are joined together, a positioning space for accommodating and limiting the strip component (10) is formed between the first sheath (21) and the second sheath (22). The strip component (10) is covered with a first hot melt adhesive layer (13), and the strip component (10) is configured to be independently prefabricated and continuously produced. The inner surfaces of the first sheath (21) and the second sheath (22) are provided with a second hot melt adhesive layer in at least a portion of the area. The second hot melt adhesive layer and the first hot melt adhesive layer (13) on the surface of the strip component (10) placed in the positioning space can be fused together under heating and pressure conditions, so that multiple strip components (10) are encapsulated and fixed in the sheath component (20). By combining different types and numbers of strip components (10), a drag chain flat cable with a predetermined functional combination can be formed. Among them, multiple strip-shaped components (10) are arranged in a straight line along the width direction of the sheath component (20).

2. The segmented anti-torsion drag chain flat cable according to claim 1, characterized in that, The functional unit includes at least one of the following types: A power transmission unit, comprising at least one multi-strand stranded conductor; The signal control unit includes at least one twisted-pair shielded wire pair; The data communication unit has impedance-matched differential pairs inside. A fluid transport unit with flexible internal pipe walls; Filling units, including solid or foamed fillers; Furthermore, the outer contour of the strip component (10) is racetrack-shaped, consisting of two parallel straight edges and two semi-circular arc edges.

3. The segmented anti-torsion drag chain flat cable according to claim 1, characterized in that, The protective layer includes a protective tube (11) independently disposed on the outer wall of a single functional unit and a flexible buffer layer (12) covering both protective tubes (11) at the same time. The first hot melt adhesive layer (13) is disposed on the surface of the flexible buffer layer (12). Among them, a tensile core (122) is embedded in the flexible buffer layer (12), and the tensile core (122) is arranged along the axial direction of the two protective tubes (11).

4. The segmented anti-torsion drag chain flat cable according to claim 3, characterized in that, The first hot melt adhesive layer (13) and the second hot melt adhesive layer include a thermoplastic hot melt adhesive layer, which is configured to be solid at room temperature and have sliding properties, be able to melt and flow when heated to a predetermined temperature, and solidify to form an adhesive after cooling.

5. The segmented anti-torsion drag chain flat cable according to claim 1, characterized in that, The first positioning part (211) is a first protrusion structure constructed on the inner wall of the first sheath (21), and the second positioning part (221) is a second protrusion structure constructed on the inner wall of the second sheath (22). The cross-sectional shape of the first protrusion structure and the second protrusion structure is semi-circular, and the interior of the second protrusion structure is provided with a cavity. The second hot melt adhesive layer includes strip-shaped adhesive portions distributed along the length of the sheath component (20) on the inner walls of the first protrusion structure, the second protrusion structure, the first sheath (21), and the second sheath (22), with at least four of the strip-shaped adhesive portions provided in each positioning space.

6. The segmented anti-torsion drag chain flat cable according to claim 5, characterized in that, The first sheath (21) is provided with at least one buffer portion (25) for providing elastic deformation when the cable is bent, and the second sheath (22) is provided with at least one reinforcing portion (24) including reinforcing ribs arranged periodically along the length of the cable to resist deformation of the sheath component (20) in the width direction.

7. The segmented anti-torsion drag chain flat cable according to claim 6, characterized in that, The buffer section (25) includes a plurality of hole structures, and the reinforcing ribs are mesh-like reinforcing ribs, and along the length direction of the cable, they include a first reinforcing region (24a), a second reinforcing region (24b) and a third reinforcing region (24c), the strength of the first reinforcing region (24a) and the third reinforcing region (24c) is higher than the strength of the second reinforcing region (24b).

8. The method for manufacturing a segmented anti-torsion drag chain flat cable according to any one of claims 1-7, characterized in that, Includes the following steps: Step S1: Prefabricate strip components (10), select at least two functional units according to functional requirements, extrude a protective layer on the outside of the functional units, and form a first hot melt adhesive layer (13) on the surface of the protective layer to make strip components with the same outer contour shape, and roll them up for later use; Step S2: Prefabricated sheath component (20), the first sheath and the second sheath are prepared by extrusion molding or injection molding respectively, and a second hot melt adhesive layer is formed on at least a portion of the inner surface of the first sheath and the second sheath. Step S3: According to the functional requirements of the target cable, select the required type and quantity of strip components (10) from the prefabricated strip components (10), and place the selected strip components (10) into the first positioning part (211) of the first sheath (21) in sequence, so that each strip component (10) is arranged in a straight line along the width direction of the first sheath (21); Step S4: Cover the first sheath (21) with the second sheath (22) and align it with the first sheath (21) so that the second positioning part (221) of the second sheath (22) is aligned with each strip component (10); Step S5: Apply pressure and heat to the laminated structure of the first sheath (21) and the second sheath (22), and control the heating temperature to melt the first hot melt adhesive layer (13) and the second hot melt adhesive layer but below the softening temperature of the internal functional unit of the strip component, so that the first hot melt adhesive layer (13) and the second hot melt adhesive layer fuse together. Step S6: Cooling under pressure to solidify the molten hot melt adhesive layer, and encapsulating and fixing multiple strip components between the first sheath (21) and the second sheath (22) to form a segmented anti-torsion drag chain flat cable.

9. The method for manufacturing the segmented anti-torsion drag chain flat cable according to claim 8, characterized in that, In step S2, the preparation of the first sheath (21) and the second sheath (22) includes at least one of the following methods: Extrusion molding method: The thermoplastic elastomer material is extruded by an extruder, and after extrusion, a periodically distributed texture structure is formed on the inner surface of the first sheath (21) and the second sheath (22), the texture structure including at least one of pits, microgrooves or protrusions; Co-extrusion molding method: Two or more extruders are used to co-extrude through a composite die. While extruding the substrate layer of the first sheath (21) or the second sheath (22), a continuously distributed fiber woven mesh is pre-embedded inside the substrate layer to form a reinforcing part (24). Injection molding method: The first sheath (21) and the second sheath (22) are prepared separately by injection molding process, so that the inner surfaces of the first sheath (21) and the second sheath (22) form a periodically distributed texture structure, the texture structure including at least one of pits, microgrooves or protrusions.

10. The method for manufacturing the segmented anti-torsion drag chain flat cable according to claim 8, characterized in that, It also includes a repair and replacement step: when it is necessary to replace a damaged strip component (10), the sheath surface of the area corresponding to the strip component (10) to be replaced is locally heated to a temperature above the softening temperature of the first hot melt adhesive layer (13) and the second hot melt adhesive layer; After the hot melt adhesive layer softens, use a tool to pry open the seam between the first sheath (21) and the second sheath (22) to expose the damaged strip component (10); Remove the damaged strip component and insert a new strip component of the same type and specifications (10). Re-close the first sheath (21) and the second sheath (22), and apply pressure and heat to the repair area again to re-fuse the hot melt adhesive layer; Repairs were completed after cooling.

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