Cable-path optimization method for industrial robot arms

•We propose automatic cable-path optimization for robot arms.•The method specifies the optimal cable length and guide configurations.•Computational efficiency increased by segmentation and robustness to disturbances.•Our simulations closely match the experimental results with an actual robot arm.•Allow inexperienced engineers in easily designing cable paths, reducing breakage. The production line engineer's task of designing the external path for cables feeding electricity, air, and other resources to robot arms is a labor-intensive one. As the motions of robot arms are complex, the manual task of designing their cable path is a time-consuming and continuous trial-and-error process. Herein, we propose an automatic optimization method for planning the cable paths for industrial robot arms. The proposed method applies current physics simulation techniques for reducing the person–hours involved in cable path design. Our method yields an optimal parameter vector (PV) that specifies the cable length and cable-guide configuration via filtering the candidate PV set through a cable-geometry simulation based on the mass–spring model. The proposed method offers two key features: 1) Increased computational efficiency via an optimization procedure that separates the entire cable into the cable segments. In the proposed method, the entire cable is segmented at the positions of the cable guides into several separate cable segments, and the PVs of the cable segments that satisfy the constraints of collision, stretch, and curvature radius are filtered into the local optimal PV set. The global optimal PV is obtained by finding the combination of the local optimal PVs which have the same guide configuration between the adjacent cable segments and have minimal total length of the adjacent cable segments. 2) Robustness to external disturbances, such as fluctuation in the physical properties of the cables and the accuracy of manually attaching the cables. The PVs of the local optimal PV sets are required to satisfy the above constraints, even if the cable length changes in the predefined range, which ensures the robustness of the obtained cable path. To verify the validity of the proposed method, we obtain the global optimal PVs by applying the method to several pick-and-place motions of a six-axis vertical articulated robot arm in our simulations and implement the cable paths on an actual robot arm based on the obtained PVs. Our results indicate that the proposed method can a