Custom Robot Connector to Electrical Wire Harness

1. Customization process and core elements
‌Demand analysis and design specifications‌
It is necessary to clarify the robot application scenarios (such as industry, service, special robots) and working environment (temperature, humidity, vibration, jne.). In this way, the current carrying capacity, signal transmission type (high frequency/low frequency), mechanical strength and other parameters of the wiring harness can be determined.
The connector type needs to be selected according to the robot interface design. Common ones include waterproof connectors (suitable for humid environments), oil-resistant connectors (industrial scenarios), and anti-interference shielded connectors (high-frequency signal transmission).
The wiring harness design tends to be modular, which is convenient for rapid replacement and maintenance, and supports flexible adjustment of the robot structure.

763061-005 24 Position Female to Male Assembly 1.64′ (500.00mm)

‌Material selection and performance requirements‌
‌Insulating materials‌: Silicone (high temperature resistance up to 200°C), polyurethane (wear-resistant and anti-bending) or special PVC (chemical corrosion resistance) are preferred.
‌Conductor material‌: high-purity copper wire (excellent conductivity), tinned copper (anti-oxidation), alloy wire (anti-stretching), jne., to meet different mechanical stress requirements.
‌Sheath and shielding layer‌: Add nylon braided layer (anti-wear) or aluminum foil shielding layer (anti-electromagnetic interference) to improve the stability of the harness in complex environments.

1W226-TZLB-250-0LC 26 Position Female to Male Assembly 8.20′ (2.50m) Harness Stabilization Performance

‌Production process and quality control‌
Adopt ‌automatic crimping/welding technology‌ to ensure reliable connection between terminals and wires to avoid cold soldering or poor contact.
‌Injection molding process‌ is used for connector sealing to meet IP67 and above protection levels.
The whole process detection includes ‌conductivity test‌ (circuit integrity), ‌voltage withstand test‌ (insulation strength), ‌mechanical life test‌ (bending/stretching times), jne.

2. Industry trends and solutions
‌Intelligent upgrade‌: Harnesses with integrated sensors (such as temperature/tension monitoring) can provide real-time feedback on operating status and support predictive maintenance.
‌Green manufacturing‌: Adopt recyclable materials (such as environmentally friendly TPE) and low-energy production processes to comply with EU RoHS and other environmental standards.
‌Customized service‌: Suppliers such as Suzhou Kubang and Jiangsu Voda provide ‌full-process customization‌, covering design, proofing, mass production and after-sales support, and are suitable for emerging fields such as collaborative robots and humanoid robots.

3. Comparison of typical suppliers
Suzhou Kubang: Oil-resistant/torsion-resistant cables imported from Japan, customized design with high flexibility for industrial robots and automotive manufacturing wiring harnesses.
Jiaxing manufacturers: Modular wiring harness design, supporting 3D printing rapid prototyping;

4. Precautions
‌Compatibility verification‌: The interface between the connector and the robot control system needs to be matched in advance to avoid signal transmission delay26.
‌Environmental simulation test‌: Verify the performance of the wiring harness under extreme conditions such as high temperature, high humidity, and salt spray to ensure long-term reliability34.

191945-02 68-pin female to male assembly 6.56′ (2.00m) Harness small batch customization

Intelligent trend of industrial robots
First of all, with the continuous application of various automation technologies such as sensor technology and big data in industrial robots, industrial robots are gradually developing towards the intelligent direction of autonomous learning and autonomous operation. Siksi, industrial robots will add more connection nodes for devices such as sensors. How to ensure stable and reliable transmission of large amounts of data at connection points will be particularly important, especially in more complex industrial field environments. Not only do you need to ensure that the interface complies with the latest industry standards, but you also need to ensure that it is perfectly compatible with other devices.

Modular requirements for industrial robots
Secondly, industrial robots often require mass production and have relatively high standardization requirements for products to ensure the performance of robot products to the greatest extent. The modularization of each core component of the robot lays a solid foundation for the standardization of the entire robot machine.

More importantly, modular-based customization will better meet the market’s continued demand for the rapid launch of new models.

To this end, the modular structure requires interfaces that cater to various application combinations of power, signal and data connections. In particular, a rich and complete connector product line is needed as a basis so that users can flexibly carry out various combinations, and it is best to carry out customized development based on the latest needs of users.

Wide adaptability of industrial robots
The application of robots has expanded from the initial automotive industry and 3C industry to more general industrial fields. Especially with the upgrading of domestic industries and the impact of the epidemic, industrial robots have gradually penetrated into some industrial segments and commercial fields.
As robots are widely used in various industries, the demand for power, signal and data connections will continue to extend and expand. A wide range of application performance and rich product lines will be the key to ensuring a variety of successful applications.

Connection solutions for industrial robots
YAXUN Electronics specializes in providing high-performance products with wide applicability and technology-oriented domestic solutions and other services in the connector field.
In addition to servo wiring harnesses, YAXUN Electronics’ representative products also include terminal blocks, connectors, wire-to-board connectors, and circular connectors. Whether it is a one-stop solution for servo drives or general-purpose products such as M8/12, RJ45, D-sub and other series. Both are committed to providing industrial robot customers with diversified connection solutions and services from connectors to overall wiring harnesses.

24AWG Wire Harness with Jst Connector for Smart Home

Related products 01: M12 circular connector
The circular connector’s cylindrical structure is naturally rugged, providing a rugged housing and strain relief to help withstand bumps, shocks and vibrations, preventing damage to the connection point. Also used to connect electrical and optical circuits with lightweight, space-saving designs that provide highly reliable, sealed connections that are resistant to moisture and chemicals.

M12 circular connectors have 12 mm locking threads, are designed for washdown and corrosive environments, and are available with 3, 4, 5, 8 or 12 nastat. It has strong durability and meets the stable operating intensity of robots in high-vibration environments. Generally sensor and power applications require 3-pin and 4-pin; PROFINET and Ethernet require 4-pin and 8-pin; Fieldbus, CAN bus and DeviceNet usually use 4-pin and 5-pin; 12-pin is used for signaling requirements.

Related products 02: terminal blocks
Terminal blocks are basic accessories for electrical connections. They mainly connect the end points or fixed parts of contacts between wires, electrical appliances, and control boards.
The commonly used terminal block screw type (also known as wall-through type) type, the number of product positions can be determined, flexible wiring, anti-vibration, low structural height, easy to install in a small space, large wiring capacity.
Screw terminal blocks can be installed side by side on panels with thicknesses ranging from 1mm to 10mm. It can automatically compensate and adjust the distance of panel thickness to form a terminal arrangement with any number of poles, and isolation plates can be used to increase air gaps and creepage distances.

Related products 03: Wire-to-board connector
The main function of the wire-to-board connector is to transmit power and signals to ensure the continuous operation of the robot.
The number of wire-to-board connectors can be customized as needed. The product has strong earthquake resistance, low structural height, easy installation in a small space, and large wiring capacity.
The development trend of modern industrial robots mainly lies in human-machine collaboration, autonomy, intelligence, informatization and networking, helping humans to perform operations in high-risk environments without harming people or themselves. Using a new generation of robots to construct a “smart factory” is the development direction proposed by Industry 4.0.
As the global “Industry 4.0” process continues to advance, the demand for power, signals and data connections will continue to extend and expand. A wide range of application performance and rich product lines will be the key to ensuring a variety of successful applications.