Highly flexible robot-specific cables with electromagnetic interference resistance

Abstract

This utility model discloses a highly flexible, electromagnetic interference-resistant cable for robots, comprising a double-layer conductor bundle with a Kevlar fiber rope at its center. The space between the inner and outer conductor bundles, and between the inner and outer conductor bundles and the Kevlar fiber rope, is filled with thermoplastic elastomer and foamed silicone. The conductor bundles are spirally twisted in opposite directions at different pitches. The cable is surrounded by braided aramid fibers, an insulation layer, an inner shielding layer, an outer shielding layer, and a sheath layer. The sheath has semi-circular ribs and embedded elastic polyurethane strips. The thermoplastic elastomer is a polyurethane-based material, the foamed silicone is phenyl silicone rubber, the insulation layer is nano-silica modified methyl vinyl silicone rubber, the inner shielding layer is copper foil wrapped with a polytetrafluoroethylene self-lubricating coating, the outer shielding layer is tin-plated copper wire braid, and the sheath layer is a blend of polyurethane and silicone rubber coated with a nano-ceramic coating. This cable exhibits a long dynamic bending life under extreme environments, improves high-frequency shielding effectiveness, and is suitable for high-frequency movements of industrial robots and complex electromagnetic environments.

Description

Technical Field

[0001] This utility model relates to the field of robot cable technology, and in particular to a highly flexible robot-specific cable with electromagnetic interference resistance. Background Technology

[0002] In the field of industrial automation, robots are increasingly widely used, such as industrial robotic arms and collaborative robots. These robots often require complex movements like high-frequency bending and twisting, and operate in environments with complex electromagnetic fields. However, traditional robot cables have many problems and cannot meet these requirements. In existing technologies, most cables use a single-layer conductor bundle structure with a fixed conductor strand pitch, coupled with ordinary rubber insulation. This makes them prone to conductor breakage and insulation wrinkling during high-frequency, large-angle bending of robot joints, resulting in short cable life. Furthermore, conventional shielding layers are mostly single-layer copper mesh or aluminum foil, failing to form a composite shielding system. In the high-frequency electromagnetic environment of industrial sites, this results in low shielding effectiveness, affecting the robot's motion accuracy.

[0003] Therefore, it is necessary to propose a highly flexible, electromagnetic interference-resistant robot-specific cable to solve the above problems. Utility Model Content

[0004] The purpose of this invention is to provide a highly flexible and electromagnetically resistant cable for robots, in order to solve the problems of poor flexibility leading to cable breakage and weak anti-interference ability.

[0005] To achieve the above objectives, this utility model provides the following technical solution:

[0006] An electromagnetic interference resistant, highly flexible robot-specific cable includes a double-layer conductor bundle. A Kevlar fiber rope is centrally located within the double-layer conductor bundle and is positioned axially along the bundle. A thermoplastic elastomer is filled between the inner conductor bundle and the outer Kevlar fiber rope. Foamed silicone is filled between the inner and outer conductor bundles. The inner and outer conductor bundles are spirally twisted in opposite directions at different pitches. Braided aramid fibers are arranged around the outer conductor bundle, and a thermoplastic elastomer is filled between them. An insulation layer surrounds the braided aramid fibers. An inner shielding layer and an outer shielding layer are sequentially wrapped around the insulation layer from the inside out. A sheathing layer surrounds the outer shielding layer. Multiple semi-circular ribs are arranged axially along the outer side of the sheathing layer. Elastic polyurethane strips are transversely embedded within the sheathing layer.

[0007] Preferably, the thermoplastic elastomer is a polyurethane-based thermoplastic elastomer material.

[0008] Preferably, the foamed silicone is made of phenyl silicone rubber.

[0009] Preferably, the insulating layer is made of methyl vinyl silicone rubber material, and the insulating layer is modified with nano-silica.

[0010] Preferably, the inner shielding layer is made of copper foil wrapped around the outside of the insulating layer, the surface of the copper foil of the inner shielding layer is coated with a self-lubricating coating, and the outer shielding layer is woven from tin-plated copper wire.

[0011] Preferably, the self-lubricating coating is made of polytetrafluoroethylene (PTFE).

[0012] Preferably, the sheath layer is made of a blend of polyurethane and silicone rubber, and the outer surface of the sheath layer is coated with a nano-ceramic coating.

[0013] The technical effects and advantages of this utility model are as follows:

[0014] In this invention, the cable's double-layer conductor bundle uses ultra-fine silver-plated copper wires twisted in opposite directions with different pitches, combined with a central Kevlar fiber rope, which reduces signal attenuation and provides high-strength support, capable of withstanding high-intensity dynamic bending. A phenyl silicone rubber foam silicone and polyurethane thermoplastic elastomer filling layer ensure the cable maintains good flexibility in extreme environments, has a low coefficient of friction, and is suitable for robot joint torsion. A double-layer shielding structure consisting of copper foil wrapping and tinned copper wire braiding, combined with a PTFE self-lubricating coating, improves shielding effectiveness in high-frequency bands and reduces the bit error rate of servo signal transmission. A polyurethane and silicone rubber blended sheath is coated with a nano-ceramic coating, combined with outer semi-circular ribs and inner elastic polyurethane strips, providing both wear resistance and cut resistance as well as dynamic stress dispersion capabilities, making it suitable for complex working conditions such as cable chains and welding, fully meeting the high reliability and long lifespan requirements of industrial automation cables. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of the electromagnetic interference resistant, highly flexible robot-specific cable of this utility model.

[0016] Figure 2 This is a schematic diagram showing the location and structure of the elastic polyurethane strip inside the sheath layer of this utility model.

[0017] In the diagram: 1. Double-layer conductor bundle; 2. Kevlar fiber rope; 3. Thermoplastic elastomer; 4. Foamed silicone; 5. Braided aramid fiber; 6. Insulation layer; 7. Inner shielding layer; 8. Outer shielding layer; 9. Sheath layer; 10. Semi-circular rib; 11. Elastic polyurethane strip; 12. Self-lubricating coating; 13. Nano-ceramic coating. Detailed Implementation

[0018] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0019] This utility model provides, for example Figures 1-2 The illustrated high-flexibility, electromagnetic interference-resistant robot cable includes a double-layer conductor bundle 1. A Kevlar fiber rope 2 is centrally located within the double-layer conductor bundle 1 and is positioned axially along the double-layer conductor bundle 1. A thermoplastic elastomer 3 is filled between the inner conductor bundle of the double-layer conductor bundle 1 and the outer layer of the Kevlar fiber rope 2. Foamed silicone 4 is filled between the inner and outer conductor bundles of the double-layer conductor bundle 1. The inner and outer conductor bundles of the double-layer conductor bundle 1 are spirally wound in opposite directions with different pitches. The outer conductor bundle of the double-layer conductor bundle 1 is surrounded by braided aramid fibers 5, and thermoplastic elastomer 3 is filled between the outer conductor bundle of the double-layer conductor bundle 1 and the braided aramid fibers 5. The braided aramid fibers 5 are wrapped with an insulating layer 6. The outer side of the insulating layer 6 is wrapped with an inner shielding layer 7 and an outer shielding layer 8 from the inside to the outside. The outer shielding layer 8 is wrapped with a sheath layer 9. Multiple semi-circular ribs 10 are arranged along the axial direction on the outer side of the sheath layer 9. An elastic polyurethane strip 11 is embedded transversely inside the sheath layer 9.

[0020] Thermoplastic elastomer 3 is made of polyurethane-based thermoplastic elastomer material.

[0021] The thermoplastic elastomer 3 is made of polyurethane thermoplastic elastomer material, which combines the high strength of plastics and the high elasticity of rubber. It can maintain excellent flexibility in the temperature range of -40℃ to +80℃. Its Shore hardness is 60-80A and its elongation at break is ≥500%. It can effectively fill the gaps between the inner conductor bundle and the outer Kevlar fiber rope 2 of the double conductor bundle 1, and between the outer conductor bundle and the braided aramid fiber 5. It buffers the friction between the conductor bundle and the supporting structure. At the same time, it absorbs stress through elastic deformation when the cable is frequently bent, preventing the conductor bundle from breaking due to excessive wear or stress concentration. Its oil and solvent resistance can adapt to the complex working environment of industrial robots. It has good compatibility with the surrounding silicone rubber materials and will not swell or deteriorate due to long-term contact.

[0022] Foamed silicone 4 uses phenyl silicone rubber material, which absorbs bending stress and reduces the coefficient of friction between conductors to below 0.05.

[0023] The insulating layer 6 is made of methyl vinyl silicone rubber material and is modified with nano silica.

[0024] The inner shielding layer 7 is made of copper foil wrapped around the outside of the insulation layer 6. The surface of the copper foil of the inner shielding layer 7 is coated with a self-lubricating coating 12. The outer shielding layer 8 is woven from tin-plated copper wire. The self-lubricating coating 12 is made of polytetrafluoroethylene material.

[0025] The inner shielding layer 7 is made of copper foil wrapped around the outside of the insulation layer 6. The copper foil is 0.01-0.02mm thick and has an overlap rate of ≥50%. It can provide a shielding effectiveness of ≥80dB in the 10MHz-1GHz frequency band, effectively suppressing electromagnetic interference. The polytetrafluoroethylene self-lubricating coating 12 on the surface of the copper foil is 1-3μm thick and has a friction coefficient of ≤0.1. It can reduce the friction loss between the copper foil and the insulation layer 6 and the outer shielding layer 8 when the cable is bent, and prevent the copper foil from cracking or falling off due to repeated bending, thus maintaining the integrity of the shielding layer. The outer shielding layer 8 is woven from tin-plated copper wire with a diameter of 0.1-0.2mm and a braiding coverage of ≥90%. It forms a double-layer shielding structure with the inner shielding layer 7, further improving the anti-electromagnetic interference capability. At the same time, the tin plating layer can enhance the oxidation resistance of the copper wire and extend the service life of the shielding layer.

[0026] The sheath layer 9 is made of a blend of polyurethane and silicone rubber, and the outer surface of the sheath layer 9 is coated with a nano-ceramic coating 13.

[0027] In this embodiment of the invention, the double-layer conductor bundle 1 of the cable is made of multiple strands of ultra-fine silver-plated copper wires twisted in opposite spirals at different pitches, which can effectively reduce the skin effect and signal attenuation. The central Kevlar fiber rope 2 provides high-strength axial support to prevent structural breakage of the cable during frequent bending. The thermoplastic elastomer 3 filling layer has excellent flexibility and wear resistance, which can buffer the friction between the conductor bundle and the Kevlar fiber rope 3 and the braided aramid fiber 5. The foamed silicone rubber 4 filling layer made of phenyl silicone rubber achieves lightweight buffering with a closed-cell structure, improving the deformation recovery ability of the cable during bending. The braided aramid fiber layer 5 enhances the tensile strength, and the nano-silica modified methyl vinyl The silicone rubber insulation layer 6 maintains stable dielectric properties within the range of -60℃ to +180℃; the copper foil wrapping of the inner shielding layer 7, combined with the PTFE self-lubricating coating 12, reduces interlayer wear during bending; the tin-plated copper wire braided mesh of the outer shielding layer 8 forms a double shield with the copper foil, improving the shielding effect in the high-frequency band; the sheath layer 9, which is a blend of polyurethane and silicone rubber, is coated with a nano-ceramic coating, which has the characteristics of wear resistance, cut resistance and low coefficient of friction; the semi-circular ribs 10 on the outside enhance the anti-flattening performance; and the elastic polyurethane strips 11 embedded laterally inside form a flexible joint structure, so that the cable has no stress concentration when twisted at a large angle, fully meeting the anti-interference and high flexibility requirements of robots in high-frequency motion scenarios.

[0028] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed utility model. The scope of protection of this utility model is defined by the appended claims and their equivalents.

Claims

1. A highly flexible, electromagnetic interference-resistant cable for robots, characterized in that: The system includes a double-layer conductor bundle (1), with a Kevlar fiber rope (2) disposed at its center and arranged along the axial direction of the double-layer conductor bundle (1). A thermoplastic elastomer (3) is filled between the inner conductor bundle and the outer layer of the Kevlar fiber rope (2), and foamed silicone (4) is filled between the inner and outer conductor bundles. The inner and outer conductor bundles of the double-layer conductor bundle (1) are spirally twisted in opposite directions with different pitches. The outer layer of the double-layer conductor bundle (1)... The conductor bundle is surrounded by braided aramid fibers (5), and thermoplastic elastomer (3) is filled between the outer conductor bundle of the double-layer conductor bundle (1) and the braided aramid fibers (5). The braided aramid fibers (5) are wrapped with an insulating layer (6). The insulating layer (6) is wrapped with an inner shielding layer (7) and an outer shielding layer (8) from the inside to the outside. The outer shielding layer (8) is wrapped with a sheath layer (9). The sheath layer (9) is provided with a plurality of semi-circular ribs (10) along its axial direction. The sheath layer (9) is embedded with an elastic polyurethane strip (11) laterally inside.

2. The electromagnetic interference resistant, highly flexible robot-specific cable according to claim 1, characterized in that: The thermoplastic elastomer (3) is made of polyurethane thermoplastic elastomer material.

3. The electromagnetic interference resistant, highly flexible robot-specific cable according to claim 1, characterized in that: The foamed silicone (4) is made of phenyl silicone rubber material.

4. The electromagnetic interference resistant, highly flexible robot-specific cable according to claim 1, characterized in that: The insulating layer (6) is made of methyl vinyl silicone rubber material, and the insulating layer (6) is modified by nano silica.

5. The electromagnetic interference resistant, highly flexible robot-specific cable according to claim 1, characterized in that: The inner shielding layer (7) is wrapped with copper foil around the outside of the insulating layer (6). The copper foil surface of the inner shielding layer (7) is coated with a self-lubricating coating (12). The outer shielding layer (8) is woven from tin-plated copper wire.

6. The electromagnetic interference resistant, highly flexible robot-specific cable according to claim 5, characterized in that: The self-lubricating coating (12) is made of polytetrafluoroethylene.

7. The electromagnetic interference resistant, highly flexible robot-specific cable according to claim 1, characterized in that: The sheath layer (9) is made of a blend of polyurethane and silicone rubber, and the outer surface of the sheath layer (9) is coated with a nano-ceramic coating (13).

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