Case Study: High-Flex Life Harness for Robotics
How our custom overmolded solution eliminated field failures and extended product lifespan by over 300%.
1. The Customer's Challenge
An industrial robotics manufacturer was experiencing costly, premature failures in their multi-axis robot arms due to cable fatigue. The constant, repetitive motion was causing standard cables to break down, leading to machine downtime and customer dissatisfaction. They needed a complex, multi-branch harness with an exceptionally high-flex life to eliminate these field failures.
2. The Cablum Solution
Through a detailed Design for Manufacturability (DFM) analysis of the robot arm's movement, we identified the key stress points. Our solution focused on material science and structural design:
- Material Selection: We proposed using a specialized high-flex life TPE (Thermoplastic Elastomer) jacketed cable, rated for over 10 million flex cycles.
- Strain Relief Redesign: We designed a custom overmolded strain relief that distributed bending stress over a wider area, preventing sharp kinks at the connector interface.
3. The Implementation Process
Our team created 3D models of the overmold for client approval and produced rapid prototypes. These samples were then subjected to millions of cycles on our in-house swing/flex life tester to validate the design. The results confirmed our engineering calculations, and we moved to mass production with a fully documented and controlled process.
4. The Results
The new assembly was a resounding success, delivering transformative results for the client:
- Product Lifespan Increased by 300%: The new harness extended the robot arm's operational lifespan far beyond the original design goal.
- Field Failures Eliminated: Warranty claims and costly service calls related to cable failure dropped to nearly zero.
- Enhanced Brand Reputation: The client's product gained a reputation for reliability and durability in the market.
Project Snapshot
- Client: Industrial Robotics Manufacturer
- Industry: Automation
- Challenge: Cable Fatigue, High-Flex Life
- Solution: Specialized Cable, Custom Overmolding
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