Multifunctional high-toughness robot cable and preparation process thereof

Abstract

The invention discloses a multifunctional high-toughness robot cable and a preparation process thereof, and relates to the technical field of cables, the multifunctional high-toughness robot cable comprises a main power supply cable unit, and the main power supply cable unit comprises a conductor assembly, an insulating layer, a shielding layer, a filling layer, an isolating layer and a sheath layer which are sequentially arranged from inside to outside; the conductor assembly comprises a plurality of conductor wires made of a graphene reinforced silver-plated copper alloy material, and the diameter of a single conductor wire is 0.05-0.10 mm; the plurality of conductor wires form a double-layer stranded structure through bunch stranding and compound stranding, the bunch stranding pitch is 10-15mm, the compound stranding pitch is 20-30mm, and the stranding directions of bunch stranding and compound stranding are opposite; the insulating layer is of a silicon rubber and XLPE gradient composite structure and sequentially comprises a silicon rubber inner layer, a gradient transition layer and an XLPE outer layer from inside to outside. The thickness of the silicon rubber inner layer is 0.3-0.5 mm, the thickness of the XLPE outer layer is 0.2-0.3 mm, and the thickness of the gradient transition layer is 0.05-0.1 mm; and the functional layer is arranged corresponding to the periphery of the main power supply cable unit so as to jointly form the multifunctional high-toughness robot cable structure. The cable has the characteristics of high toughness, multiple functions and high marketization adaptability.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and in particular to multifunctional high-toughness robot cables and their manufacturing process. Background Technology

[0002] With the explosive growth of the global robotics industry, cables, as the "blood vessels and nerves" of robots, directly determine the reliability and intelligence level of equipment. It is predicted that the global humanoid robot market will reach US$16.57 billion in 2031, with China accounting for 32.7%, creating an urgent demand for high-performance cables.

[0003] The existing technology has significant drawbacks: First, it lacks toughness. Traditional cables use Class 5 conductors and ordinary PVC sheaths, with a bending life of less than 5 million cycles, which cannot meet the high-frequency joint movement requirements of humanoid robots. Second, it has limited functionality. Most products can only transmit power or signals and lack status monitoring capabilities, making them prone to downtime due to hidden faults. Third, it has poor market adaptability. International brands mostly use standard specifications, with customization cycles as long as 3 months and high costs, while domestic products suffer from unstable performance and inconsistent testing standards.

[0004] For example, Germany's igus Chainflex cable boasts a bending life of up to 20 million cycles, but it lacks integrated sensing functionality and its unit price is three times that of domestically produced products. While the flexible cable developed by Far East Cable in China achieves tens of millions of bends, it still lags behind in terms of lightweight design and anti-interference performance. Furthermore, the industry lacks unified dynamic performance testing standards, leading to inconsistent product quality and hindering marketization. Therefore, developing robot cable technology that combines high toughness, multifunctionality, and market adaptability has become an urgent priority. Summary of the Invention

[0005] In view of this, the present invention proposes a multifunctional high-toughness robot cable and its manufacturing process, aiming to solve at least one of the above-mentioned technical problems.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] This invention provides a multifunctional, high-strength robot cable, comprising: The main power cable unit includes, from the inside out, a conductor assembly, an insulation layer, a shielding layer, a filling layer, an isolation layer, and a sheath layer; The conductor assembly includes multiple conductor wires made of graphene-reinforced silver-plated copper alloy, each conductor wire having a diameter of 0.05-0.10 mm; the multiple conductor wires are bundled and twisted together to form a double-layer twisted structure, with a bundled pitch of 10-15 mm and a twisted pitch of 20-30 mm, and the bundled and twisted wires are twisted in opposite directions. The insulating layer is a gradient composite structure of silicone rubber and XLPE, consisting of an inner silicone rubber layer, a gradient transition layer, and an outer XLPE layer from the inside out; the thickness of the inner silicone rubber layer is 0.3-0.5 mm, the thickness of the outer XLPE layer is 0.2-0.3 mm, and the thickness of the gradient transition layer is 0.05-0.1 mm. The functional layer is arranged around the main power cable unit to form a multifunctional, high-toughness robot cable structure.

[0008] The multifunctional high-toughness robot cable provided by this invention uses graphene-reinforced silver-plated copper alloy for the conductor assembly, controlling the diameter of each filament to be only 0.05-0.10mm. It also features a double-layer stranding structure with a bundled pitch of 10-15mm and a re-stretched pitch of 20-30mm in opposite directions, giving the conductor high conductivity, excellent fatigue resistance, and ultra-high flexibility. This allows it to withstand high-frequency bending and torsion at robot joints without core breakage. The insulation layer uses a composite structure of a silicone rubber inner layer, a gradient transition layer, and an XLPE outer layer. The silicone rubber inner layer provides high elasticity and low-temperature flexibility to absorb bending stress, the XLPE outer layer ensures heat resistance and high insulation strength, and the gradient transition layer eliminates abrupt changes in interlayer physical properties through gradual compositional changes, effectively preventing interface peeling and cracking caused by differences in thermal expansion, thus maintaining stable electrical and mechanical properties over a wide temperature range. Mechanical properties: The shielding layer, located outside the insulation layer, resists strong electromagnetic interference from equipment such as frequency converters and motors, ensuring stable transmission of control signals; the filler layer maintains the cable's roundness and distributes stress evenly, while the isolation layer prevents adhesion or wear between the filler layer and the sheath layer, ensuring that each layer can slide relatively freely during dynamic bending, further improving bending fatigue life; the outermost sheath layer provides reliable external protection against oil, wear, and chemical corrosion, enabling it to adapt to the harsh working environment of industrial robots; and the functional layer located around the main power cable unit integrates power transmission with signal and communication functions, significantly reducing cable space occupation and lowering the inertial load on robot joints, ultimately achieving excellent levels in terms of high flexibility, high reliability, strong anti-interference, compact structure, and long lifespan.

[0009] As a further improvement to the above technical solution, the functional layer includes a video cable unit, a communication control cable unit, a multi-channel digital communication optoelectronic sensing cable unit, an aramid-reinforced filling unit, a flexible cable tie sleeve layer, and a flexible sheath layer. The video cable unit, the communication control cable unit, the multi-channel digital communication optoelectronic sensing cable unit, and the two sets of main power cable units are arranged side by side inside the flexible cable tie sheath along the length direction of the flexible cable tie sheath. The outer peripheral walls of the video cable unit, the communication control cable unit, the multi-channel digital communication optoelectronic sensing cable unit, and the two sets of main power cable units are filled with the aramid reinforcing filler units between the outer peripheral walls of the corresponding flexible cable tie sheath and the inner peripheral walls of the flexible cable tie sheath. The flexible sheath layer coaxially wraps around the outer periphery of the aramid reinforcing filler units, thereby forming a multifunctional high-toughness robot cable structure.

[0010] As a further improvement to the above technical solution, the video cable unit includes a video unit, an aramid-reinforced filling unit, a flexible cable tie sleeve, and a protective sleeve. The video unit and the two sets of main power cable units are arranged side by side along the length of the flexible cable tie sleeve inside the flexible cable tie sleeve. The outer peripheral wall of the video unit and the two sets of main power cable units is filled with the aramid-reinforced filling unit between the corresponding inner peripheral wall of the flexible cable tie sleeve. The protective sleeve is coaxially wrapped around the outer periphery of the flexible cable tie sleeve.

[0011] As a further improvement to the above technical solution, the communication control cable unit includes a communication control unit, an aramid-reinforced filling unit II, a flexible cable tie sleeve II, and a protective sleeve II. The communication control unit and the three main power cable units are arranged side by side along the length of the flexible cable tie sleeve two inside the flexible cable tie sleeve two. The outer peripheral wall of the communication control unit and the three main power cable units and the inner peripheral wall of the corresponding flexible cable tie sleeve two are filled with the aramid reinforced filling unit two. The protective sleeve two is coaxially wrapped around the outer periphery of the flexible cable tie sleeve two.

[0012] As a further improvement to the above technical solution, the multi-channel digital communication optoelectronic sensing cable unit includes a multi-channel digital communication unit, an optoelectronic sensing unit, an aramid-reinforced filling unit, a flexible cable tie sheath, and a protective sheath. The multi-channel digital communication unit, the two sets of photoelectric sensing units, and the four sets of main power cable units are arranged side by side inside the flexible cable tie sleeve three along the length direction of the flexible cable tie sleeve three. The outer peripheral wall of the multi-channel digital communication unit, the two sets of photoelectric sensing units, and the four sets of main power cable units is filled with the aramid reinforcing filling unit three between the inner peripheral wall of the corresponding flexible cable tie sleeve three. The protective sleeve three is coaxially wrapped around the outer periphery of the flexible cable tie sleeve three.

[0013] As a further improvement to the above technical solution, the sheath layer is made of polyether-type thermoplastic polyurethane (TPU) material modified with nano-silica; wherein the particle size of the nano-silica is 50-100nm, and the amount added accounts for 5%-8% of the total mass of the sheath material.

[0014] As a further improvement to the above technical solution, the radial cross-section of the sheath layer is an asymmetrical structure, and its thickness is gradually distributed along the circumference; the tensile strength of the sheath layer is ≥18MPa, and the elongation at break is ≥350%.

[0015] As a further improvement to the above technical solution, the main power cable unit further includes a flexible sensor array, which includes a PT1000 temperature sensor, an optical fiber strain sensor, and a dedicated signal bus. The PT1000 temperature sensor and the optical fiber strain sensor are embedded and braided between the shielding layer and the filling layer. The spacing between the PT1000 temperature sensor and the optical fiber strain sensor along the length of the main power cable unit is 300-500mm. The dedicated signal bus is embedded between the shielding layer and the filling layer, with one end electrically connected to the PT1000 temperature sensor and the optical fiber strain sensor, and the other end extending along the length of the main power cable unit to the end of the main power cable unit to form a connection end for the robot control system.

[0016] Another aspect of the present invention provides a method for preparing a multifunctional high-toughness robot cable, comprising the following steps: S1: Conductor assembly preparation; graphene powder is uniformly mixed into silver-plated copper alloy melt at a mass ratio of 0.5%-1.0%, and multiple conductor wires are drawn by continuous casting and rolling process; the conductor wires are subjected to continuous annealing treatment, and then bundled and re-stranded using a multi-head stranding machine to produce a conductor assembly with a double-layer stranded structure; wherein the bundled stranding pitch is 10-15mm, the re-stranding pitch is 20-30mm, and the stranding directions of the bundled stranding and re-stranding are opposite; S2: Insulation layer molding; an insulation layer is coated around the conductor assembly using a double-layer co-extrusion device. Specifically, the inner silicone rubber is extruded at 120-140℃ to form a silicone rubber inner layer with a thickness of 0.3-0.5mm, and the outer XLPE is extruded at 180-200℃ to form an XLPE outer layer with a thickness of 0.2-0.3mm. Through gradient temperature control, the silicone rubber inner layer and the XLPE outer layer diffuse or cross-link at the interface to form a gradient transition layer with a thickness of 0.05-0.1mm. S3: A shielding layer, a filling layer, an isolation layer, and a sheath layer are sequentially wrapped around the insulation layer to obtain the main power cable unit; S4: Set a functional layer; Set a functional layer around the main power cable unit to obtain a multifunctional high-toughness robot cable.

[0017] As a further improvement to the above technical solution, the shielding layer in step S3 specifically includes: adopting a composite structure of tin-plated copper wire braiding and aluminum foil, with a braiding density of not less than 95% and an aluminum foil overlap rate of not less than 30%, forming a shielding layer with a shielding attenuation of not less than 90dB, and a test frequency range of 1MHz-1GHz; Before setting the filling layer in step S3, the method further includes embedding a flexible sensor array between the shielding layer and the filling layer: PT1000 temperature sensor and fiber optic strain sensor are arranged at intervals of 300-500mm along the length of the main power cable unit, fixed to the outer surface of the shielding layer by braiding process, and one end of the dedicated signal bus is electrically connected to the PT1000 temperature sensor and fiber optic strain sensor, and the other end extends to the end of the main power cable unit to form the connection end of the robot control system. In step S3, the extrusion of the sheath layer adopts a low-temperature extrusion process. The nano-silica modified polyether thermoplastic polyurethane (TPU) material is extruded at 160-180°C, and the sheath layer after molding is formed into an asymmetric thickness structure in the radial section by using a shaped mold.

[0018] As can be seen from the above technical solutions, compared with the prior art, the present invention discloses a multifunctional high-toughness robot cable and its manufacturing process, which has the following advantages and beneficial effects.

[0019] 1. The conductor assembly of the present invention has ultra-high flexibility and fatigue resistance: by using graphene-reinforced silver-plated copper alloy material and controlling the diameter of the single wire to 0.05-0.10mm, combined with a double-layer structure of 10-15mm bundle pitch and 20-30mm double strand pitch with opposite stranding directions, the conductor has both high conductivity and excellent fatigue resistance, and can withstand high-frequency bending and torsion at robot joints without core breakage, significantly improving the dynamic service life of the cable.

[0020] 2. This invention has stable electrical and mechanical properties over a wide temperature range: The insulating layer adopts a composite structure of a silicone rubber inner layer, a gradient transition layer, and an XLPE outer layer. The silicone rubber inner layer provides high elasticity and low-temperature flexibility to absorb bending stress, the XLPE outer layer ensures heat resistance and high insulation strength, and the gradient transition layer eliminates abrupt changes in interlayer physical properties through gradual changes in composition, effectively preventing interface peeling and cracking caused by differences in thermal expansion, thereby maintaining stable electrical and mechanical properties over a wide temperature range.

[0021] 3. This invention achieves a high degree of integration and compact design: By setting up functional layers such as video cable unit, communication control cable unit and multi-channel digital communication photoelectric sensing cable unit around the main power cable unit, the integrated design of multiple functions such as power transmission, signal and communication is realized, which greatly reduces the space occupied by the cable, reduces the inertial load of the robot joint, and meets the stringent requirements of industrial robots for compact cable structure.

[0022] 4. This invention enhances external protection and has strong environmental adaptability: The sheath layer is made of polyether-type thermoplastic polyurethane (TPU) material modified with nano-silica, and an asymmetric thickness structure is formed by a special mold. Combined with its mechanical properties of tensile strength ≥18MPa and elongation at break ≥350%, it provides excellent oil resistance, wear resistance and chemical corrosion resistance, enabling the cable to adapt to the harsh working environment of industrial robots.

[0023] 5. This invention features intelligent self-sensing and high reliability: A flexible sensor array, consisting of a PT1000 temperature sensor, an optical fiber strain sensor, and a dedicated signal bus, is embedded between the shielding and filling layers of the main power cable unit. This array can monitor the temperature and strain status of the cable in real time during operation and transmit the signals to the robot control system, achieving online monitoring and early warning of the cable's health status, significantly improving the overall reliability of the system. Through functional integration, it achieves a three-in-one function of "power transmission - signal interaction - status monitoring," solving the pain point of difficult early warning of traditional cable faults and effectively reducing robot downtime for maintenance. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0025] Figure 1 This is a schematic diagram of the overall structure of the multifunctional high-toughness robot cable of the present invention.

[0026] Figure 2 This is a schematic diagram of the main power cable unit of the multifunctional high-toughness robot cable of the present invention.

[0027] Figure 3 This is a schematic diagram of the video cable unit of the multifunctional high-toughness robot cable of the present invention.

[0028] Figure 4 This is a schematic diagram of the communication control cable unit of the multifunctional high-toughness robot cable of the present invention.

[0029] Figure 5 This is a schematic diagram of the multi-channel digital communication unit of the multifunctional high-toughness robot cable of the present invention.

[0030] In the diagram: 1. Main power cable unit; 11. Conductor assembly; 12. Insulation layer; 13. Shielding layer; 14. Filling layer; 15. Isolation layer; 16. Sheath layer; 2. Video cable unit; 21. Video unit; 22. Aramid reinforced filler unit one; 23. Flexible cable tie sleeve layer one; 24. Protective sleeve layer one; 3. Communication control cable unit; 31. Communication control unit; 32. Aramid reinforced filler unit two; 33. Flexible cable tie sleeve layer two; 34. Protective sleeve layer two; 4. Multi-channel digital communication photoelectric sensor cable unit; 41. Multi-channel digital communication unit; 42. Photoelectric sensor unit; 43. Aramid reinforced filler unit three; 44. Flexible cable tie sleeve layer three; 45. Protective sleeve layer three; 5. Aramid reinforced filler unit; 6. Flexible cable tie sleeve layer; 7. Flexible sheath layer. Detailed Implementation

[0031] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0032] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0033] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0034] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0035] According to embodiments of the present invention, such as Figures 1 to 5 As shown, the multi-functional high-toughness robot cable includes a main power cable unit 1 and a functional layer.

[0036] The main power cable unit 1 includes, from the inside out, a conductor assembly 11, an insulation layer 12, a shielding layer 13, a filling layer 14, an isolation layer 15, and a sheath layer 16.

[0037] The conductor assembly 11 includes multiple conductor wires made of graphene-reinforced silver-plated copper alloy, with a diameter of 0.05-0.10 mm for each conductor wire. The multiple conductor wires are bundled and twisted together to form a double-layer twisted structure, with a bundled pitch of 10-15 mm and a twisted pitch of 20-30 mm. The twisting directions of the bundled and twisted wires are opposite.

[0038] The insulating layer 12 is a gradient composite structure of silicone rubber and XLPE, consisting of an inner silicone rubber layer, a gradient transition layer, and an outer XLPE layer from the inside out. The thickness of the inner silicone rubber layer is 0.3-0.5 mm, the thickness of the outer XLPE layer is 0.2-0.3 mm, and the thickness of the gradient transition layer is 0.05-0.1 mm.

[0039] The functional layer is set around the outer periphery of the main power cable unit 1 to jointly form a multifunctional, high-toughness robot cable structure.

[0040] The multifunctional high-toughness robot cable provided in this embodiment uses graphene-reinforced silver-plated copper alloy for its conductor assembly, with a single wire diameter controlled to be only 0.05-0.10mm. It also features a double-layer stranding structure with a bundled pitch of 10-15mm and a reversed stranded pitch of 20-30mm, with opposite stranding directions. This gives the conductor high conductivity, excellent fatigue resistance, and ultra-high flexibility, enabling it to withstand high-frequency bending and torsion at robot joints without core breakage. The insulation layer uses a composite structure of a silicone rubber inner layer, a gradient transition layer, and an XLPE outer layer. The silicone rubber inner layer provides high elasticity and low-temperature flexibility to absorb bending stress, the XLPE outer layer ensures heat resistance and high insulation strength, and the gradient transition layer eliminates abrupt changes in interlayer physical properties through gradual compositional changes, effectively preventing interface peeling and cracking caused by differences in thermal expansion, thus maintaining stable electrical properties over a wide temperature range. Regarding mechanical properties; the shielding layer, located outside the insulation layer, can resist strong electromagnetic interference generated by equipment such as frequency converters and motors, ensuring stable transmission of control signals; the filling layer maintains the roundness of the cable and distributes the stress evenly, while the isolation layer prevents the filling layer from sticking or wearing with the sheath layer, ensuring that each layer can slide relatively freely during dynamic bending, further improving bending fatigue life; the outermost sheath layer provides reliable external protection against oil, wear, and chemical corrosion, enabling it to adapt to the harsh working environment of industrial robots; and the functional layer located around the main power cable unit integrates multiple functions such as power transmission, signal, and communication, significantly reducing the space occupied by the cable and lowering the inertial load on the robot joints, ultimately achieving excellent levels in terms of high flexibility, high reliability, strong anti-interference, compact structure, and long life.

[0041] In some embodiments, the functional layer includes a video cable unit 2, a communication control cable unit 3, a multi-channel digital communication optoelectronic sensing cable unit 4, an aramid-reinforced filling unit 5, a flexible cable tie sleeve layer 6, and a flexible sheath layer 7.

[0042] The video cable unit 2, communication control cable unit 3, multi-channel digital communication optoelectronic sensing cable unit 4, and two sets of main power cable units 1 are arranged side by side along the length of the flexible cable tie sleeve 6 inside the flexible cable tie sleeve 6. The outer peripheral wall of the video cable unit 2, communication control cable unit 3, multi-channel digital communication optoelectronic sensing cable unit 4, and two sets of main power cable units 1 is filled with aramid reinforcing filler units 5 between the outer peripheral wall of the corresponding flexible cable tie sleeve 6 and the inner peripheral wall of the flexible cable tie sleeve 6. The flexible sheath layer 7 is coaxially wrapped around the outer peripheral wall of the aramid reinforcing filler units 5, thus forming a multifunctional high-toughness robot cable structure.

[0043] By arranging the video cable unit, communication control cable unit, multi-channel digital communication optoelectronic sensing cable unit, and two sets of main power cable units side-by-side along the length of the flexible cable tie layer, vertical integration of multiple functions such as power transmission, video signal, conventional communication control, and optoelectronic sensing is achieved. This significantly reduces the space occupied by the cable components and lowers the inertial load on the robot joints. The flexible cable tie layer provides shaping and constraint for each functional unit, ensuring the long-term stability of the multi-unit parallel structure. Aramid-reinforced filling units are placed between each functional unit and the flexible cable tie layer, utilizing the high strength of aramid material... The high modulus and fatigue resistance provide excellent tensile strength for the entire cable, while also acting as a buffer, vibration damper, and maintain cable roundness, effectively preventing mutual compression and wear between units during dynamic bending. The flexible sheath layer coaxially wraps around the outermost perimeter, providing uniform oil-resistant, wear-resistant, and chemical corrosion-resistant external protection for all internal units, while maintaining the overall flexibility of the cable. The synergistic effect of each structural layer enables the robot cable to simultaneously achieve high-capacity power transmission, high-fidelity transmission of multiple types of signals, high tensile strength, excellent bending fatigue resistance, and compact and lightweight design within a limited cross-section.

[0044] In some embodiments, the video cable unit 2 includes a video unit 21, an aramid-reinforced filling unit 22, a flexible cable tie sleeve 23, and a protective sleeve 24.

[0045] The video unit 21 and two sets of main power cable units 1 are arranged side by side inside the flexible cable tie sleeve 23 along the length of the flexible cable tie sleeve 23. The outer peripheral wall of the video unit 21 and the two sets of main power cable units 1 and the inner peripheral wall of the corresponding flexible cable tie sleeve 23 are filled with aramid reinforced filling unit 22. The protective sleeve 24 is coaxially wrapped around the outer periphery of the flexible cable tie sleeve 23.

[0046] The video cable unit integrates the video unit and two main power cable units side-by-side within a flexible cable tie layer, achieving composite integration of video signal transmission and partial power supply within a single sub-unit. This further optimizes space utilization and wiring neatness. An aramid-reinforced filler unit fills the space between each functional unit and the flexible cable tie layer, utilizing the high strength and fatigue resistance of aramid material to provide excellent tensile strength and buffer protection for the sub-unit, effectively preventing mutual compression and wear between the video unit and the main power cable units during dynamic bending. The flexible cable tie layer acts as a shaper and constraint for each parallel unit, ensuring the long-term stability and consistency of the sub-unit's internal structure. A protective sleeve layer coaxially wraps the outermost perimeter, providing unified external protection for all components within the sub-unit and enhancing the overall structural integrity and reliability. Through this layered integrated design, the video cable unit achieves a high degree of integration of power and video signals, a compact structure, high tensile strength, and accurate and stable positioning of each internal unit while maintaining overall flexibility. This provides a more refined modular structural foundation for the multi-functional integration of robot cables.

[0047] In some embodiments, the communication control cable unit 3 includes a communication control unit 31, an aramid-reinforced filling unit 32, a flexible cable tie sleeve 33, and a protective sleeve 34.

[0048] The communication control unit 31 and three main power cable units 1 are arranged side by side along the length of the flexible cable tie sleeve 33 inside the flexible cable tie sleeve 33. The outer peripheral wall of the communication control unit 31 and the three main power cable units 1 and the inner peripheral wall of the corresponding flexible cable tie sleeve 33 are filled with aramid reinforced filling unit 32. The protective sleeve 34 is coaxially wrapped around the outer periphery of the flexible cable tie sleeve 33.

[0049] The communication control cable unit internally integrates the communication control unit and three main power cable units side-by-side within the second flexible cable tie layer. This achieves deep integration of communication control functions and multi-channel power supply within a limited space, meeting the robot system's requirements for multi-channel power distribution while enabling communication control signals to be transmitted locally, effectively shortening the signal path and reducing the risk of electromagnetic interference. The second aramid-reinforced filler unit is positioned between each functional unit and the second flexible cable tie layer. Leveraging the high strength, high modulus, and excellent fatigue resistance of aramid material, it provides reliable tensile strength and buffer protection for the sub-units, effectively preventing the communication control unit from collapsing under dynamic bending and dragging conditions. The mutual compression, friction, and relative displacement between the main power cable units; the flexible cable tie layer two plays a shaping and constraining role for each parallel unit, ensuring the long-term stability and positional accuracy of the multi-unit parallel structure; the protective sleeve layer two coaxially wraps around the outermost perimeter, providing unified mechanical and environmental protection for all components inside the sub-unit, further enhancing the integrity and reliability of the overall structure; through this modular layered integrated design, this communication control cable unit achieves a high degree of integration of communication control and multi-channel power transmission while maintaining overall flexibility, with a compact structure, high tensile strength, and accurate and stable positioning of each internal unit, providing a more complete functional integration solution for robot cable systems.

[0050] In some embodiments, the multi-channel digital communication optoelectronic sensing cable unit 4 includes a multi-channel digital communication unit 41, an optoelectronic sensing unit 42, an aramid-reinforced filling unit 43, a flexible cable tie sheath 44, and a protective sheath 45.

[0051] The multi-channel digital communication unit 41, two sets of photoelectric sensing units 42 and four sets of main power cable units 1 are arranged side by side along the length of the flexible cable tie sleeve 44 inside the flexible cable tie sleeve 44. The outer peripheral wall of the multi-channel digital communication unit 41, two sets of photoelectric sensing units 42 and four sets of main power cable units 1 and the inner peripheral wall of the corresponding flexible cable tie sleeve 44 are filled with aramid reinforcing filling unit 43. The protective sleeve 45 is coaxially wrapped around the outer periphery of the flexible cable tie sleeve 44.

[0052] The multi-channel digital communication optoelectronic sensing cable unit internally integrates multiple digital communication units, two sets of optoelectronic sensing units, and four sets of main power cable units within the flexible cable tie layer three. This achieves a high degree of integration of high-speed digital communication, optoelectronic sensing detection, and multi-channel power supply within a limited cross-section, fully meeting the comprehensive needs of modern intelligent robots for massive data transmission, precise sensing feedback, and large-capacity power distribution. The aramid-reinforced filling unit three fills the space between each functional unit and the flexible cable tie layer three. Utilizing the high strength, high modulus, and excellent fatigue resistance of aramid material, it provides reliable tensile strength and all-around buffer protection for this highly integrated composite unit. Under the robot's high-frequency bending, torsion, and dragging conditions, it effectively prevents mutual compression and friction between the multiple digital communication units, optoelectronic sensing units, and multiple sets of main power cable units. The friction and relative displacement ensure stable transmission of photoelectric sensing signals and reliable digital communication; the three flexible cable tie layers provide precise shaping and constraint for each parallel unit, ensuring the long-term stability and positional accuracy of the complex multi-unit structure; the three protective sleeve layers coaxially wrap around the outermost perimeter, providing unified mechanical and environmental protection for all internal functional components, further enhancing the integrity and durability of the overall structure; through this highly modular layered integrated design, this multi-channel digital communication photoelectric sensing cable unit achieves high-density integration of three major functions—digital communication, photoelectric sensing, and multi-channel power transmission—while maintaining overall flexibility. It features a compact structure, high tensile strength, and accurate positioning of internal units, providing a comprehensive solution for robot cable systems that combines high-speed communication, precise sensing, and powerful power supply capabilities.

[0053] In some embodiments, the sheath layer 16 is made of polyether-type thermoplastic polyurethane (TPU) material modified with nano-silica; wherein the particle size of the nano-silica is 50-100 nm, and the amount added accounts for 5%-8% of the total mass of the sheath material.

[0054] The sheath layer uses polyether-type thermoplastic polyurethane (TPU) material modified with nano-silica. The polyether-type TPU, as the matrix material, possesses excellent hydrolysis resistance, microbial erosion resistance, and good low-temperature flexibility, providing a fundamental guarantee for the long-term stable operation of the cable in harsh industrial environments such as humidity and oil contamination. Nano-silica, with a particle size of 50-100 nm, is uniformly dispersed in the TPU matrix, with the addition amount controlled at 5%-8% of the total mass. This optimized ratio allows the nanoparticles to form physical cross-linking points within the matrix, significantly enhancing the sheath layer's abrasion resistance, tear strength, and cut resistance. Simultaneously, the rigid particle effect of nano-silica effectively improves the sheath's heat deformation resistance and aging resistance, while the reasonable addition amount avoids material embrittlement or decreased flexibility due to excessive filling. Under these combined effects, this modified sheath layer significantly improves resistance to mechanical damage, weather resistance, and service life while maintaining the overall flexibility and bending fatigue life of the cable, providing more reliable external protection for the internal structure.

[0055] In some embodiments, the radial cross-section of the sheath layer 16 is asymmetrical, and its thickness is gradually distributed along the circumference; the tensile strength of the sheath layer 16 is ≥18MPa, and the elongation at break is ≥350%.

[0056] The sheath layer features an asymmetrical radial cross-section and a gradually varying thickness along the circumference. This non-uniform structure allows for targeted optimization for robot cables subjected to varying bending, torsion, friction, and tensile stresses in different directions during actual use. It appropriately thins the sheath in the main bending directions to improve flexibility and bending fatigue life, while thickening it in areas prone to compression or friction to enhance mechanical protection. This achieves a precise match between overall cable flexibility and localized protection. Simultaneously, the sheath layer boasts a tensile strength exceeding 18 MPa and an elongation at break exceeding 350%. These superior mechanical properties ensure that the sheath layer can withstand significant axial tension without breakage during high-frequency dynamic robot motion, while maintaining sufficient elastic deformation capacity during repeated bending and torsion. This effectively prevents the exposure and damage of internal functional units due to sheath cracking or fatigue failure. In summary, the synergistic effect of this asymmetrical gradually varying thickness structure and high-strength, high-toughness mechanical properties further enhances the mechanical protection in specific directions and the overall structural reliability of the cable while maintaining excellent flexibility and dynamic fatigue life.

[0057] Specifically, the sheath layer 16 has the smallest thickness in the area corresponding to the predetermined bending direction to reduce bending resistance, and the largest thickness in the wear-prone area to improve wear resistance.

[0058] Specifically, the sheath layer 16 is 10%-15% thinner on the inner side of the pre-curved section than on the outer side.

[0059] In some embodiments, the main power cable unit 1 further includes a flexible sensor array, which includes a PT1000 temperature sensor, an optical fiber strain sensor, and a dedicated signal bus. The PT1000 temperature sensor and the optical fiber strain sensor are embedded and braided and fixed between the shielding layer 13 and the filling layer 14. The spacing between the PT1000 temperature sensor and the optical fiber strain sensor along the length of the main power cable unit 1 is 300-500mm. The dedicated signal bus is embedded between the shielding layer 13 and the filling layer 14, with one end electrically connected to the PT1000 temperature sensor and the optical fiber strain sensor, and the other end extending along the length of the main power cable unit 1 to the end of the main power cable unit 1 to form a connection end for the robot control system.

[0060] The main power cable unit integrates a flexible sensor array consisting of a PT1000 temperature sensor, a fiber optic strain sensor, and a dedicated signal bus, upgrading the traditional single-function power transmission cable into a smart cable with self-sensing capabilities. The PT1000 temperature sensor and fiber optic strain sensor are embedded and braided between the shielding layer and the filler layer. This design allows for precise monitoring by being close to the heat source and stress area, while the electromagnetic protection of the shielding layer and the buffering effect of the filler layer protect the sensors from external interference and mechanical damage. The braided fixing method ensures that the sensors maintain stable positioning during dynamic bending, preventing measurement inaccuracies or damage due to relative displacement. The sensors are arranged at intervals of 300-500mm along the length of the main power cable unit. The spacing ensures full coverage monitoring of critical parts of the entire cable while avoiding the increased structural complexity and cost caused by excessive sensor density, achieving a reasonable balance between monitoring accuracy and engineering economy. A dedicated signal bus is also embedded between the shielding and filling layers, with one end electrically connected to each sensor and the other extending to the cable end to form the connection point for the robot control system, creating a complete sensor signal transmission link. This enables the real-time and reliable transmission of temperature and strain signals to the control system. Through this integrated design, the main power cable unit, while undertaking power transmission functions, can monitor its own operating temperature and mechanical strain in real time, providing proactive fault warning and lifespan prediction capabilities for the robot control system, significantly improving the intelligence level and operational reliability of the robot cable system.

[0061] In some embodiments, the shielding layer 13 adopts a "tinned copper wire braid and aluminum foil composite" structure, that is, the shielding layer 13 includes a tinned copper wire braid layer and an aluminum foil layer; the tinned copper wire braid layer is wrapped around the outer periphery of the insulating layer 12; the aluminum foil layer is wrapped around the outer periphery of the tinned copper wire braid layer. The braiding density of the tinned copper wire braid layer is ≥95%, the aluminum foil overlap rate of the aluminum foil layer is ≥30%, and the shielding attenuation is ≥90dB (1MHz-1GHz).

[0062] Specifically, multiple PT1000 temperature sensors and fiber optic strain sensors are alternately and electrically connected to a dedicated signal bus. A flexible sensor array is positioned between a tin-plated copper wire braided layer and an aluminum foil layer, and the dedicated signal bus is braided and fixed to the tin-plated copper wire braided layer using a braiding method. This ensures that the flexible sensor array moves at the same frequency as the cable, without affecting bending performance. The flexible sensor array positioned between the tin-plated copper wire braided layer and the aluminum foil layer effectively achieves shielding fidelity and high-sensitivity detection and control. Through the dedicated signal bus, it interfaces with the robot control system, enabling high-precision monitoring of temperature ±0.3℃ and strain ±0.8%FS.

[0063] Another aspect of the present invention provides a method for preparing a multifunctional high-toughness robot cable, comprising the following steps: S1: Conductor assembly preparation; graphene powder is uniformly mixed into silver-plated copper alloy melt at a mass ratio of 0.5%-1.0%, and multiple conductor wires are drawn by continuous casting and rolling process; the conductor wires are continuously annealed, and then bundled and re-stranded using a multi-head stranding machine to produce conductor assembly 11 with a double-layer stranded structure; wherein the bundled stranding pitch is 10-15mm, the re-stranding pitch is 20-30mm, and the stranding directions of bundled stranding and re-stranding are opposite; S2: Insulation layer molding; An insulation layer is coated around the conductor assembly 11 using a double-layer co-extrusion device. Specifically, the inner silicone rubber is extruded at 120-140℃ to form a silicone rubber inner layer with a thickness of 0.3-0.5mm, and the outer XLPE is extruded at 180-200℃ to form an XLPE outer layer with a thickness of 0.2-0.3mm. Through gradient temperature control, the silicone rubber inner layer and the XLPE outer layer diffuse or cross-link at the interface to form a gradient transition layer with a thickness of 0.05-0.1mm. S3: Cover the insulation layer with shielding layer 13, set filling layer 14, cover with isolation layer 15, and extrude sheath layer 16 in sequence to obtain main power cable unit; S4: Set up a functional layer; Set up a functional layer around the main power cable unit to obtain a multi-functional, high-toughness robot cable.

[0064] In the preparation method of the multifunctional high-toughness robot cable provided in this embodiment, the technical means of each step work together to achieve high performance and high reliability of the cable: In step S1, graphene powder is uniformly mixed into silver-plated copper alloy melt at a mass ratio of 0.5%-1.0%, and conductor wire is drawn by continuous casting and rolling process, so that graphene is uniformly dispersed in the matrix to give full play to its nano-effect of enhancing conductivity and fatigue resistance. Continuous annealing treatment eliminates the internal stress in the drawing process, thereby improving the flexibility of the conductor wire. Then, multiple... The head stranding machine performs double-layer stranding with a bundle stranding pitch of 10-15mm and a re-stretching pitch of 20-30mm, with opposite stranding directions, ensuring that the conductor assembly has both high conductivity and excellent resistance to bending fatigue. In step S2, a double-layer co-extrusion device is used to coat the outer periphery of the conductor assembly with an insulating layer. The inner layer of silicone rubber is extruded at 120-140℃ to form a silicone rubber inner layer with a thickness of 0.3-0.5mm to provide high elasticity and low-temperature flexibility. The outer layer of XLPE is extruded at 180-200℃ to form... An XLPE outer layer with a thickness of 0.2-0.3 mm is used to ensure heat resistance and insulation strength. By controlling the gradient temperature, the two layers diffuse or cross-link at the interface, naturally forming a gradient transition layer with a thickness of 0.05-0.1 mm. This process eliminates the abrupt change in the interface physical properties of traditional double insulation and effectively prevents interlayer peeling and thermal stress cracking. In step S3, a shielding layer, a filling layer, an isolation layer, and an extruded sheath layer are sequentially wrapped around the insulation layer. The reasonable interlayer structure design and process sequence ensure the accurate positioning and reliable bonding of each functional layer. In step S4, a functional layer is set around the outer periphery of the main power cable unit, realizing the integrated integration of multiple functional units. The entire preparation method ensures the structural stability, interface bonding strength, and overall performance consistency of each functional layer of the cable through precise material ratio, optimized process parameters, and reasonable process arrangement. Finally, a multifunctional high-toughness robot cable with ultra-high flexibility, wide temperature range stability, strong anti-interference ability, and long service life is produced.

[0065] In some embodiments, the shielding layer 13 in step S3 specifically includes: using a composite structure of tin-plated copper wire braiding and aluminum foil, with a braiding density of not less than 95% and an aluminum foil overlap rate of not less than 30%, to form a shielding layer with a shielding attenuation of not less than 90dB, and the test frequency range is 1MHz-1GHz; Before setting the filling layer 14 in step S3, the method further includes embedding a flexible sensor array between the shielding layer 13 and the filling layer 14: PT1000 temperature sensor and fiber optic strain sensor are arranged at intervals of 300-500mm along the length of the main power cable unit 1, fixed to the outer surface of the shielding layer 13 by braiding process, and one end of the dedicated signal bus is electrically connected to the PT1000 temperature sensor and fiber optic strain sensor, and the other end extends to the end of the main power cable unit 1 to form the connection end of the robot control system; In step S3, the extrusion of the sheath layer 16 adopts a low-temperature extrusion process. The nano-silica modified polyether thermoplastic polyurethane (TPU) material is mixed by a twin-screw extruder and extruded at 160-180°C. The sheath layer 16 after molding is formed into an asymmetric thickness structure in the radial section by a shaped die.

[0066] Each process step achieved a comprehensive improvement in cable performance through refined parameter control and structural optimization: In the shielding layer preparation, a composite structure of tin-plated copper wire braiding and aluminum foil was adopted, with the braiding density controlled to be no less than 95% and the aluminum foil overlap rate no less than 30%. This created a continuous and dense electromagnetic shielding network, achieving a shielding attenuation of no less than 90dB in a wide frequency range of 1MHz-1GHz. This effectively blocked strong electromagnetic interference generated by inverters, motors, and other equipment in the robot's operating environment, ensuring the stability and reliability of internal signal transmission. Before setting the filler layer, a flexible sensor array was embedded. PT1000 temperature sensors and fiber optic strain sensors were arranged at intervals of 300-500mm along the length of the main power cable unit and fixed to the outer surface of the shielding layer through braiding. This achieved accurate positioning and reliable fixation of the sensors under dynamic bending conditions, while avoiding structural complexity caused by excessive sensor density. At the same time, a dedicated signal bus was connected to the sensors at one end and extended to the end to form a control system connection point, forming a complete online monitoring link. This enabled the cable to have real-time self-sensing capabilities in addition to its power and signal transmission functions. In the sheath extrusion, a low-temperature extrusion process was used. The nano-silica-modified polyether-type thermoplastic polyurethane (TPU) material is extruded at 160-180℃. This temperature window ensures sufficient plasticization and flowability of the material while avoiding damage to the performance of the nano-modified material due to high-temperature degradation. At the same time, the use of irregular molds allows the sheath layer to form an asymmetric thickness structure in the radial cross section, achieving differentiated protection for different stress directions. The entire preparation method utilizes the synergistic effect of key technologies such as high-density composite shielding, embedded sensor array integration, and low-temperature irregular extrusion sheathing to ultimately produce a multifunctional, high-toughness robot cable with strong electromagnetic compatibility, intelligent self-sensing capabilities, and directional optimized mechanical protection performance.

[0067] Specifically, the sheath layer 16 after molding can be made to form an asymmetric thickness structure in the radial section by using a special-shaped mold, with the ratio of its minimum thickness to its maximum thickness being 0.85-0.9.

[0068] Specifically, the molded sheath layer 16 is formed in a radial section by using a special-shaped mold to create a gradually varying thickness structure with a thinner inner side and a thicker outer side, wherein the thickness of the inner side is 1.0-1.2 mm and the thickness of the outer side is 1.2-1.5 mm.

[0069] Specifically, the flexible sensor array is fixed using a braiding method. The process involves first weaving a tin-plated copper wire braid layer, then simultaneously embedding a dedicated signal bus that connects multiple PT1000 temperature sensors and fiber optic strain sensors. The dedicated signal bus and the shielding layer are braided together synchronously, with the braiding tension controlled at 5-10N to ensure that the sensors and cables move at the same frequency and do not affect the bending performance.

[0070] Specifically, the addition of graphene increases the conductivity of the conductor component by 15%; the silver plating layer is 2-3 μm thick, which enhances its oxidation resistance; and the double-layer structure of 19 strands + 7 sets of multiple strands is adopted, and the stranding pitch is optimized through finite element simulation, which improves the bending stress dispersion by 40%.

[0071] In some embodiments, R2 series humanoid robot cable samples are prepared according to the following steps.

[0072] Conductor preparation: 0.8% graphene powder by mass was added to silver-plated copper alloy melt, ultrasonically dispersed for 20 min, continuously cast and drawn into 0.08 mm monofilaments, annealed at 320℃, 19 monofilaments were bundled together at a 12 mm pitch, and 7 bundled conductors were reverse-stranded at a 25 mm pitch.

[0073] Insulation molding: A double-layer co-extrusion machine is used. The inner layer of silicone rubber is extruded at 130℃ and 7MPa, with a thickness of 0.4mm. The outer layer of XLPE is extruded at 190℃ and 11MPa, with a thickness of 0.25mm. The die temperature is controlled in a gradient manner, and a 0.08mm transition layer is formed.

[0074] Shielding and sensing integration: First, a tin-plated copper wire shielding layer is woven with a weaving density of ≥95%. Simultaneously, a PT1000 sensor and an optical fiber strain sensor are embedded with a spacing of 400mm. Then, aluminum foil is overlapped by 30% to form a composite shielding structure.

[0075] Filler and sheath: Aramid fiber filler accounts for 18% of the overall cable cross-section. After being wrapped with polyester tape for isolation, a TPU sheath modified by low-temperature extrusion at 170℃ is used. The average thickness of the sheath is 1.2mm, which meets the comprehensive protection function of the overall cable.

[0076] In some embodiments, comprehensive performance tests were performed on the prepared R2 series humanoid robot cable samples, and the results are as follows: Mechanical properties: Bending life 32 million cycles (bending radius 5 × outer diameter, frequency 1 Hz), tensile strength 19.2 MPa, elongation at break 365%, torsional life 8 million cycles (±180° / m).

[0077] Transmission performance: 2.5mm 2 Conductor resistance 7.2Ω / km, CAN bus signal transmission error rate 8×10^10 m over 100m.-8 The Ethernet signal (1Gbps) attenuates by 0.42dB / m.

[0078] Sensing performance: Temperature measurement accuracy ±0.2℃, strain measurement accuracy ±0.7%FS, data transmission packet loss rate <0.1%.

[0079] Environmental adaptability: After soaking in mineral oil at 100℃ for 72 hours, the performance change rate is 12%; after 50 cycles at -40℃ to 125℃, the bending life still reaches 28 million cycles.

[0080] Electromagnetic compatibility: Shielding attenuation 92dB (1MHz-1GHz), compliant with EN 55032 Class B requirements.

[0081] The following explanation is required regarding the core manufacturing process: The conductor component manufacturing process of this invention adopts an integrated process of "melt doping - continuous casting - precision drawing - annealing - stranding". Graphene is uniformly doped by ultrasonic dispersion, the drawing speed is controlled at 5-8m / min, and the annealing temperature is 300-350℃ to ensure the balance between the flexibility and conductivity of the conductor component.

[0082] The gradient insulation molding process of this invention utilizes a self-designed double-layer co-extrusion die. The inner layer of silicone rubber is extruded at a pressure of 5-8 MPa, and the outer layer of XLPE is extruded at a pressure of 10-12 MPa. A gradual transition layer is formed by controlling the die temperature gradient (120℃→180℃) to avoid interfacial delamination. An innovative gradient composite structure of silicone rubber and XLPE is adopted. The inner silicone rubber layer provides excellent elasticity, the outer XLPE layer ensures insulation strength, and the transition layer eliminates interfacial stress through molecular bonding technology. The breakdown voltage is ≥25kV / mm, and the temperature range is -40℃ to 125℃.

[0083] The sensor integration process of this invention: The sensor adopts a braided fixing method, which is braided and formed synchronously with the shielding layer. The braiding tension is controlled at 5-10N to ensure that the sensor and the cable move at the same frequency and do not affect the bending performance.

[0084] The online quality monitoring process of this invention involves installing a laser diameter gauge, an insulation thickness detector, and a shielding continuity tester on the extrusion production line, achieving a detection accuracy of 0.01 mm and enabling real-time early warning of defects.

[0085] In some embodiments, a commercialization solution for a multifunctional, high-toughness robot cable includes: (1) Product series development: Based on multi-functional high toughness robot cables, develop two series: industrial robot (bending life ≥ 20 million times) and humanoid robot (bending life ≥ 30 million times), covering the combination specifications of 2-8 core power core wires and 4-12 core signal core wires.

[0086] (2) Quality control system: Establish a CNAS accredited laboratory, equipped with equipment such as a million-cycle bending tester and an electromagnetic shielding tester, and implement the dual standards of GB / T 39560.1-2020 and IEC 60228.

[0087] (3) Industry-university-research collaboration: jointly build special cable laboratories with universities, jointly develop material modification and process optimization technologies, and realize the transformation of research and development results within 6 months.

[0088] (4) Scenario-based services: Provide non-standard core number customization (9 cores, 19 cores, etc.), length cutting and connector pre-installation services to adapt to the interface requirements of different brands of robots.

[0089] Specifically, the market-based implementation system includes: Product matrix construction: Based on core technologies, we have developed three major product series: ① R1 series for industrial robots (bending life of 20 million cycles, unit price of 8-12 yuan / meter); ② R2 series for humanoid robots (bending life of 30 million cycles, unit price of 15-20 yuan / meter); ③ R3 series for special robots (resistant to extreme environments, unit price of 25-30 yuan / meter), covering the needs of more than 80% of robot models.

[0090] Standard alignment strategy: Participate in the revision of the group standard "Humanoid Robot Cables", and the products simultaneously meet domestic and international standards such as GB / T39560.1-2020, IEC 60228, and EN 55032. The test reports have obtained German TÜV and American UL certifications, opening up channels to the international market.

[0091] Capacity expansion plan: Build a production line with an annual output of 1 million kilometers, using advanced equipment such as fully automatic stranding machines and precision extrusion equipment. The production line utilization rate is ≥90%, and the unit cost is reduced by 40% compared with imported products.

[0092] Supply chain management: We have established a materials research and development base in cooperation with Shanghai Jiao Tong University and Harbin University of Science and Technology to achieve the localization of core materials such as modified TPU and composite conductors, and shorten the supply chain response cycle to 7 days.

[0093] The beneficial effects of this invention are reflected in: Performance breakthrough: Bending life reaches 30 million cycles, a 60% improvement over existing domestic products and a 50% improvement over similar products from German igus; shielding attenuation ≥90dB, signal transmission bit error rate ≤10. -7 With a sensing response time of <100ms, its overall performance reaches the international leading level.

[0094] Functional integration: For the first time, it realizes the three-in-one function of "power transmission - signal interaction - status monitoring", which solves the pain point of traditional cable faults being difficult to predict and reduces robot downtime for maintenance by 30%.

[0095] Market adaptability: The product series coverage rate reaches 90%, the non-standard customization cycle is only 7-15 days, the unit price is 40%-60% lower than imported products, and it has been matched with well-known companies such as UBTECH and Tesla, with a market conversion rate of 85%.

[0096] Industrial value: It will drive the development of upstream and downstream industries such as modified materials and precision equipment, and is expected to generate an additional output value of 1 billion yuan per year, promoting the transformation of China's robot cable industry from "follower" to "leader".

[0097] The above describes a multifunctional high-toughness robot cable and its manufacturing process. Many specific details have been elaborated in the above description to facilitate a full understanding of this invention. However, this technology can be implemented in many other ways different from those described herein. Those skilled in the art can make similar extensions without departing from the essence of this technology; therefore, this technology is not limited to the specific embodiments disclosed below. This technology is not limited to the above-described embodiments. Any modifications or variations to this patented technology that do not depart from its scope of implementation are valid. All equivalent changes and improvements made within the scope of this patent application should fall within the patent coverage of this technology.

[0098] This invention, through material system innovation, structural optimization, and process breakthroughs, successfully fabricates multifunctional, high-toughness robot cables, solving the dual challenges of insufficient performance and poor market adaptability of traditional products. The core technology has formed independent intellectual property rights, and the supporting marketization solutions achieve full-chain coverage from R&D to application. The product not only meets the upgrading needs of the domestic robot industry but also breaks the international technological monopoly, enhancing China's voice in the global special cable industry chain. In the future, further expansion into self-healing materials and wireless sensing integration technology is expected to achieve even higher performance breakthroughs, adapting to high-end supporting applications for robots in extreme environments such as deep sea and space.

[0099] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. In addition, those skilled in the art can combine and integrate the different embodiments or examples described in this specification.

[0100] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A multi-functional, high-toughness robot cable, characterized in that: include: The main power cable unit (1) includes a conductor assembly (11), an insulation layer (12), a shielding layer (13), a filling layer (14), an isolation layer (15), and a sheath layer (16) arranged sequentially from the inside to the outside. The conductor assembly (11) includes multiple conductor wires made of graphene-reinforced silver-plated copper alloy, each conductor wire having a diameter of 0.05-0.10 mm; the multiple conductor wires are bundled and twisted together to form a double-layer twisted structure, with a bundled pitch of 10-15 mm and a twisted pitch of 20-30 mm, and the bundled and twisted strands are twisted in opposite directions. The insulating layer (12) is a gradient composite structure of silicone rubber and XLPE, and consists of an inner silicone rubber layer, a gradient transition layer and an outer XLPE layer from the inside to the outside; the thickness of the inner silicone rubber layer is 0.3-0.5 mm, the thickness of the outer XLPE layer is 0.2-0.3 mm, and the thickness of the gradient transition layer is 0.05-0.1 mm. The functional layer is set around the main power cable unit (1) to form a multifunctional high-toughness robot cable structure.

2. The multifunctional high-toughness robot cable according to claim 1, characterized in that, The functional layer includes a video cable unit (2), a communication control cable unit (3), a multi-channel digital communication optoelectronic sensing cable unit (4), an aramid reinforced filling unit (5), a flexible cable tie sleeve (6), and a flexible sheath layer (7). The video cable unit (2), the communication control cable unit (3), the multi-channel digital communication optoelectronic sensing cable unit (4), and the two sets of main power cable units (1) are arranged side by side along the length of the flexible cable tie sleeve (6) inside the flexible cable tie sleeve (6). The outer peripheral wall of the video cable unit (2), the communication control cable unit (3), the multi-channel digital communication optoelectronic sensing cable unit (4), and the two sets of main power cable units (1) are filled with the aramid reinforcing filler unit (5) between them and the inner peripheral wall of the corresponding flexible cable tie sleeve (6). The flexible sheath layer (7) is coaxially wrapped around the outer periphery of the aramid reinforcing filler unit (5), thereby forming a multifunctional high-toughness robot cable structure.

3. The multifunctional high-toughness robot cable according to claim 2, characterized in that, The video cable unit (2) includes a video unit (21), an aramid-reinforced filling unit (22), a flexible cable tie sleeve (23), and a protective sleeve (24). The video unit (21) and the two sets of main power cable units (1) are arranged side by side along the length of the flexible cable tie sleeve (23) inside the flexible cable tie sleeve (23). The outer peripheral wall of the video unit (21) and the two sets of main power cable units (1) and the inner peripheral wall of the corresponding flexible cable tie sleeve (23) are filled with the aramid reinforcing filling unit (22). The protective sleeve (24) is coaxially wrapped around the outer periphery of the flexible cable tie sleeve (23).

4. The multifunctional high-toughness robot cable according to claim 2, characterized in that, The communication control cable unit (3) includes a communication control unit (31), an aramid reinforced filling unit (32), a flexible cable tie sleeve (33), and a protective sleeve (34). The communication control unit (31) and the three main power cable units (1) are arranged side by side along the length of the flexible cable tie sleeve (33) inside the flexible cable tie sleeve (33). The outer peripheral wall of the communication control unit (31) and the three main power cable units (1) and the inner peripheral wall of the corresponding flexible cable tie sleeve (33) are filled with the aramid reinforcing filling unit (32). The protective sleeve (34) is coaxially wrapped around the outer periphery of the flexible cable tie sleeve (33).

5. The multifunctional high-toughness robot cable according to claim 2, characterized in that, The multi-channel digital communication optoelectronic sensing cable unit (4) includes a multi-channel digital communication unit (41), an optoelectronic sensing unit (42), an aramid reinforced filling unit three (43), a flexible cable tie sleeve three (44), and a protective sleeve three (45). The multi-channel digital communication unit (41), the two sets of photoelectric sensing units (42) and the four sets of main power cable units (1) are arranged side by side along the length of the flexible cable tie sleeve (44) inside the flexible cable tie sleeve (44). The outer peripheral wall of the multi-channel digital communication unit (41), the two sets of photoelectric sensing units (42) and the four sets of main power cable units (1) is filled with the aramid reinforcing filling unit (43) between the inner peripheral wall of the corresponding flexible cable tie sleeve (44). The protective sleeve (45) is coaxially wrapped around the outer periphery of the flexible cable tie sleeve (44).

6. The multifunctional high-toughness robot cable according to claim 1, characterized in that, The sheath layer (16) is made of polyether-type thermoplastic polyurethane (TPU) material modified with nano-silica; wherein the particle size of the nano-silica is 50-100nm, and the amount added accounts for 5%-8% of the total mass of the sheath material.

7. The multifunctional high-toughness robot cable according to claim 6, characterized in that, The radial cross section of the sheath layer (16) is asymmetrical, and its thickness is gradually distributed along the circumference; the tensile strength of the sheath layer (16) is ≥18MPa, and the elongation at break is ≥350%.

8. The multifunctional high-toughness robot cable according to claim 1, characterized in that, The main power cable unit (1) further includes a flexible sensor array, which includes a PT1000 temperature sensor, an optical fiber strain sensor, and a dedicated signal bus. The PT1000 temperature sensor and the optical fiber strain sensor are embedded and braided between the shielding layer (13) and the filling layer (14). The PT1000 temperature sensor and the optical fiber strain sensor are spaced 300-500 mm apart along the length of the main power cable unit (1). The dedicated signal bus is embedded between the shielding layer (13) and the filling layer (14), with one end electrically connected to the PT1000 temperature sensor and the optical fiber strain sensor, and the other end extending along the length of the main power cable unit (1) to the end of the main power cable unit (1) to form a connection end for the robot control system.

9. A method for preparing a multifunctional high-toughness robot cable as described in any one of claims 1-8, characterized in that, Includes the following steps: S1: Conductor assembly preparation; graphene powder is uniformly mixed into silver-plated copper alloy melt at a mass ratio of 0.5%-1.0%, and multiple conductor wires are drawn by continuous casting and rolling process; the conductor wires are subjected to continuous annealing treatment, and then bundled and re-stranded using a multi-head stranding machine to make a conductor assembly (11) with a double-layer stranded structure; wherein, the bundled stranding pitch is 10-15mm, the re-stranding pitch is 20-30mm, and the stranding directions of bundled stranding and re-stranding are opposite; S2: Insulation layer forming; an insulation layer is formed on the outer periphery of the conductor assembly (11) using a double-layer co-extrusion equipment, specifically: the inner layer of silicone rubber is extruded at 120-140℃ to form a silicone rubber inner layer with a thickness of 0.3-0.5mm, and the outer layer of XLPE is extruded at 180-200℃ to form an XLPE outer layer with a thickness of 0.2-0.3mm. The silicone rubber inner layer and the XLPE outer layer diffuse or cross-link at the interface through gradient temperature control to form a gradient transition layer with a thickness of 0.05-0.1mm. S3: Cover the insulation layer with a shielding layer (13), set a filling layer (14), cover the insulation layer (15), and extrude a sheath layer (16) to obtain the main power cable unit; S4: Set a functional layer; Set a functional layer around the main power cable unit to obtain a multifunctional high-toughness robot cable.

10. The method for preparing the multifunctional high-toughness robot cable according to claim 9, characterized in that, The shielding layer (13) in step S3 specifically includes: using a composite structure of tin-plated copper wire braid and aluminum foil, with a braiding density of not less than 95% and an aluminum foil overlap rate of not less than 30%, to form a shielding layer with a shielding attenuation of not less than 90dB, and the test frequency range is 1MHz-1GHz; Before setting the filling layer (14) in step S3, the method further includes embedding a flexible sensor array between the shielding layer (13) and the filling layer (14): PT1000 temperature sensor and fiber optic strain sensor are arranged at intervals of 300-500mm along the length direction of the main power cable unit (1), fixed to the outer surface of the shielding layer (13) by braiding process, and one end of the dedicated signal bus is electrically connected to the PT1000 temperature sensor and fiber optic strain sensor, and the other end extends to the end of the main power cable unit (1) to form the connection end of the robot control system; In step S3, the extrusion of the sheath layer (16) adopts a low-temperature extrusion process. The nano-silica modified polyether thermoplastic polyurethane (TPU) material is extruded at 160-180°C. The sheath layer (16) after molding is formed by using a shaped mold to form an asymmetric thickness structure in the radial section.

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