Cable guidance in the tightest of installation spaces: moving robots for sensor technology

This robot is used in the automotive industry to test intelligent sensor systems for vehicles. All four wheels of the robot can be controlled, which means it can move in any direction at any angle of rotation. The system is operated remotely and powered by a 30KW battery pack at a voltage of 250V, weighs 480kg, reaches a maximum speed of 50km/h and a maximum acceleration of 10m/s2. The problem that had to be solved was to guide the resolver signal and the power from the drive motor to the motor control system in the frame, with the steering motor rotating the drive motor structure by ±360°. The cable solution also had to be realised in an extremely small installation space and be particularly lightweight.

To solve the problem, the customer opted for an energy chain that was able to rotate upwards or downwards. More precisely, the E2 mini energy chain is used today, a particularly space-saving chain in which the two cables - 13mm for the motor power and 8mm for the resolver - fit well. Mounted on the steering axis, they fit nicely into the particularly small installation space. To support the length of the energy chain, it runs in a box installed on each steering axis. The cables enter the box at the side and then go into the energy chain. At the end of the energy chain, the cables lead to the motor and the resolver.