Our Guide to Robotic Cabling

In the rapidly evolving robotics industry, the integrity and performance of robotic systems heavily rely on the unsung hero of technology: cable assembly. “Cable assembly for the robotics industry” is not just a phrase; it’s a cornerstone of modern robotics, ensuring that power, data, and signals are transmitted efficiently and reliably across various components.

The Importance of Cable Assembly in Robotics

Cable assemblies play a critical role in the robotics industry, serving as the lifelines that connect various components and systems within a robot. Their importance cannot be overstated, as they transmit power and data essential for the robot’s operation. Precision in cable assembly ensures that electrical connections are accurate and secure, directly influencing a robot’s performance and reliability. Flexibility is also crucial, allowing cables to move with the robot without compromising their structural integrity or functionality. Additionally, the durability of these assemblies guarantees long-term operation, even in harsh conditions where robots are often deployed. Together, these attributes ensure that robotic systems can perform their tasks efficiently, safely, and without interruption, highlighting the indispensable role of high-quality cable assemblies in robotics.

Types of Cables Used in Robotics

The robotics industry utilises a diverse range of cables. Let’s dive into the types of cables that are commonly used in robotics:

  • Power Cables: Power cables in the robotics industry are designed to deliver electrical energy from the power source to the motors, actuators, and other components that require power to operate. These cables must be highly durable and capable of handling the voltage and current levels necessary to drive the robotic system without overheating or degradation over time. The construction of power cables often includes thick conductors to manage high power loads and insulation materials that can withstand environmental stressors commonly encountered in robotic applications.


  • Data Cables: Data cables are used for transmitting signals and data between the various electronic components within a robotic system, such as between sensors, control units, and processing units. These cables are crucial for smooth communication and task coordination within the robot. They enable response to sensor inputs, command execution, and performance of intended functions. Data cables must offer high-speed transmission capabilities and protection against electromagnetic interference (EMI) to ensure the data’s integrity.


  • Hybrid Cables: Hybrid cables represent an innovative solution in robotic cabling, combining power and data lines within a single cable assembly. This integration allows for a more compact and organised setup, reducing the cables required and simplifying the cable management within the robot. Hybrid cables are especially useful in applications where space is limited or where it’s advantageous to minimise the potential for cable entanglement. Hybrid cables offer a streamlined solution by incorporating both power and data transmission capabilities.

Key Considerations for Robotics Cabling

Correct Cabling

Choosing the right type of cable for robotic applications is paramount. “Correct cabling” means selecting cables that are specifically designed for the movements, environments, and operational demands of robotic systems. GEM Cable provides a wide range of specialised cable assemblies that cater to the unique requirements of the robotics industry, ensuring optimal performance and longevity.

Long Enough but Not Too Long

The length of the cable plays a critical role in robotic systems. Cables should be long enough to accommodate the full range of robotic movement without stretching, yet not so long that they create loops or excess that could snag or tangle. GEM Cable excels in creating custom cable lengths tailored to specific robotic configurations, striking the perfect balance between mobility and efficiency.

Flexing vs. Twisting

Robotic cables must be flexible enough to bend with the robot’s movements but resistant to twisting, which can damage the internal structure of the cable. Understanding the distinction between flexing and twisting is crucial for the longevity of cable assemblies in robotics. GEM Cable’s products are engineered to withstand high flex cycles while maintaining their integrity, even in applications that involve complex or repetitive movements.

Firm but Not Rigid

While robotic cables need to be durable, they should not be so rigid that they impede the robot’s operation. The ideal cable assembly combines firmness for protection and durability with sufficient flexibility to seamlessly follow the robot’s movements. GEM Cable’s expertise in material science and cable design ensures that their cable assemblies meet these critical criteria.

No Cables

In some advanced robotics applications, reducing cable use through wireless communication or integrated circuits can be advantageous. However, when cables are necessary, it is vital to ensure they are correctly integrated and protected. GEM Cable stays at the forefront of technology, advising clients on when and how to use cable assemblies efficiently and innovatively in their robotic systems.

Making Connections

The points at which cables connect to robotic systems and components are critical. These connections must be secure and maintain stability despite movement and vibration. GEM Cable creates robust connectors and junctions that ensure reliable connectivity, even in the most demanding robotic applications.

Challenges in Robotic Cabling

Robotic applications present unique challenges for cabling. The cables must withstand extreme conditions, including high flex cycles, exposure to chemicals, and temperature variations. Additionally, the trend towards miniaturisation demands cables that deliver optimal performance in increasingly compact spaces.

How GEM Cable Supports the Robotics Industry

Understanding that each robotic application has its own set of requirements, GEM Cable focuses on providing tailored solutions that address specific operational needs. Whether it’s for industrial automation, medical robotics, or consumer robotics, GEM Cable’s team works closely with clients to develop and manufacture cable assemblies that enhance the functionality and longevity of robotic systems.

Get in touch with us for your cabling solutions.