igus Twisterchain Enables 600-Degree Robot Rotation

igus has introduced the twisterchain, a self-supporting energy chain designed to solve critical cable management challenges in compact industrial robotics. The system allows for rotation angles exceeding 600°, providing a controlled path for energy and data cables that prevents collisions with robot tools and connector plates.

The system is specifically engineered for the first axis of small industrial robots—such as the FANUC LR Mate and KUKA KR AGILUS—as well as the fifth axis of palletizing robots. Because the twisterchain is unsupported, it requires only two connection points to operate. This design removes the need for expensive guide troughs, reducing both the cost and the physical footprint of the installation. To simplify maintenance, the chain opens at the inner radius for easier cable insertion and includes removable shelves to keep different cables separated.

Solving the "Hanging Hose" Problem

Design engineers working with compact robots have long struggled to manage energy supplies on the first axis. In many setups, connector plates block rotary modules, forcing technicians to rely on makeshift "hanging hoses." These improvised solutions are prone to rapid wear and tear, leading to frequent system failures. Similarly, palletizing robots often lack dedicated guidance for the fifth axis, leading operators to use corrugated hoses that risk colliding with end-of-arm tooling during operation.

Impact on Industrial Reliability

By establishing a defined, two-level movement path, the twisterchain eliminates the unpredictability of loose cabling. This shift increases the reliability and stability of highly dynamic robotic applications, particularly in high-precision environments. For industries relying on assembly, gluing, and pick-and-place operations, this means a significant reduction in downtime caused by cable fatigue and a boost in process repeatability.

Matthias Meyer, Head of the triflex e-chains and Robotics Business Unit at igus, stated that the system now makes it possible to rotate 360° around a robot's base without colliding with the connector contour. He noted that the system ensures a "permanently reliable energy supply even with highly dynamic movement profiles."

Future Outlook

The introduction of the twisterchain marks a move toward integrated, modular cable management that can keep pace with the increasing agility of small-scale robotics. As manufacturers push for tighter footprints and faster cycle times, the ability to achieve extended rotation angles without external support structures will likely become a standard requirement for compact robotic cells.