Description

3HAC031977-001-04/3HAC031851-001-05 Technical Specifications

Product Model:

3HAC031977-001-04:Upper Arm Cable for Robot External Control Cabinet Connection

3HAC031851-001-05:Sixth Axis Motor Cable for Robot Main Body Connection

Manufacturer:ABB

Product Type:High-Flex Cable Assembly for Industrial Robots

System:ABB RobotStudio/RobotWare Control Systems

Applicable Robot Models:

IRB 6640

IRB 6700 Series(e.g.,6700-155/3.20,6700-200/2.60)

IRB 7600(select configurations)

Cable Construction:

Multi-core composite construction:Contains power cables(3 x 25 mm²or 3×16mm²),encoder signal cable,brake cable,ground cable

Conductor Material:High-purity oxygen-free copper,twisted strands

Insulation:Special PVC or TPE,oil-resistant and high-temperature resistant(-40°C to+105°C)

Shield:Double-layer aluminum foil+tinned copper mesh,excellent EMC performance

Outer Jacket:Highly flexible PUR(polyurethane),cut-resistant,abrasion-resistant,and UV-resistant

Connector Type:

One end:AMP or HARTING heavy-duty connector(with locknut)

Other end:Robot-specific plug(such as the MS/MD series)

Protection Rating:IP67(dustproof,waterproof,and high-pressure washdown-resistant)

Mechanical Properties:

Flex Life:≥2,000,000 cycles(tested according to IEC 60227)

Tensile Strength:≥500 N

Minimum Bend Radius:6×Cable OD

Mounting Method:Secure along the internal or external cable duct of the robot arm using cable ties or clips

Color:Black(Standard)

Length:Customizable based on the robot’s arm span and mounting method(typically 4–8 meters)

3HAC031977-001-04/3HAC031851-001-05 Product Overview

Hey friends,today we’re talking about the two ABB 3HAC031977-001-04 and 3HAC031851-001-05 cables—they’re the lifeblood of ABB’s large industrial robots!Don’t underestimate them;they’re the key to the robot’s movement.

Just think about it:an IRB6700 robot,carrying a 200 kg payload,rotating several times per minute at full acceleration.How does it power its servo motors?How does it transmit encoder signals?How does it control the brakes?It all depends on these highly flexible cables.

The 3HAC031977-001-04,commonly called the”upper arm cable”or”external connection cable,”connects one end to the control cabinet and the other to the robot’s third or fourth axis,carrying power and signals from the cabinet to the robot’s”shoulder.”The 3HAC031851-001-05,the”sixth-axis motor cable,”is specifically designed for the wrist(sixth-axis)motor.Its routing is the most complex and requires the most frequent flexing.

These aren’t ordinary wires,but rather specially formulated,highly flexible composite cables:they contain large-section power lines(for motor power),hair-thin encoder lines(for position feedback),brake lines,and ground wires,all encased in a PUR sheath.This sheath is oil-resistant,abrasion-resistant,and flex-resistant,withstanding temperatures as low as-40°C in a freezer and as high as+100°C in a paint booth,and boasts a lifespan of up to 2 million flexes.

You see it swaying around every day in automotive welding lines,foundries,and machine tool loading and unloading.It’s no exaggeration to say that if a cable breaks,the entire line has to stop!

Key Features and Advantages

First,let’s talk about high flexibility and long life.The ABB 3HAC031977-001-04/3HAC031851-001-05 uses a multi-strand ultra-fine copper wire conductor with a highly elastic PUR sheath.It’s as flexible as noodles and has a small bending radius,making it ideal for the frequent movement of robot joints.Its 2 million flex cycles,calculated at 3,000 times per day,means it can last almost two years,far exceeding ordinary cables.

Next,let’s talk about reliability.Double-layer EMC shielding(aluminum foil+copper mesh)provides strong resistance to electromagnetic interference,ensuring encoder signal loss and accurate robot positioning.The connector is IP67-rated and resistant to water,oil splashes,and dust.The internal wiring harness has a strain relief design to prevent breakage.

Original compatibility is its greatest advantage.These two models are custom-designed by ABB for the IRB6640/6700,with fully compatible length,connectors,wiring sequence,and shield grounding.Using third-party”compatible cables”could result in alarms(encoder failure)at best,and even damage to the driver at worst,which is more trouble than it’s worth.

They’re also easy to maintain.The modular design allows you to replace any broken cable,eliminating the need to replace the entire wiring harness.The connectors feature locking nuts,ensuring they remain stable in vibration environments.For replacement,follow the ABB manual,and an experienced electrician can complete the task in two hours.

The ABB 3HAC031977-001-04 and 3HAC031851-001-05 are critical high-flexibility cable assemblies designed for ABB’s IRB6640 and IRB6700 series industrial robots.These cables serve as the primary power and signal transmission pathways between the robot controller and the servo motors,particularly for the demanding sixth axis.Constructed with multi-core,shielded conductors and a robust polyurethane(PUR)jacket,they withstand millions of bending cycles,extreme temperatures,and harsh industrial environments such as oil,coolant,and mechanical abrasion.The 3HAC031977-001-04 connects the controller to the upper arm,while the 3HAC031851-001-05 specifically services the sixth axis motor,ensuring precise motion control and feedback.Featuring IP67-rated connectors and superior EMC protection,these cables are essential for maintaining the reliability,accuracy,and uptime of automated production Lines in automotive,metalworking,and general manufacturing.As genuine ABB components,they guarantee perfect compatibility and long-term performance,minimizing unplanned downtime and costly repairs.

Application Areas

The ABB 3HAC031977-001-04/3HAC031851-001-05 cables are primarily used in high-speed,automated production lines.You’ll find them on automotive body-in-white welding lines,where robots wield welding tongs,sending cables swaying daily.In die-casting plants,they handle high-temperature oil and dirt,controlling the pick-up robots.In machine tool loading and unloading systems,they ensure precise pick-and-place operations without downtime.

In other applications,such as grinding,spray painting,and palletizing,these cables are critical consumables wherever large robots like the IRB6640/6700 operate.Timely replacement keeps the machines running;delayed replacement can halt production,resulting in significant losses.

Selection Guide/Purchasing Advice

If you’re looking to replace the ABB 3HAC031977-001-04 or 3HAC031851-001-05,please confirm three points:

First,what is your robot model and arm span?Different arm lengths require different cable lengths,so don’t buy the wrong one.

Second,make sure it’s an external or internal cable.The 3HAC031977-001-04 has external wiring,while the 3HAC031851-001-05 has internal wiring.Don’t confuse them.

Third,avoid buying”imitation cables”!Some cables on the market may look similar,but they have thinner copper cores,poor shielding,and brittle sheaths.They can break within three months and may even burn out the driver.

Our recommendation:Buy genuine new or certified refurbished parts with ABB labels and test reports for peace of mind.

Customer Case Study/Successful Application Analysis

Last year,an IRB6700 robot at an automotive parts factory in Guangdong suddenly reported a”sixth-axis encoder failure”alarm,halting production.Upon investigation,they discovered a broken encoder wire within the 3HAC031851-001-05 cable.They urgently ordered a new,genuine cable,which we shipped that same day and replaced the next day,restoring the system.The customer commented,”That cable is worth 100,000 yuan in production value.It’s a waste of money!”

Related Products

ABB 3HAC031978-001-04:Upper arm cable from the same series(different lengths or configurations).

ABB 3HAC031852-001-05:Fifth-axis motor cable for the IRB6700.

ABB M2004/M2006 Control Cabinet:The robot controller,to which the other end of the cable connects.

ABB RobotWare 6.x:The robot operating system,which relies on cables to transmit control commands.ABB SMC-01/SMC-02:Servo drive module,drives the motor via a cable.

ABB IRB6700 Spare Parts Kit:Contains common wear parts,including cable assemblies.

ABB Cable Protection System(CPS):Drag chain or reel system to extend cable life.

Pre-Installation Preparation

When replacing the ABB 3HAC031977-001-04/3HAC031851-001-05,first return the robot to zero position!Do not remove the cable at any point,as this will cause strain relief and damage the joints.Disconnect the power cord and release any residual pressure.When removing the old cable,take photos to record the cable routing and cable tie placement.Ensure the new cable is bent in the same direction as the old cable;do not twist it in the opposite direction.Insert the connector fully and tighten the lock nut.Before applying power,manually twist the cable to check for pinching or excessive stretching.

Maintenance Recommendations

This cable is a”consumable item”and is recommended for inspection every six months:

Check the outer sheath for cracks,dents,and oil accumulation.Check for loose connectors and locknuts.

Check the wiring path for interference and ensure the drag chain is functioning smoothly.

Use a multimeter to test the power cable continuity and encoder cable resistance for normal operation.

Don’t wait until it breaks to replace it;replace it in advance to prevent problems.

Product Guarantee

We at Shenzhen Changxin take every ABB 3HAC031977-001-04/3HAC031851-001-05 seriously.Upon arrival,we first inspect the appearance,length,and connector model,then use specialized equipment to test for continuity,insulation,and shielding.We offer a three-year warranty and will replace any damage not caused by human error.We’re not in the business of quick profits;we’re committed to being your long-term support for robot maintenance.Trust us,we’ll take our responsibility!

The ABB 3HAC031977-001-04 and 3HAC031851-001-05 are mission-critical components in robotic automation,and at Shenzhen Changxin,we treat every cable with the care it deserves.Each assembly undergoes rigorous visual inspection,electrical testing(continuity,insulation resistance,shielding integrity),and compliance verification with ABB specifications.We offer genuine new and certified refurbished units,backed by a 3-year warranty,global shipping,and technical support.Our goal is simple:to keep your robots moving—reliably,safely,and without unplanned downtime.Partner with us,and you’re not just buying a cable;you’re investing in production continuity.