SUMCAB Robotics is the division specialized in connectivity and automation solutions for demanding industrial environments. With a strong focus on the design and optimization of power-delivery systems for robotic applications, the company develops technical solutions such as SUMOTEX™ and SUMOSENSE™, aimed at improving operational efficiency and extending equipment service life.
Renault, an internationally recognized automobile manufacturer, contacted SUMCAB to strengthen the operational reliability of its bodyshop line. In this stage of the process—which requires high precision in the geometric verification of chassis—the goal was to ensure optimal performance of the robot-mounted vision systems. The collaboration enabled integration of technical solutions that improve operational continuity during subsequent vehicle assembly phases.
THE CHALLENGE
During the inline geometric control phase, each robot had to move quickly and perform complex turns while checking key reference points with vision cameras. However, this demanding motion subjected the cables to extreme stresses, which led to frequent breakages and, consequently, unplanned stoppages on the production line.
The impact was significant: each stoppage required technicians to be mobilized to replace wiring, interrupting the process flow and affecting the plant’s overall efficiency. Renault needed a robust and adaptable solution capable of withstanding the robot’s aggressive movements while also providing continuous system monitoring.
THE SOLUTION
In industrial robotics, the dresspack—the bundle of cables, hoses and support elements that accompanies the robot arm—plays a fundamental role in ensuring operational reliability under demanding working conditions. As part of the solution designed by SUMCAB, a dresspack optimized specifically to protect the vision system cables against continuous torsional stresses was integrated, adapting to the robot’s complex movements and significantly improving the assembly’s durability.
SUMCAB’s technical proposal was comprehensive, combining bespoke mechanical design with predictive software. First, the SUMOTEX™ system was applied: a highly resistant, lightweight and flexible textile energy package. This system protects the wiring with an airbag-type structure that cushions the robot arm’s movements, minimizing friction and wear—even in areas of direct contact with the robot chassis. Thanks to this technology, an optimal balance was achieved between mechanical flexibility and functional protection of the system.
In parallel, the camera cable’s performance was enhanced using the SUMFLEX® Mechatronic range, a solution developed specifically for environments with high flexion, torsion and repeatability demands. This cable—optimized in collaboration with Renault’s team—not only guarantees a longer service life but also better compatibility with the package routing and the robot’s complex motions.
To complete the solution, SUMOSENSE™ was incorporated: an intelligent monitoring module that maintains and supervises the air pressure inside the energy package. This device automatically regulates airflow, records real-time pressure maps and issues visual alerts via a traffic-light system. Additionally, when connected to the plant control network, it enables direct interaction with centralized supervision systems, triggering notifications or automatic responses in case of deviations.
All data collected by the system is sent to the cloud and managed through artificial intelligence tools. This digital ecosystem enables continuous monitoring of the energy package and cables, generates historical records, detects behavior patterns and anticipates possible failures. Thanks to this predictive maintenance approach, the system learns from the process over time, increasing its reliability and enabling data-driven decisions. SUMCAB has developed a dedicated application from which operators can easily view these parameters, consult logs and act based on the actual condition of the system.
From the project’s outset, Renault’s technical team demonstrated an open, co-creative attitude, which allowed for smooth, coordinated work at every stage. Following a detailed analysis of the robot model, SUMCAB designed custom mechanical structures adapted to the specific attachment points of the arm that ensured robust mounting of the SUMOTEX™ package and efficient routing of the assembly—capable of withstanding fast, repetitive turns without compromising integrity.
Finally, customized electrical and pneumatic adjustments were made to ensure full integration with the plant’s technical ecosystem. From calibrating air flow to implementing compatible sensors and connectors, every decision was taken in close coordination with Renault’s teams, ensuring a harmonious, functional implementation aligned with the plant’s quality standards.
RESULTS
Thanks to the new energy system with textile protection and active monitoring, unplanned stoppages caused by camera cable breakages were completely eliminated. Continuous, safe, incident-free operation was achieved.
• 100% reduction in camera cable breakages.
• Elimination of unexpected line stoppages.
• Estimated 3× increase in dresspack service life.
• Savings on intervention and spare-part costs.
• Predictive information useful for planned maintenance.
The solution was very positively valued by Renault’s team, which highlighted SUMCAB’s adaptability, speed of execution and technical support throughout all project phases. Renault’s readiness to share operational challenges, collaborate closely and trust innovative proposals was key to achieving shared success.
This case demonstrates how SUMCAB not only supplies components but acts as a strategic technological partner. By integrating advanced mechanics, smart sensors and cloud connectivity, the company helped Renault operate with minimized risk and maximized efficiency.
The implemented model can be easily replicated on other robotic production lines, both within the automotive sector and in other industries. In an environment where every second counts, anticipating incidents is no longer just a competitive advantage but a new standard of operational excellence—and this collaboration between Renault and SUMCAB has proven that in practice.