igus Unveils Cable Chain That Lets Small Industrial Robots Spin More Than 600 Degrees Without Tangling
The German motion-plastics company says its new twisterchain solves a long-standing wiring headache on the first and fifth axes of compact industrial robots, and needs no guide troughs to work.
Key points
- igus GmbH announced the twisterchain energy chain, designed to manage cables through rotation angles exceeding 600 degrees on compact industrial robots.
- The self-supporting design requires only two connection points, removing the need for guide troughs or complex alignment hardware.
- The chain targets two specific robot joints: the base axis of small industrial robots and the fifth axis of palletizing robots, machines that stack and sort goods.
- igus, headquartered in Cologne, Germany, reported a turnover of €1.15 billion (about $1.32 billion) in 2022.
- The product is recyclable through igus's own "change" take-back programme.
When a small industrial robot spins to grab, glue, or screw something together, the cables carrying its power and data have to spin with it. For decades, those cables were often just bundled in a corrugated hose, a flexible ribbed tube, and left to flop around. That worked until the robot moved fast enough, or far enough, for the hose to snag on something.
igus GmbH, a Cologne-based maker of what it calls "motion plastics" (high-performance polymer components designed to move without lubrication), says its new twisterchain energy chain fixes that. An energy chain, sometimes called a cable carrier, is a linked plastic track that keeps cables organised and protected as a machine moves. The twisterchain version handles rotations beyond 600 degrees, meaning the robot can spin nearly two full circles without the cables fighting back.
How does it actually work?
The chain sits in a loose loop around the base of the robot. As the robot rotates, the chain lifts in steps across two distinct levels, which lets it complete a full 360-degree turn without hitting the metal connector plate it is anchored to. Defined movement across those two levels is what keeps the cables safe during fast, repetitive motion.
Because the chain holds its own shape, installers need only two attachment points. There are no guide troughs, the metal channels that normally keep a cable carrier from sagging all over the floor, and no elaborate alignment process. igus says that cuts installation time and cost.
Cable maintenance is also simpler. The chain opens along its inner curve, so a technician can pull out a cable for inspection or replacement without dismantling the whole assembly. Removable interior shelves separate different cables or hoses inside the chain, and an adjustable tension setting can be tuned to match the weight of the cables and the range of motion needed.
Which robots does this actually fit?
The twisterchain targets two trouble spots that igus identified, as reported by The Robot Report. First, the base joint (axis 1) of small industrial robots used for screwing, gluing, assembly, and pick-and-place work. Those robots spin quickly and frequently, and until now lacked a tidy cable-management answer for that first rotating joint. Second, the fifth axis of palletizing robots, the articulated arm segment closest to the gripping tool at the end. Loose hoses at that joint often collide with the tool itself, causing stoppages.
| Feature | Detail |
|---|---|
| Max rotation angle | Over 600 degrees |
| Guide trough required | No |
| Connection points needed | 2 |
| Target axes | Axis 1 (robot base), Axis 5 (palletizer arm) |
| End-of-life option | Recyclable via igus "change" programme |
For factory operators, the practical upshot is fewer cable-related stoppages and, potentially, a simpler maintenance routine. The chain is available in stock alongside igus's catalogue of roughly 234,000 other parts, and the company's website lets buyers calculate expected service life before ordering.
Common questions
What is an energy chain and why does a robot need one?
An energy chain is a linked plastic track that bundles and protects the power and data cables running to a moving machine. Without one, cables can snag, fray, or snap when a robot joint rotates repeatedly at speed.
Does this work on any brand of robot?
Igus says the twisterchain can be mounted on the floor or on a raised plinth for axis-1 applications, and on the robot arm or end-of-arm tool for axis-5 use, suggesting broad compatibility. Buyers should confirm fit with their specific robot model before ordering.
What happens to the chain when it wears out?
Igus accepts used energy chains through its "change" recycling programme, so the worn parts do not have to go to landfill.
