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Product

3D torsion robot hybrid cable0.6/1 kV + 24 V + Signal±180°/m 3D TorsionSingle-Cable EOAT

Robot Hybrid Power and Signal CableSingle-jacket ±180°/m 3D torsion robot power, control & screened signal cable

All-in-one 3D torsion-resistant robot dress-pack cable integrating 0.6/1 kV power cores, 24 V brake/valve control cores and individually spiral-screened signal/feedback pairs inside one weld-spatter-proof PUR jacket for hollow-wrist robots and EOAT.

Anti-torsion braid
Low-EMC design
EMC screen
Oil-resistant
Order designation
ROBOT-HYB 4G2.5+(2×1.0)C+2×(2×0.25)C
Outer Ø ≈
14.1 mm
Total copper
182 kg/km
Total weight ≈
286 kg/km
Min. bend R (moving)
106 mm
Check against my drumAll sizes (12)
Request a quoteDatasheetWhatsApp
Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum
Power voltage
0.6/1 kV
control 300/500 V · signal 300 V
Torsion rating
±180°/m
≥ 5M cycles on 1 m robot loop
Pair screening
Spiral D-screen
individual + overall Cu shields
Bend radius
7.5 × OD
moving & 3D flex · 4 × OD fixed
Temperature
−40…+80 °C
moving · −50…+80 °C fixed
Outer sheath
Matte Black PUR
weld-spatter & LABS-free TMPU

Typical values for this cable type, based on DIN VDE 0250 / UL AWM Style 21223 — confirmed in the datasheet and quotation for your order.

Application fit

Is Robot Hybrid Power and Signal Cable right for your machine?

Replaces 2 or 3 separate cables inside hollow-wrist robot arms and external corrugated dress packs feeding servo weld guns, grippers and tool changers.

Energy chain / drag chain

Suitable

Engineered for both ±180°/m 3D robot wrist rotation and 7th-axis linear gantry cable carriers.

VFD inverter to AC motor screened feeder

Suitable

Individually spiral-screened signal pairs + overall D-shield prevent 0.6/1 kV PWM power from disturbing encoder/bus signals.

Fixed installation

Suitable

UL 1000 V AWM Style 21223 allows single-cable routing from cell controller to the Axis-6 tool flange.

Motorised monospiral reel

Not suitable

Optimised for multi-axis robot torsion rather than high-tension monospiral outdoor crane drums.

Use NSHTÖU Reeling Cable
Typical machinesHollow-Wrist 6-Axis RobotsServo Spot-Welding GunsRobotic Tool Changers & GrippersCobot Force/Torque Wrist HarnessesDispensing, Sealing & Laser Heads

Construction

Layer by layer

Shown: 4G2.5 + (2×1.0)C + 2×(2×0.25)C hybrid robot cable combining four 2.5 mm² power cores, one screened 1.0 mm² brake pair, and two screened 0.25 mm² feedback pairs.

123456
Schematic, not to scale — generated from the layer data
#LayerMaterial & reference
1Hybrid power, control & data conductorsSuperfine bare/tinned copper strands (0.05–0.10 mm filaments, IEC 60228 Class 6+)Reverse-lay stranding matched across different cross-sections for uniform torsion
2Low-capacitance TPE-E / PP insulation0.6/1 kV TPE-E on power cores; low-loss PP on signal/feedback pairsPrevents capacitive coupling and dielectric heating
3Individual pair spiral D-screens (C)Helically wound tinned copper D-shield (≥ 85 % coverage) + PTFE wrap on each brake and signal pairIsolates millivolt encoder/bus pairs from 400–690 V PWM motor cores under ±180°/m twist
4Interlayer PTFE sliding wrapsLow-friction fluoropolymer tapes around hybrid sub-bundlesAllows power cores and screened pairs to shift independently during 3D torsion
5Overall helical copper D-shieldTinned copper spiral screen (≥ 85 % optical coverage) over entire hybrid core bundle360° EMC shielding without cross-braid wire shear
6Weld-spatter PUR outer jacketLow-adhesion matte black polyurethane (TMPU, RAL 9005)DIN EN 50363-10-2 · LABS-free, oil- and weld-slag resistant

Servo Weld-Gun Hybrid

4G power (1.5–16 mm²) + 1 screened brake pair + 2 screened encoder/resolver pairs for single-cable servo guns

EOAT / Tool-Changer Hybrid

24 V / 400 V power cores + unscreened valve control cores + screened RS-485 / CAN / IO-Link pair

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on DIN VDE 0250 / UL AWM Style 21223. Values for your order are confirmed in the datasheet and quotation.

Electrical

Rated voltage U0/U
Power: 0.6/1 kV · Control: 300/500 V · Data: 300 V
AC test voltage
Power: 4000 V AC · Control/Data: 1500–2000 V AC
Screen / Field control
Individual spiral Cu D-screens + overall D-shield
Capacitance
Power ≈ 60 pF/m · Signal pairs ≈ 48 pF/m
Near-end cross-talk (NEXT)
≥ 60 dB between power cores and screened signal pairs

Thermal

Temperature, flexing
−40 °C to +80 °C
Temperature, fixed installation
−50 °C to +80 °C
Max. conductor temperature
+90 °C (VDE) · +80 °C (UL AWM)

Mechanical

Torsional stress
±180°/m over 1 m vertical robot dress pack
Torsion endurance
≥ 5,000,000 combined torsion & bend cycles
Min. bending radius, moving
7.5 × OD (≤ 16 mm) · 10 × OD (> 16 mm)
Min. bending radius, fixed
4 × OD
Max. acceleration
Up to 30 m/s² (3D wrist) · 50 m/s² (linear)

Resistance

Oil resistance
DIN EN 50363-10-2 · UL Oil Res I & II
Flame retardance
IEC 60332-1-2 · UL 1581 VW-1 / FT1
Halogen-free / Smoke density
IEC 60754-1/2 halogen-free PUR
Weld-spatter & LABS
Weld-slag resistant & LABS-free (VW PV 3.10.7)

Reference standards

Cable type (construction standard)
DIN VDE 0250 / 0812 & ISO 10218 hybrid dress-pack
Conductor
Superfine copper exceeding IEC 60228 Class 6
Product approvals
UL AWM Style 21223 (1000 V 80 °C) · CSA AWM
RoHS & REACH
2011/65/EU (RoHS 2) & EC 1907/2006 compliant

Identification

Sheath colour
Matte Black (RAL 9005)
Core identification
Power: U/V/W+GNYE · Control: Numbered · Pairs: DIN 47100
Marking
TEBAOFLEX ROBOT-HYB <size> ±180°/m 1000V UL CE
Customs tariff (HS)
8544.49

Sizes

12 standard composite robot hybrid configurations

Combines power, brake/valve control, and individually screened feedback/bus pairs in one torsion-resistant dress-pack cable.

Dimensions & weights
Order designationComposite configurationPrimary robot tool applicationOuter Ø ≈
mm		Total Cu
kg/km		Weight ≈
kg/km		Min. bend R
moving mm		Enquiry
Single-Cable Servo Weld-Gun & 7th-Axis Hybrids (Power + Brake + Feedback)
ROBOT-HYB 4G1.5+(2×0.75)C+2×(2×0.25)C4G1.5 + (2×0.75)C + 2×(2×0.25)C7th-Axis / Servo Gripper + Encoder12.613221894
ROBOT-HYB 4G2.5+(2×1.0)C+2×(2×0.25)C4G2.5 + (2×1.0)C + 2×(2×0.25)CServo Weld Gun + Brake + Feedback14.1182286106
ROBOT-HYB 4G4.0+(2×1.0)C+2×(2×0.34)C4G4.0 + (2×1.0)C + 2×(2×0.34)CMedium Servo Gun + Bus + Brake15.8258384118
ROBOT-HYB 4G6.0+(2×1.5)C+2×(2×0.34)C4G6.0 + (2×1.5)C + 2×(2×0.34)CHigh-Force Servo Gun Single-Cable17.9364520134
ROBOT-HYB 4G10+(2×1.5)C+(2×0.5)C4G10 + (2×1.5)C + (2×0.5)CHeavy Spindle / Weld Gun + Sensor20.6548745154
ROBOT-HYB 4G16+(2×1.5)C+(2×0.5)C4G16 + (2×1.5)C + (2×0.5)CMFDC Spot-Weld Transformer Hybrid24.28151,070182
End-of-Arm Tooling (EOAT), Gripper & Cobot Wrist Hybrids
ROBOT-HYB 4G1.5+4×0.5+(2×0.25)C4G1.5 + 4×0.5 + (2×0.25)CEOAT Actuator + Solenoid Valves + Bus11.510818286
ROBOT-HYB 4G2.5+8×0.5+(2×0.25)C4G2.5 + 8×0.5 + (2×0.25)CMulti-Valve Tool Changer + Power13.8174272104
ROBOT-HYB 3G2.5+4×0.75+2×(2×0.25)C3G2.5 + 4×0.75 + 2×(2×0.25)CDispensing Head Heater + Flow Sensors13.4162256100
ROBOT-HYB 2×1.5+4×0.5+4×(2×0.25)C2×1.5 + 4×0.5 + 4×(2×0.25)C24 V Cobot Wrist Power + Force/Torque11.811418888
ROBOT-HYB 4G2.5+2×(2×0.5)C4G2.5 + 2×(2×0.5)CRobot Axis Power + Dual CAN/RS-48512.415223893
ROBOT-HYB 4G6.0+4×1.0+2×(2×0.5)C4G6.0 + 4×1.0 + 2×(2×0.5)CRobotic Deburring Spindle + Tool I/O18.4388552138
  • Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
  • Custom composite lay-ups (combining power cores, coax, Cat.6A Ethernet quads, or pneumatic tubing) can be engineered from 300 m MOQ.

Reel check

Will it fit your machine?

A first screen using datasheet values. Engineering confirms drum geometry, acceleration and tension with your quotation.

Check results

Drum core 160 mm is below 212 mmUse a larger drum core or a smaller cable size
180 m/min ≤ 240 m/minWithin the rated travel speed
Minimum bending radius
106 mm
Min. drum core diameter
≈ 212 mm
Cable weight on drum
3.4 kg
Copper content
2.2 kg
Indicative only: based on the datasheet outer diameter and 7.5 × OD bending radius. Current derating for wound layers per DIN VDE 0298-4 is assessed separately.

Quality & approvals

Testing & inspection

Routine tests on every production length, sample and type tests per batch — documented on an EN 10204 3.1 inspection certificate.

  1. ConductorClass 5 stranding
  2. Spark test100 % in-line
  3. Lay-upCores, earth, fillers
  4. SheathingInner, braid / screen, outer
  5. Electrical testsAC voltage, resistance
  6. DimensionsOD, wall thickness
  7. Inspection documents & dispatchDrum & dispatch
Testing & inspectionTest value / referenceFrequency
Routine tests
Multi-stage AC dielectric voltage test4000 V AC on power cores · 1500/2000 V AC on control & data pairsEvery manufactured length
Power-to-signal cross-talk attenuationNEXT ≥ 60 dB between phase cores and screened feedback pairsEvery production lot
Sample tests
3D torsion & flexing endurance test≥ 5 million cycles at ±180°/m without conductor or screen fracturePeriodic factory audit
LABS-free & weld-spatter resistancePass VW PV 3.10.7 paint-wetting test and DIN EN 50363-10-2 TMPUType approval

Inspection certificate

Issued with every drum, listing the routine test results for that length.

Product approvals

CE (2014/35/EU LVD & 2014/30/EU EMC)UL AWM Style 21223 (80 °C 1000 V Composite)VW PV 3.10.7 LABS-Free (Automotive Approved)

Company certificates

ISO 9001ISO 14001ISO 45001VDE marks approvalUL / cULCE · LVD / EMC

Marking & supply

Ordering & delivery

Sheath marking

TEBAOFLEX ROBOT-HYB <size> ±180°/m 1000V UL LABS-FREE CE
Delivery form
Non-returnable fumigated wooden drums or coils
Standard lengths
100 m · 500 m · 1000 m (cut lengths on request)
MOQ
100 m (stock sizes) · 300 m (custom)
Lead time
2–3 weeks ex-works
Incoterms
EXW, FCA, FOB, CIF, DAP

Technical documents

Downloads

PDFRobot Hybrid Power and Signal Cable – technical datasheet12 sizes · construction, technical data, approvalsXLSXRobot Hybrid Power and Signal Cable spec data (Excel)All 12 sizes with dimensions and data, for your BOM or quotation
Revision
2026-10-20
Updated
2026-10-20

FAQ

Questions engineers ask first

Not covered here? Send your drawing — an engineer replies within 2 business hours.

Why combine robot power, brake, and feedback signals into a single Robot Hybrid Power and Signal Cable?
When three separate cables (motor power, valve control, and encoder feedback) are pulled through a narrow hollow robot wrist or corrugated dress-pack conduit, they rub against each other and tangle into corkscrews under ±180°/m torsion. Combining all circuits into one torsion-balanced hybrid cable reduces dress-pack diameter by 30 %, eliminates cable-on-cable abrasion, and cuts harness installation time in half.
How do you prevent different conductor gauges (e.g. 6.0 mm² power vs 0.25 mm² signal) from pulling apart during 3D torsion?
In a hybrid cable, thin 0.25 mm² pairs have much lower axial stiffness than 6.0 mm² power cores. We strand the 0.25 mm² pairs around elastic elastomer buffers with a shorter pitch angle and wrap each sub-bundle in PTFE sliding tape so the smaller pairs can elongate elastically without taking tensile load when the robot wrist bends and twists.
Can this cable support single-cable digital servo protocols such as HIPERFACE DSL or EnDat 2.2?
Yes. Both the 2-pair and 1-pair hybrid configurations include low-capacitance (≈ 48 pF/m), 100–110 Ω matched individually screened pairs suitable for RS-485 digital encoder communication alongside 0.6/1 kV PWM power.
Can TEBAOFLEX supply this hybrid cable pre-terminated with hybrid circular connectors (M23 / Han-Modular)?
Yes. We supply both bulk drum lengths and turnkey dress-pack harnesses terminated with hybrid M23, M40, or modular rectangular heavy-duty connectors with 360° internal EMC screen separation.

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01Selected sizes

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03Message for our engineers

Robot Hybrid Power and Signal Cable

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Reel & motion:
- Reel type: 
- Drum core diameter (mm): 
- Cable length on drum (m): 
- Travel speed (m/min): 
- Max. acceleration: 
- Cycles per hour: 
- Length and quantity: 
- Ambient temperature: 
- Exposure (outdoor, water, oil, abrasion): 
- Destination country: 
- Equipment and operating conditions:
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