igus has introduced a new self-supporting twisterchain rotary module designed to simplify energy and cable management for compact industrial robots. The latest solution enables rotational movements of up to 600 degrees, offering a reliable alternative to conventional cable routing systems while reducing installation time and maintenance requirements.
The new twisterchain addresses one of the most common challenges faced by robot manufacturers and system integrators—providing a dependable energy supply for the first axis of compact articulated robots, where limited installation space and continuous rotational movement often make cable management difficult. Existing solutions typically require guide troughs or improvised cable arrangements that are prone to wear and unexpected failures.
The self-supporting rotary module eliminates the need for guide trough systems by using a suspended energy chain that follows the robot’s movement in a controlled manner. Installed around the robot base, the system allows cables to move smoothly as the robot rotates, preventing interference with connector plates and other structural components. This enables unrestricted 360-degree movement while improving cable protection and overall system reliability.
According to Matthias Meyer, Head of the triflex e-chains and Robotics Business Unit at igus, compact industrial robots are widely used for assembly, pick-and-place, gluing and fastening applications, but cable routing around the robot base has remained a persistent engineering challenge. The new twisterchain has been developed to eliminate the need for temporary cable arrangements, offering a more durable and dependable solution for modern automation systems.
The product also addresses cable management on the fifth axis of palletising robots, another area where conventional solutions have been limited. In many robotic systems, cables can only be routed internally up to the fourth axis, forcing designers to rely on corrugated hoses that may move unpredictably or interfere with tools during operation.
The unsupported twisterchain provides controlled cable guidance for power and data lines on the fifth axis, allowing them to follow continuous rotational movements while maintaining a defined path. This reduces the risk of cable collisions with the robot arm or end-of-arm tooling, improving operational safety and extending cable life in demanding applications.
The new solution has also been designed for quick installation and easy retrofitting. Since the system requires only two connection points, installation is significantly simpler than conventional cable carrier systems. Flexible internal separators allow users to configure different cable layouts, while the chain opens on the inner radius, enabling cables to be inserted from the outside without threading them through the entire system.
An adjustable pretension mechanism allows the twisterchain to be fine-tuned according to cable weight and required rotation angle, ensuring smooth movement, high repeatability and stable performance. With this latest development, igus continues to expand its robotics portfolio by providing practical cable management solutions that improve machine reliability, simplify installation and support the growing demand for high-performance industrial automation.
