Detailed Description
"Combined" vs "Composite" — Understanding the Robot Cable Hierarchy
The terms are not interchangeable. They describe different levels of cable integration:
| Cable Type | What It Combines | Special Features | Best For |
|---|---|---|---|
| Combined Multi-Core | Multiple conductor sizes in one cable (power + control + signal) | Concentric stranding; Class 6 copper | General robot arm wiring; power distribution + I/O |
| Composite (Power+Signal+Data) | Power + shielded signal pairs + data bus elements | SZ stranding; torsion-rated; impedance-controlled data pairs | Complete robot wiring harness; high-torsion axes |
| Torsion | Optimized for torsional stress | SZ lay; anti-torsion fillers; ±180°/m rated | Axis 4/5/6 wrist segments |
| Manipulator | End effector connections | Compact; flexible; connector-ready | Robot wrist to gripper/weld gun |
The combined multi-core cable is the workhorse — it replaces multiple individual single-type cables with one multi-type cable. It is not torsion-rated (no SZ stranding) and does not include impedance-controlled data elements. It is the right choice for the robot arm segments that flex but do not twist — the upper arm and forearm (axes 1–3), the cable run from the robot base to the arm junction box, and the robot cell interconnections.
Core Size Grouping — Why Mix Sizes?
A robot arm requires different conductor cross-sections for different functions:
- Servo motor power: 4–16 mm² — carries 10–40 A per phase
- Motor brake: 0.75–1.5 mm² — 24 V DC, <2 A
- Sensors (proximity, temperature): 0.22–0.50 mm² — signal-level currents <100 mA
- Solenoid valves: 0.75–1.5 mm² — 24 V DC, 0.5–2 A
- Digital I/O: 0.50–0.75 mm² — 24 V DC, signal-level
Yichi Combined Multi-Core Cable Manufacturing
- Custom core size combinations: The customer specifies the required core sizes and counts. Our engineering team designs the cross-section to optimize roundness and minimize OD — a cross-section drawing is provided for approval
- Size group identification: The numbering system (VDE 0293) groups cores by size — e.g., cores 1–4 are 4 mm² power, cores 5–8 are 1.5 mm² control, cores 9–16 are 0.5 mm² signal. Clear grouping simplifies termination
- Class 6 verified: Every production batch is sampled for strand count — Class 6 requires significantly more individual wire strands per cross-section than Class 5. Verified under microscope at 20× magnification
- TPE insulation oil resistance: TPE (thermoplastic elastomer) is specified instead of PVC for robot applications because PVC absorbs oil and coolant over time — swelling, softening, and losing dielectric strength. TPE's oil absorption is <5% compared to PVC's 20–30% after extended exposure