As smart factories and machine vision systems continue to evolve, industrial equipment requires network cables that deliver both reliable Gigabit Ethernet communication and long-term durability in continuously moving applications. Designed for these demanding environments, OKI Electric Cable's C5E (S-HFR) Series combines high-speed data transmission with excellent flex performance, making it well suited for industrial robots, factory automation (FA) equipment, and other motion-intensive applications.

Why High Flexibility and Gigabit Performance Are Difficult to Achieve

Maintaining Gigabit Ethernet performance requires the internal structure of a LAN cable to remain stable. In applications involving repeated bending, twisting, and continuous movement, conventional cables may experience insulation deformation or shield damage, leading to communication errors or cable failure.

The C5E (S-HFR) Series addresses these challenges by incorporating a specially developed polymer insulation material and a high-performance braided shield. This design provides exceptional flexibility while maintaining reliable transmission performance under demanding operating conditions.

Proven Flex Performance

The durability of the C5E (S-HFR) Series has been verified through proprietary testing designed to simulate the types of motion commonly encountered in industrial environments.

• Sliding Flex: More than 3 million cycles (Bending radius: 50 mm)

• Torsion: 3 million to over 5 million cycles (Twisting angle: ±180°)

• Swing Flex: More than 300,000 cycles (Bending radius: 20 mm, Flex angle: ±90°)

The recommended minimum bending radius is 50 mm during continuous movement and 30 mm for fixed installation, allowing flexible cable routing even in compact equipment.

Gigabit Ethernet Performance and Industrial Durability

Beyond its outstanding flex characteristics, the C5E (S-HFR) Series offers communication performance suitable for industrial networking applications.

It supports 1 Gbps Gigabit Ethernet (1000BASE-T) for reliable high-speed data transmission. The specially designed braided shield helps maintain stable communication in electrically noisy environments, including those with inverters, servo motors, and other industrial equipment. An oil-resistant PVC jacket provides additional protection in machine tools, robotic systems, and other applications where exposure to oil is common.

For harness assemblies, the cable supports Gigabit Ethernet transmission over distances of up to 40 meters.

Connector Options for Industrial Applications

To meet a variety of installation requirements, the C5E (S-HFR) Series is available with multiple connector options in addition to standard RJ45 connectors.

A screw-lock RJ45 connector helps prevent accidental disconnection caused by vibration and is ideal for machine vision cameras and other equipment requiring secure connections. The cable is also compatible with the compact IX Industrial® connector for space-constrained installations and the rugged M12 X-coded connector, which provides excellent resistance to water and dust in harsh industrial environments.

Typical Applications

The C5E (S-HFR) Series is suitable for a wide range of industrial applications where both communication reliability and cable durability are critical.

Typical applications include high-speed image transmission in machine vision systems, Ethernet wiring for moving sections of industrial robots, and automatic machine tools where cables are exposed to oil, electrical noise, and continuous movement inside cable carriers.

Conclusion

The C5E (S-HFR) Series offers an excellent balance of flexibility, durability, and Gigabit Ethernet performance for moving industrial applications. Its flexible construction simplifies cable routing, supports more compact equipment designs, and contributes to longer maintenance intervals through its high flex life.

For applications requiring reliable Gigabit Ethernet communication in continuously moving equipment, the OKI Electric Cable C5E (S-HFR) Series is a dependable solution.

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The flex performance data shown above are reference values obtained under OKI Electric Cable's proprietary test conditions and are provided for reference only. They do not constitute guaranteed performance values. Please contact us for detailed product specifications and information on cable extension configurations.

 

◇Manufacturer’s Website
https://www.okidensen.co.jp/en/prod/cable/movable/index_gigab.html

C5E (S-HFR) (K) - **　Harness with RJ45 connectors on both ends

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High-Performance Displays Designed for Professional Drone Operations

Drones are increasingly being used across a wide range of industries, including infrastructure inspection, surveying, precision agriculture, public safety, cinematography, and defense. While flight performance is essential, the quality of the display used to monitor live video and flight data is equally important for safe and efficient operations.

Outdoor environments present several challenges, such as poor screen visibility under direct sunlight, operation in extreme temperatures, and limited battery life during extended missions.

Lincoln Technology Solutions (LTS) develops industrial-grade display solutions designed to address these challenges. Backed by a U.S.-based engineering team, LTS provides display solutions for handheld drone controllers, Ground Control Stations (GCS), and vehicle-mounted systems, with customization available to meet specific application requirements.

Up to 5,300 Nits of Brightness for Excellent Outdoor Visibility

Typical laptops and tablets offer display brightness of approximately 300 to 500 nits. In comparison, LTS high-brightness LCDs provide up to 5,300 nits, allowing pilots to clearly view live video, telemetry, maps, and on-screen overlays even in direct sunlight.

High brightness alone is not sufficient for outdoor readability. LTS enhances visibility by combining several optical technologies, including:

• Anti-Reflective (AR) coating

• Anti-Glare (AG) surface treatment

• Optimized polarizers

• High-efficiency LED backlights

• Advanced optical film design

These technologies help minimize reflections while maintaining excellent contrast, resulting in improved readability in bright outdoor conditions.

Three Display Technologies for Different Applications

LTS offers three display technologies to meet different performance requirements: LCD, OLED, and Mini-LED.

LCD

LTS industrial LCDs are designed for demanding outdoor applications and offer:

• Brightness up to 5,300 nits

• Resolution up to 4K UHD

• Up to 10-bit color depth

• Up to 110% DCI-P3 color gamut (depending on the product series)

• Display sizes ranging from 1 inch to 32 inches

The LED-backlit design provides long operating life and excellent durability, making LCDs well suited for drone controllers, industrial equipment, and outdoor monitoring systems.

OLED

OLED technology uses self-emissive pixels, eliminating the need for a backlight. Key features include:

• True Black reproduction

• Contrast ratio up to 15,000,000:1

• Thin and lightweight construction

• Display sizes from 7 to 27 inches

• 4K UHD support

Its exceptional contrast and image quality make OLED suitable for applications such as aerial cinematography, inspection, and nighttime operations.

Mini-LED (FALD)

LTS Mini-LED displays utilize Full Array Local Dimming (FALD) technology, allowing precise control of individual backlight zones.

Benefits include:

• HDR-quality images

• High contrast

• Uniform brightness

• Enhanced black levels

In addition, Chip Scale Packaging (CSP) technology reduces power consumption by up to 75% compared with conventional backlight systems. Lower power consumption helps extend battery operating time for handheld controllers and Ground Control Stations during long missions.

Rugged Design for Harsh Operating Environments

Drone equipment is frequently deployed in demanding outdoor environments. LTS displays are designed to withstand these conditions with features including:

• Operating temperature: –30°C to +85°C

• IK08 impact resistance

• 5G vibration resistance

• UV exposure testing

• Thermal shock testing

• High-humidity cycling tests

These environmental qualifications help ensure reliable operation in challenging field conditions.

Various protective cover glass options are also available to improve scratch resistance and impact durability.

High Image Quality for Professional Drone Applications

LTS offers display solutions with 4K resolution, wide color gamut, and high contrast for applications requiring precise image evaluation.

Typical applications include:

Infrastructure Inspection

High-resolution 4K displays combined with contrast ratios of up to 15,000,000:1 help operators identify fine cracks, corrosion, and other structural defects.

Precision Agriculture

Displays supporting 97% DCI-P3 color coverage and high brightness improve the visibility of subtle color differences in NDVI (Normalized Difference Vegetation Index) imagery, even under bright sunlight.

Surveying and Mapping

High-resolution displays allow detailed visualization of contour lines, terrain features, and mapping data while maintaining excellent readability outdoors.

Cinematography

With 97% DCI-P3 color accuracy and response times below 5 ms, LTS displays support real-time monitoring and accurate color evaluation during aerial filming.

Flexible Integration and Customization

Beyond supplying display panels, LTS provides complete embedded display solutions for OEM applications.

Available display sizes range from 1 inch to 32 inches, supporting interfaces such as:

• MIPI

• HDMI

• LVDS

• eDP

Additional customization options include:

• Projected Capacitive (PCAP) touch screens

• Glove-touch operation

• Custom cover glass

• Logo printing

• Backlight optimization

• Thermal management design

LTS also offers integrated solutions using System on Module (SOM) technology, helping OEMs shorten development cycles and simplify system integration.

Typical Applications

LTS drone display solutions are suitable for a wide variety of applications, including:

• Drone remote controllers

• Ground Control Stations (GCS)

• Infrastructure inspection

• Surveying and mapping

• Precision agriculture

• Public safety

• Aerial cinematography

• Defense and military systems

For public safety and defense applications, selected models also support Night Vision Goggle (NVG) compatibility, enabling reliable operation during nighttime missions.

Conclusion

Lincoln Technology Solutions (LTS) provides industrial display solutions designed to meet the demanding requirements of professional drone applications. Featuring high-brightness LCDs, OLEDs, and Mini-LED displays, LTS products combine excellent outdoor visibility, low power consumption, superior image quality, and rugged environmental performance.

With brightness up to 5,300 nits, power savings of up to 75%, contrast ratios up to 15,000,000:1, and an operating temperature range from –30°C to +85°C, these displays are well suited for professional drone systems operating in challenging environments.

Combined with display sizes from 1 to 32 inches, multiple interface options, and extensive OEM customization capabilities, LTS solutions can be integrated into applications ranging from handheld drone controllers to advanced Ground Control Stations.

 

◇Manufacturer's Website
https://lincolntechsolutions.com/drone-display-solutions/

 

The CoaXPress 2.0 (CXP12 Series) from OKI Electric Cable is a high-speed interface cable developed for machine vision systems. Supporting transmission speeds of up to 12.5 Gbps per lane and up to 50 Gbps in a 4-lane configuration, it enables high-capacity data communication required by high-resolution cameras and high-speed image processing systems.

 

In addition to image data transmission, the series supports camera control signals and power delivery via Power over CoaXPress (PoCXP), helping reduce cable count and simplify system wiring. The product lineup ranges from cables for fixed installations to high-durability movable applications, making it suitable for a wide variety of uses, including semiconductor manufacturing equipment, image inspection systems, industrial robots, and factory automation (FA) equipment.

 

In particular, the high-durability RA Type is designed to withstand complex motions such as bending and torsion in robotic arms, while the latest K Type combines an ultra-slim 3.7 mm outer diameter with more than 50 million cycles of sliding flex durability. These features make it an ideal solution for equipment requiring routing in confined spaces and extended service life.

 

High-Speed Transmission Performance with CoaXPress 2.0

The CXP12 Series complies with the CoaXPress 2.0 standard established by the Japan Industrial Imaging Association (JIIA).

• High-speed transmission up to 12.5 Gbps (CXP-12)

• Up to 50 Gbps in a 4-lane configuration

• Supports Power over CoaXPress (PoCXP)

• Compatible with both BNC and Micro-BNC connectors

• Enables data transmission, control, and power delivery through a single coaxial cable

Product Lineup for Various Applications

Fixed Installation Applications

The H Type is designed for standard fixed installation applications, while the L Type features a low-attenuation design that enables transmission distances of up to 20 meters at CXP-12 speeds.

Movable Installation Applications

The KH Type is intended for general flexing applications. The RA Type is specifically designed for robotic applications involving bending and torsional movements, while the K Type combines an ultra-slim 3.7 mm outer diameter with exceptional sliding flex durability.

High-Durability, Slim-Diameter K Type

The K Type is a high-durability model developed for routing in confined spaces within semiconductor manufacturing equipment, image inspection systems, and other advanced industrial equipment.

• Outer diameter: 3.7 mm (single-channel type)

• Sliding flex durability: Over 50 million cycles (R = 50 mm)

• Recommended minimum bend radius: 15 mm

• Ideal for confined spaces and high-speed moving sections

RA Type for Robot Vision Applications

The RA Type is a high-durability model designed for camera cabling in industrial robots.

• Torsion durability: More than 300,000 cycles (±180°)

• Bending durability: More than 300,000 cycles

• Available in both single-channel and 4-channel versions

• Designed to withstand the complex motions of robotic arms and automated equipment

Summary

OKI Electric Cable's CoaXPress 2.0 (CXP12 Series) is a machine vision cable solution that combines high-speed image transmission with outstanding durability for dynamic applications. From fixed installations to robot vision systems, it meets a wide range of industrial requirements and contributes to the performance enhancement and miniaturization of semiconductor manufacturing equipment, image inspection systems, and factory automation equipment.

 

◇Manufacturer's website

https://www.okidensen.co.jp/en/prod/cable/movable/coaxpress-cxp12.html

 

◇Product page

 https://nisho-en.ocnk.net/product/1263

 

 

 

 

Prouduct name

CXP12 - ① - ② - ③ - ④

①Number of cores：　1 core：1C    4 cores：4C

②Cable type　　　　　

for Fixed wiring：    High-Flex & Slim：K     Standard：H,     Long distance：L

for Movable wiring：    Standard：KH,     High durability：RA

③Connector symbol　

for BNC on both ends：BSBS, Micro-BNC／BNC: MBSBS, and Micro-BNC on both ends: MBSMBS

④Cable length：　ex. 5m: 050, 10m: 100

OKI Electric Wire's "FAKRA Connector-Equipped Machine Vision Cable" is a high-speed image transmission cable compliant with GVIF and GMSL standards, designed to support the advanced automation and digital transformation of AI robots and industrial FA equipment. AI image inspection and automated processes require the ability to transmit high-resolution video in real time and with stability. However, with the miniaturization and increasing complexity of equipment, wiring in confined spaces and durability in moving parts are also critical issues. This product addresses these manufacturing demands by optimizing the proven GVIF/GMSL and FAKRA connectors for industrial applications.

GVIF (Gigabit Video Interface) and GMSL (Gigabit Multimedia Serial Link) are LVDS-based high-speed serial transmission standards supporting high-speed data communication of approximately 5Gbps. This enables real-time transmission of high-definition image data with low latency and low CPU load, maximizing the performance of AI inference and image processing. Furthermore, its noise-resistant structure maintains stable image quality even in FA environments where large motors are located nearby.

The cable features an ultra-thin design with a standard outer diameter of 3mm, achieving superior wiring performance compared to conventional GigE, USB3, and CXP12 cables. Its ease of handling in confined spaces such as inside robot arms and small devices, along with its reduced weight, minimizes inertial load on moving parts, contributing to high-speed and high-precision motion control.

The connector utilizes the FAKRA connector, widely adopted in automotive telematics and ADAS applications. FAKRA is an automotive-grade connector that ensures high vibration resistance and connection reliability through its unique locking mechanism, maintaining stable communication even in harsh vibration environments. Furthermore, it boasts IPX7 equivalent water resistance, allowing for safe use even in environments where water droplets or coolant may be present.

The product lineup includes the "H-type" for fixed wiring and the "K-type" for movable wiring that accommodates sliding and bending. The movable cable has been confirmed to have high durability of over 10 million sliding and bending cycles under R37mm conditions in OKI Electric's proprietary tests, enabling long-term stable operation in robot and cable carrier applications. Furthermore, it supports configurations that connect fixed and movable parts via an intermediary, allowing only the wear-prone movable parts to be replaced, thus contributing to reduced equipment downtime and maintenance costs. It supports configurations with up to four connections and a total length of 15m or less.

This product is a machine vision cable suitable for a wide range of manufacturing environments requiring high-speed communication, high reliability, durability, and space-saving features, such as AI robots, image inspection equipment, and monitoring systems.

◇Manufacturer's website
https://www.okidensen.co.jp/en/prod/cable/movable/index_fakra.html


Coaxial cable with FAKRA connector

Jack (left) and plug (right)

Cable for machines with FAKRA connector: movable (left) and fixed (right)

Product name
FKR(CX) - ① - ② - ③ - ④
① Cable Type Code　　　　Fixed Wiring: H　　Movable Wiring: K
② Connector Combination　Code Both Ends Plug: PZPZ　　Jack / Plug: JZPZ
③ Waterproof　　　　　　　With waterproof: WP　　Without waterproof: Not indicated
④ Cable Length　　　　　　Example codes　3m: 030　　15m: 150 Specifications

OKI Electric Cable will be exhibiting at "ROBOT TECHNOLOGY JAPAN," the largest exhibition of industrial robots and automation systems in the Chubu region, held in June. Experience the lightness, thinness, and flexibility of our various cables and flexible circuit boards; the sliding and bending properties of composite and parallel cables; and the necessity of flexible cables for moving machinery. See, touch, and experience it for yourself.

Venue: Aichi Sky Expo (Aichi International Exhibition Center)
Dates: June 11th (Thu) - 13th (Sat), 2026
Opening Hours: 10:00 - 17:00 *Until 16:00 on the final day, June 13th (Sat)
Booth Number: D27

Exhibited Products
Cables for Movability and Twisting
●Robot Cables/FA Products
New Product "ORP-SL 105℃"
・Complies with UL standard (UL 758 Style2517) with a rated temperature of 105°C
・Approximately 20% smaller in diameter than ORP cable on average
●Machine Vision Cables
●Flexible Printed Circuit Boards (FPCs)
●Fiber Optic Cables

https://robot-technology.jp/visitor/Information/index/ChargeNo=114

ORP-SL 105℃ Cable Series

Meets UL standard (UL 758 Style 2517) with a rated temperature of 105°C.
A 300V rated voltage cable with a reduced diameter to accommodate the miniaturization of robots.
Suitable for moving parts such as those that bend, slide, and twist.

High-Sliding Parallel Cable - VEYOR-CABLE

This is a custom-made cable with cables for moving parts, air tubes, etc., bonded in parallel. It also offers excellent sliding performance.

Flexible Printed Circuits -FPC-

FPCs are thin and highly flexible, making them suitable for three-dimensional and movable wiring within equipment. Similar to cables, they can be connected to various devices using standard PCB connectors or FPC connectors.

The “ORP-SL105°C Cable Series” offered by OKI Electric Cable is a high-performance cable designed to meet the demands of miniaturization and harsh operating environments in industrial robots and factory automation (FA) equipment. Its key features include a 105°C temperature rating compliant with UL 758 Style 2517 and an approximately 20% reduction in outer diameter compared to conventional ORP cables.

 

The cable provides exceptional durability against complex robotic motions such as sliding, bending, and torsion, achieving over 100 million cycles in sliding flex applications. Combining flexibility, oil resistance, and flame retardancy, it is a next-generation wiring solution suitable for both fixed and moving parts within and between equipment.

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1. Standards Compliance and Basic Design

This series complies with international UL safety standards, ensuring high reliability.

• Applicable standard: UL 758 Style 2517 (105°C, 300V)

• Flame resistance: Compliant with VW-1 standard

• Additional options: UL Listing (CL3) compliant versions are available upon request (limited to conductor sizes of 0.25 mm², 0.3 mm², and 0.5 mm²)

• Operating environment: Suitable for indoor use, including both fixed and moving parts within and between equipment; operating temperature range from -10°C to 105°C

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2. Key Features and Functional Advantages

2.1 Advanced Miniaturization and Flexibility

While maintaining the characteristics of the conventional ORP-SL series, this cable achieves an average diameter reduction of approximately 20% compared to standard ORP cables. This contributes to compact robot design and enables space-saving installations. Its excellent flexibility also allows for easy routing in confined spaces.

2.2 Superior Oil Resistance and Robust Materials

Designed for harsh industrial environments, the cable incorporates the following materials:

• Insulation: Special elastomer that balances high flexibility and electrical performance

• Sheath: Oil-resistant PVC (matte black), resistant to degradation in oil-exposed environments

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3. Outstanding Dynamic Performance

The cable is engineered to withstand all types of robotic motion, including sliding, bending, and torsion, and has demonstrated high durability under stringent test conditions.

• Sliding flex: Over 100 million cycles (bend radius: approx. 6× cable OD, speed: 70 cycles/min, travel distance: 350 mm)

• Bending (swing): Over 20 million cycles (bend radius: approx. 8× cable OD, angle: ±90°, speed: 40 cycles/min)

• Torsion: Over 20 million cycles (angle: ±180°, speed: 70 cycles/min, span: 500 mm)

Note: These values are reference data provided by OKI Electric Cable and are not guaranteed.

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4. Product Lineup and Structural Specifications

Two structural types are available depending on the application: “layer-stranded type” and “twisted-pair type.”

• Layer-stranded type:

  • Non-shielded only

  • Conductor cross-section: 0.05 to 0.5 mm²

  • Core count: 3 to 15 cores

• Twisted-pair type:

  • Available in both non-shielded and shielded (tinned copper braid) versions

  • Conductor size: 0.05 to 0.5 mm²

  • Pair count: 1 to 20 pairs

Electrical performance varies depending on conductor size, with specifications defined for conductor resistance, insulation resistance, and withstand voltage, all suitable for industrial applications.

Minimum bending radius is defined as follows:

• Fixed installation: at least 4× the cable outer diameter

• მოძრing applications:

  • Non-shielded: at least 6× the cable outer diameter

  • Shielded: at least 8× the cable outer diameter

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5. Conclusion

The ORP-SL105°C Cable Series simultaneously achieves high heat resistance (105°C), over 100 million sliding flex cycles, and significant miniaturization. It is a key component that enhances wiring reliability and design flexibility in today’s FA market, where high performance and compact robot design are increasingly required.

◇Manufacturer's website
https://www.okidensen.co.jp/jp/prod/cable/robot/orps105c.html

◇Product page
ORP-SL 105°C Shielded(SB)
https://nisho-en.ocnk.net/product-list/167

ORP-SL 105°C Unshielded
https://nisho-en.ocnk.net/product-list/168

The current cable market is in a highly distinctive phase, characterized by the simultaneous rise in naphtha and copper prices. These are key raw materials for sheathing and conductor materials, respectively, and price fluctuations in both directly and comprehensively impact the cost structure of cable products. This paper analyzes cable prices and demand trends, taking into account the structural background of these raw materials.

First, let's consider copper. Copper has excellent electrical conductivity and processability, making it an indispensable material for electric wire conductors. In recent years, its use has increased in areas such as electrification (EVs), renewable energy, and the expansion of data centers, resulting in a structurally increasing demand. On the other hand, developing copper mines takes a long time, making short-term supply increases difficult. Therefore, supply cannot keep up with increasing demand, and prices are likely to rise in the medium to long term. Since copper benchmark prices are determined by these international market conditions and exchange rates, domestic prices are similarly susceptible to upward pressure.

Next, let's consider naphtha. Naphtha is a hydrocarbon mixture obtained during the petroleum refining process and is used as a raw material for basic chemicals such as ethylene. Polyethylene (PE), cross-linked polyethylene (XLPE), and even polyvinyl chloride (PVC) rely partly on naphtha-derived ethylene as their raw material. Furthermore, many of the plasticizers and additives used in PVC compounds are petrochemical products and are therefore affected by naphtha prices. Consequently, rising naphtha prices contribute to increased sheathing costs through resin prices.

As such, cost-increasing pressures are simultaneously acting on both the conductor and the sheathing, the main components of cables, leading to a strong tendency for product prices to rise or remain high. Copper, in particular, accounts for a high proportion of product costs, making it significantly affected by price fluctuations.

On the other hand, when considering demand trends, it's important to note that current order volumes don't necessarily reflect actual demand. When information about supply concerns or price increases spreads to the market, customers tend to order larger quantities than usual in advance to mitigate future procurement risks. As a result, statistical demand temporarily increases, but this is actually inventory buildup rather than consumption.

This accelerated demand will, in the short term, tighten supply and demand, leading to extended delivery times and shortages of some products. However, once supply recovers to a certain extent and inventory becomes apparent, new orders will plummet, and demand will fall sharply. This phenomenon has been repeated in the past and can be explained as a self-amplifying fluctuation in supply and demand.

Therefore, while future cable demand may remain strong in the short term due to increased speculative demand, a scenario where demand slows down in the medium term as inventory adjustments begin is considered reasonable. This is due to a temporal shift in supply and demand, not an expansion of actual demand.

Regarding prices, considering the structural supply constraints of copper and fluctuations in the price of petrochemical raw materials derived from naphtha, a significant decline in the short term is unlikely, and prices are expected to remain in a high range for a certain period. However, in the phase of slowing demand, temporary adjustments may occur due to changes in the supply-demand balance.

As described above, the current market is in a unique state where "cost increases" and "accelerated demand" are occurring simultaneously. In this environment, mistaking a apparent increase in demand for an expansion of actual demand can lead to misjudgments of supply and demand. To accurately grasp market trends, it is crucial to focus on actual consumption trends and inventory levels, rather than order quantities.

As past examples clearly show, supply and demand imbalances always correct themselves over time. Therefore, instead of overreacting to short-term market fluctuations, it is necessary to make judgments based on the structural factors of raw materials and the mechanisms of supply and demand.

We offer suggestions for selecting high-flex robot cables for moving part power supplies, including the OKI Electric Cable ORP-D, Hanshin Electric Cable MRC UL2501, and Dyden Robotop DP6.Each cable is sold cut to length.Please refer to the product page via the address link in the middle of the page.

 

— Technical Comparison and Practical Engineering Guidance —

As industrial automation continues to evolve, the reliability requirements for cables used in moving parts have become increasingly demanding. In robot arms, transfer systems, and cable carrier applications, power cables are subjected to continuous bending, sliding, and torsional stress. In such environments, general-purpose fixed-installation cables are not sufficient. Dedicated robot power cables are essential to ensure long-term operational stability.

This column provides a comprehensive technical overview of selection criteria, including electrical capacity, mechanical durability, and a comparative review of three major Japanese products: OKI Electric Cable ORP-D, Hanshin Cable MRC UL2501, and Dyden Robotop DP6.

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Operating Environments and Application Scope

Robot power cables for moving applications are typically installed in:

• Industrial robot arms (internal routing)

• Transfer and inspection systems with reciprocating motion

• Cable carriers (energy chains)

• Power supply lines for three-phase motors and servo drives

These applications involve repeated bending cycles that may reach tens of millions or even exceed one hundred million cycles. Mechanical stress is often the primary failure factor, making conductor structure, insulation material, and sheath durability critical design elements.

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Why Dedicated Robot Power Cables Are Required

Mechanical Durability Under Repeated Motion

Robot cables use finely stranded conductors and optimized internal structures to resist bending fatigue. Compared to standard power cables, they are engineered to withstand long-term dynamic operation.

UL Compliance for Global Equipment

All three products discussed in this article are rated at 600V and 105°C in accordance with UL758 standards. For equipment exported to North America or used in globally standardized production lines, UL compliance is often mandatory.

Shielded and Unshielded Variants

In inverter-driven systems or installations where power and signal cables are routed together, electromagnetic noise becomes a design consideration. Shielded models reduce noise interference, while unshielded versions provide improved flexibility and reduced cable weight.

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Specification Comparison of Three Major Products

The following products are widely recognized in Japan for moving power cable applications:

• OKI Electric Cable ORP-D

• Hanshin Cable MRC UL2501

• Dyden Robotop DP6

Key Specification Overview

Item	ORP-D	MRC UL2501	Robotop DP6
Standard	UL758 Style 2586, 105°C, 600V	UL758 Style 2501, 105°C, 600V	UL758 Style 2501, 105°C, 600V
AWG Range	AWG21 to AWG12 (0.5–5.5 mm²)	AWG18 to AWG10	AWG18 to AWG4 (depending on series)
Core Count	2 to 10 cores	2 to approx. 20 cores	2 to approx. 30 cores
Shielding	Available (shielded / unshielded)	Available (shielded / unshielded)	Primarily unshielded (shielded versions available in other series)
Recommended Bending Radius (moving use)	6–8 × overall diameter	Approx. 6 × overall diameter	Typically around 6 × overall diameter (varies by size)

Although all three products share the same 600V and 105°C rating, their design focus and lineup breadth differ significantly.

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Allowable Current and Conductor Selection

Allowable current depends primarily on conductor size (AWG) and installation conditions.

As general engineering references:

• AWG12 class: approximately 20A

• AWG10 class: approximately 30A

• Larger conductors (e.g., AWG4): suitable for higher current motor applications

When selecting conductor size, engineers must consider:

• Continuous load current

• Inrush or peak current

• Ambient temperature

• Cable bundling conditions

• Installation method and heat dissipation

Proper derating calculations are necessary, especially in enclosed cable carriers or high-temperature environments.

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Recommended Minimum Bending Radius

For dynamic applications, a commonly accepted engineering guideline is:

• 6 to 8 times the overall cable diameter

Designing below this limit accelerates conductor fatigue and insulation degradation. In robot arm design, sufficient routing space must be secured at the mechanical design stage to prevent premature failure.

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Product Positioning and Application Suitability

OKI Electric Cable　　ORP-D

ORP-D emphasizes reduced outer diameter and high flexibility. It is particularly suitable for compact robotic systems and installations where routing space is restricted. The availability of shielded and unshielded models allows flexibility in addressing noise-sensitive environments.Available in shielded and unshielded versions.

 

ORP-D Shielded (SB) Power Supply Robot Cable UL2586 105°C 600V

https://nisho-en.ocnk.net/product-list/46

ORP-D Unshielded Power Supply Robot Cable UL2586 105°C 600V

https://nisho-en.ocnk.net/product-list/47

 

 

Hanshin Electric Cable　　MRC UL2501

MRC UL2501 focuses on enhanced bending and torsional resistance. It is well suited for applications involving higher mechanical stress or complex motion patterns. Shielded variants provide additional protection in inverter-driven or noise-prone systems.Available in shielded and unshielded versions.

 

MRC UL2501 105°C 600V Shielded (SB)

https://nisho-en.ocnk.net/product-list/86

MRC UL2501 105°C 600V Unshielded

https://nisho-en.ocnk.net/product-list/85

 

 

 Dyden　　Robotop DP6

Robotop DP6 offers a broad lineup in conductor sizes and core counts. It is appropriate for general-purpose moving power applications, including cable carrier systems and factory automation equipment. Its versatility makes it suitable for a wide range of electrical load conditions.

 

Robotop DP*6 UL2501 105°C 600V Unshielded

https://nisho-en.ocnk.net/product-list/92

 

 *Images are for reference only.

 

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Engineering Selection Checklist

When selecting a robot power cable for moving applications, engineers should verify:

1. Continuous and peak current requirements

2. Required bending cycle life and motion speed

3. Stroke length and routing constraints

4. Noise environment and shielding necessity

5. Compliance requirements (UL, CSA, etc.)

A robot power cable in a moving system functions not only as an electrical component but also as a mechanical element under continuous stress. Electrical capacity alone is not sufficient for proper selection; mechanical endurance must be evaluated with equal importance.

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Conclusion

In automated systems, long-term reliability is often determined by components that are not visible—such as internal power cabling. Selecting an appropriate robot power cable directly impacts equipment durability, maintenance frequency, and operational safety.

A careful balance of electrical performance, mechanical flexibility, environmental resistance, and installation constraints ensures stable operation throughout the lifecycle of the equipment.

Curl cords have been around for a long time, but their essential value remains unchanged. Their spiral structure combines flexibility and durability, and their ability to automatically absorb excess length is a feature essential for any device with moving parts. While primarily associated with telephones, they are actually used in a wide range of fields, including industrial equipment, factory automation (FA) systems, medical equipment, retail facilities, and movable furniture. Even in an age of widespread AI and robotics, this structural value may be reevaluated.

Our product lineup includes Nagaoka Electric Wire's general-purpose curl cords, as well as highly flexible custom curl cords based on Oki Electric Cable's robot cables. This positioning us as a leader in addressing changing market conditions. While general-purpose products enjoy stable demand for retail facilities, office automation equipment, and light-load applications, it is high-durability and application-specific custom products that offer greater potential for future growth. This is because, as devices become more sophisticated, the operating conditions of moving parts become increasingly stringent, limiting the number of situations in which standard products are no longer suitable.

The widespread adoption of collaborative robots and compact automated equipment is a prime example. Labor shortages are driving investments in automation, even in small and medium-sized manufacturing companies. However, not all moving parts have strokes or loads large enough to warrant the use of cable carriers. For short reciprocating motions or limited ranges of motion, lightweight and flexible coiled cords offer design flexibility and cost advantages. Furthermore, as equipment becomes more compact, wiring space becomes more limited. A structure that naturally absorbs excess cable length is highly compatible with space-saving designs, contributing to internal organization and improved safety. Thus, the dual trends of equipment miniaturization and increasing functionality are supporting the adoption of coiled cords.

The medical and nursing care fields are also areas where stable demand is expected. Due to the aging population, the number of devices with moving mechanisms, such as height-adjustable medical chairs, rehabilitation support equipment, and home medical equipment, is on the rise. In these fields, safety and reliability are prioritized over wireless technology. For equipment requiring high power output or long periods of continuous operation, the reliability of wired power supply remains important. Furthermore, eliminating excess cords on the floor helps prevent falls and is a rational safety measure in medical facilities. A structure that can absorb excess cords using an extension mechanism offers clear advantages in terms of maintaining aesthetics while ensuring safety.

EV and battery-related equipment is also an area of ​​interest. With the advancement of electrification, demand for maintenance equipment, inspection equipment, and evaluation equipment is expanding. These equipment often handle relatively high currents, making fully wireless deployment impractical from both a technical and safety standpoint. For equipment that repeatedly connects and moves over short distances, custom coiled cords with their elasticity and flexibility are potentially applicable. Robot cable-based specifications, in particular, offer increased design flexibility while ensuring durability against repeated bending and twisting.

Height-adjustable desks and adjustable furniture are becoming increasingly common in offices and homes. While electric lifting mechanisms have become commonplace since the spread of telework, wiring management remains a challenge. The degradation of aesthetics and the risk of wire breakage due to sagging wires directly impact product value. Curl cords, with their elasticity that naturally accommodates excess length, are a rational choice in terms of both design and functionality. While this market is not experiencing explosive growth, it is likely to remain stable at a certain scale.

Looking to the long term, the market is expected to move toward qualitative differentiation rather than quantitative expansion. While improvements in wireless technology and battery performance may replace some applications, wired power supplies remain essential for high-current applications, safety-standard compliant equipment, and long-term continuous operation in industrial applications. Furthermore, as AI advances, the number of sensors and small actuators will increase, resulting in an increase in the amount of wiring in moving parts. In other words, we expect a polarization to continue, with wireless advances advancing while high-reliability wired applications remain.

Amid this structural change, custom specifications optimized for each application will become increasingly important. Demand is likely to continue to grow, including hybrid specifications that combine power and signaling, high-reliability shielded types, and special-environment compatibility such as oil and chemical resistance and low dust generation. As equipment becomes more sophisticated, the need for specifications that cannot be met with standard products will expand. The idea of ​​curling robot cables is a proposal that simultaneously satisfies the requirements for mobility and flexibility, and is an effective differentiating factor.

While curled cords are not eye-catching products, they are essential components that will be necessary as long as machines move in physical space. The possibility of a completely wireless society is limited, and wired devices will continue to play a role from the perspective of high output, safety, and reliability. Going forward, the market is likely to shift away from the mass supply of general-purpose products and instead become more focused on application-specific, high-value-added products. Having a system that can handle both general-purpose products and highly durable custom products will be a major advantage in adapting to this change. Being a niche market does not mean shrinking; rather, it is important to consider it as a market where expertise can be utilized when considering future developments.

Nisho Electronics is a company based in Tokyo, Japan that sells cables, electronic components and wire harnesses.We distribute products from Japanese manufacturers such as Oki Electric Cable.We also distribute electronic components and wire harnesses from Taiwan.We were established in 1967. Although we are a small company, we want to do business with customers all over the world by focusing on web marketing.We would like to sell Japanese cables and electronic components to overseas customers. We are also looking for partner companies to do business with on an ongoing basis.If you wish to purchase a large quantity of any of the items listed in our shop, we will provide you with a separate quotation.Please contact us using the "Contact Us" link on each product page.

We are also a supplier in Japan and will promote your products in Japan free of charge.We will promote your products on our website and other manufacturing websites. If you have a product that you would like to introduce to Japan, please contact us.We want to make the world a better place through our work.We will respond sincerely. Thank you very much.

https://nisho-en.ocnk.net/contact

Nisho Electronics is a trading company that sells cables and electronic components, and was established in Tokyo, Japan in 1967.In 1976, we became an authorised dealer of Oki Electric Industry, and in 1993, we became an authorised dealer of Oki Electric Cable.In 1996, we became an authorised dealer of OKI Sensor Device (now Standex Electronics Japan).In 2010, we became a distributor of ROHM.In 2010, we opened our own online store, and in 2013, we opened an online store for overseas customers.

When we first started, we sold semiconductors, switches and wires from Japanese manufacturers domestically, but in recent years we have also sold wiring harnesses and parts from Taiwanese manufacturers in Japan. We also focus on exporting and selling products from Japanese manufacturers overseas.

As a supplier in Japan, we also focus on promoting the products of overseas manufacturers in Japan, and we support the promotional activities of overseas manufacturers by posting their products on our own website and on Japanese manufacturing industry websites free of charge.

In the world of electronic components, new technologies emerge one after another, centered on miniaturization and high performance. Meanwhile, there are wiring components that have built up a proven track record and continue to be used in the field. While jumper cables fall into this category of "old technology," there are good reasons why they continue to be selected.

In recent years, major Japanese manufacturers, including Sumitomo Electric Industries, have ceased production of jumper leads one after another. While this movement suggests a shrinking market, in reality, demand for jumper cables has not disappeared due to the continued use of design assets and the existence of industrial equipment still in operation. Rather, stable demand remains, primarily for replacing existing products and maintaining legacy equipment whose specifications are difficult to change.

Amid this market environment, Taiwanese specialized manufacturer YEH CHI (Yeh Chi Electronics) is making its presence known. YEH CHI's main product is jumper cables, supporting a wide range of pitches from 1.27mm to 3.96mm, and specializes in custom manufacturing to customer-specified dimensions. Not only have they become an alternative supplier after domestic manufacturers withdrew from the market, but they are also increasingly being adopted as mounted components for new design projects.

One of the reasons YEH CHI's jumper cables are so highly rated is their on-site design. The terminals are solder-coated, allowing for stable soldering while suppressing oxidation. Their compatibility with through-hole PCBs and the ease of forming solder fillets ensures both connection strength and electrical reliability. Furthermore, the ability to visually inspect the soldered condition is a major advantage in terms of quality control.

Direct wiring to PCBs using jumper cables has a simpler structure than connector connections and is also more reliable over long-term use. By avoiding the risks of disconnection due to vibration or poor contact due to micro-friction wear on the contact surfaces, they are ideal for applications requiring stable operation, such as industrial and infrastructure-related equipment.

Jumper cables are also a cost-effective option. Compared to connectors and harnesses, they not only reduce the number of components but also occupy less board space. YEH CHI offers a variety of pitches, including 3.96mm, 2.54mm, 2.5mm, 2.0mm, 1.5mm, and 1.27mm, and allows you to customize the insulation and strip lengths, optimizing costs without sacrificing design flexibility.

YEH CHI jumper cables are also effective in new development projects. Flexibility to accommodate design changes and quick delivery are particularly important during the early prototyping and evaluation stages of development. Custom jumper cables, with a minimum order of approximately 1,000 units and a delivery time of approximately one month, are ideal for prototype development, compared to FPCs, which require expensive molds and long lead times.

YEH CHI products are UL-certified and can withstand temperatures ranging from -20°C to 105°C and voltages up to 300V. As a result, jumper cables have been adopted in a wide range of applications, from home appliances to industrial equipment. They are a reliable option not only for replacing discontinued products from domestic manufacturers, but also for new designs.

As electronic devices become increasingly denser and more compact, the overall jumper cable market may gradually shrink. However, jumper cables will continue to play a vital role in the maintenance and repair of legacy systems, projects requiring custom specifications, and areas where stable signal quality is important.

YEH CHI (Yeh Chi Electronics) continues to meet this undeniable demand with its long-cultivated manufacturing know-how and flexible response capabilities. For companies that prioritize quality, responsiveness, and supply stability in a seemingly simple product like jumper cables, YEH CHI will remain a valuable partner.

◇YEH CHI Website
https://www.yehchi.com.tw/en/jumpercable

This column introduces the single-core, highly flexible robot cable UL11527 AWG28 (Ø0.60 mm) stocked and sold by our company. The article covers product specifications, the technical background behind its structure, a comprehensive list of potential applications, implementation notes, and demand outlooks for the next 5, 10, and 30 years. Sources are provided for key technical facts.

◇Product Page – Available from 1 m Cut Lengths

UL11527 AWG28 Flexible Wire for Moving Parts – Ø0.60 mm (White / Black)

https://nisho-en.ocnk.net/product/168

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Product Overview (Key Points)

• Product Type: Single-core wire used in OKI’s robot cables (core wire for the ORP-30F series)

• Standard / Type: Conforms to UL11527, equivalent to ultra-thin AWG28

• Insulation Diameter: Ø0.60 mm — extremely thin outer insulation (nisho.ocnk.net)

• Conductor: 49 strands × Ø0.05 mm (49/0.05), contributing to superior flexibility (nisho.ocnk.net)

• Insulation Material: Polyester elastomer (FRPEL10/U) — elastic, flexible insulation (nisho.ocnk.net)

• Rating: 105°C, 30 V, RoHS2 compliant; suitable for short-run signal or low-voltage wiring (nisho.ocnk.net)

• Stock & Supply: Available in white and black; sold in 1 m units (standard 300 m bobbin) — ideal for prototypes and maintenance (nisho.ocnk.net)

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Technical Explanation — Why This Structure is Suited for Moving Parts

1. Flexibility from the 49/0.05 Multi-Stranded Conductor

Using many extremely fine strands distributes bending stress along the wire length and greatly improves fatigue life during repeated flexing. Even at the same AWG28 cross-section, “more strands = higher flexibility” is a well-established principle in dynamic cable design (okidensen.co.jp).

2. Benefits of Polyester Elastomer Insulation

Polyester elastomers exhibit strong elastic recovery, preventing deformation and abrasion during repeated bending. When combined with the robust design used in ORP-30F series cables, the insulation provides excellent heat and oil resistance—an advantage in industrial environments (okidensen.co.jp).

3. Design Freedom from Ultra-Thin Ø0.60 mm Insulation

Such a small diameter eases cable routing in narrow spaces, compact joints, miniature mechanisms, and dense connector housings. Designers can benefit from easier wiring paths and reduced mass for moving modules, enhancing motion response (okidensen.co.jp).

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Comprehensive Application List (as Exhaustive as Possible)

Applications are grouped into “current/typical uses” and “technically feasible extensions.”

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A. Industrial and Robotics Applications (Mainstream Uses)

• Internal wiring in robot arm joints (sensors, encoders, limit switches, heaters) for reciprocating motion (okidensen.co.jp)

• Signal wiring inside cable carriers/drag chains (okidensen.co.jp)

• Sensor-to-controller wiring such as proximity sensors, encoders, and temperature sensors — all requiring flexible, repetitive motion tolerance (okidensen.co.jp)

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B. Drones, Aviation, and Mobility Systems

• Gimbal wiring for drone-mounted cameras/sensors, where lightweight and tight routing are essential (nisho-en.ocnk.net)

• Wiring in autonomous mobile robots (AMR) for movable sensor mounts and compact actuator connections

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C. Medical and Care-Assist Devices

• Actuator and sensor wiring in surgical-assist robots and medical robotic arms where compact, highly reliable wiring is required

• Flexible sensor/drive wiring for wearable medical assist devices or exoskeletons that must follow human movement

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D. Consumer and Small Electronics

• Internal flexible wiring in AR/VR headsets (folding/rotating mechanisms)

• Wiring in handheld cameras, mini gimbals, and robotic toys

• Moving-joint wiring in household robots such as cleaning and serving robots

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E. Laboratory Automation and Research Equipment

• Compact automatic pipetting devices and sample handling modules requiring repetitive motion and miniaturization

• Flexible wiring for precision movement actuators within micro-automation systems

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F. Other Specialized Applications

• Movable wiring in optical mechanism assemblies (aperture and focus control)

• Internal wiring for precision measuring devices with rotation or tilt motions

All of the above share common requirements: low voltage (30 V or below), short wiring length, and repetitive flexing within limited installation space.

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Connector Compatibility and Implementation Notes

Connector Compatibility

Common compatible connectors include:

• JST ACH / SACH series (AWG30–28, insulation Ø0.50–0.63 mm)

• Hirose DF52 / DF57 / DF58 series for compact wire applications

Always verify the connector’s “applicable wire range” and the terminal’s conductor and insulation crimp dimensions (JST Manufacturing).

Crimping Considerations

Ultra-thin wires require precise terminal, die, and tooling selection. Incorrect crimping will lead to poor electrical contact or insufficient pull strength. Proper strip length and crimp height must be validated through testing (JST Manufacturing).

Harness Design Notes

When bundling multiple single-core wires, carefully design stress relief, sleeve selection, cable tie locations, and slack loops. For cable carriers, evaluate abrasion and consider additional sheathing.

Operational Verification

Before mass adoption, perform:

• Flex-life testing

• Pull-out force tests

• Environmental tests (temperature, oil, chemical exposure)
  Even though the ORP-30F family is designed for dynamic durability, real-world conditions must be verified (okidensen.co.jp).

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Benefits Summary

• Compact Routing: Ultra-thin Ø0.60 mm insulation enables efficient wiring in dense connectors and confined joints (nisho.ocnk.net)

• Excellent Flex Durability: 49/0.05 stranding + elastomer insulation ensures long cycle life (okidensen.co.jp)

• High Temperature and Oil-Resistant Variants: Available within ORP-30F product series (okidensen.co.jp)

• Easy Small-Lot Procurement: Stocked for 1 m minimum purchase—ideal for prototyping, maintenance, and engineering builds (nisho.ocnk.net)

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Practical Notes (Risks and Mitigations)

• Voltage/Current Limitations: Rated for 30 V; unsuitable for power lines or high current applications (nisho.ocnk.net)

• Mechanical Abrasion: Use sleeves or guides in environments prone to friction

• Crimp Quality Control: Avoid conductor splay or oxide formation by strictly managing crimp processes

• Environmental Limits: For harsh chemicals, strong UV, or extreme low temperatures, perform material testing and consider alternate sheathing (okidensen.co.jp)

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Market and Demand Outlook (Evidence-Based Forecast)

5-Year Outlook (to 2030) — Growth Phase

Demand is expected to rise with the miniaturization and diversification of drones, service robots, and industrial robots. Ultra-thin flexible cables such as the ORP-30F cores are already expanding in product lines (okidensen.co.jp).

10-Year Outlook (to 2035) — Cross-Sector Expansion

Adoption is likely to increase in medical devices, nursing/assistive tools, wearables, and laboratory automation. Continuous connector miniaturization (finer pitch) will support steady growth (HIROSE).

30-Year Outlook (to 2055) — Restructuring but Persistent Need

Wireless systems and flexible printed circuits (FPC, conductive polymers) may replace some traditional wires. However, robust physical wiring will remain essential for power distribution, high-reliability interconnects, and harsh-environment systems. The market will evolve, not disappear (okidensen.co.jp).

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Implementation Flow and Support

1. Sample Procurement (1–5 m):
   For mechanical routing tests or flex/pull tests. Small-lot stock allows quick delivery (nisho-en.ocnk.net).

2. Connector/Terminal Selection Support:
   We provide selection guidance for JST, Hirose, and other compatible parts (JST Manufacturing).

3. Harness Design Advisory:
   Recommendations for bundling, strain relief, protective materials, and routing strategies.

4. Mass Production Support:
   Stable supply in bobbin units (300 m) and inventory planning proposals (nisho.ocnk.net).

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Conclusion

The OKI Electric Cable UL11527 AWG28 wire (Ø0.60 mm, 49/0.05, polyester elastomer insulation) is an exceptionally thin yet highly flexible single-core conductor. It satisfies critical design needs such as compact routing, low mass, and long flex life—making it valuable for robotics, drones, medical devices, wearables, and laboratory automation.

When considering adoption, confirm voltage limits (30 V), crimping compatibility, and connector requirements, and conduct appropriate evaluation testing. Sample provision, connector selection, and harness design support are available through our trading company (nisho.ocnk.net).

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UL11527 AWG28 Thin Diameter φ0.60mm White 300m Bobbin

UL11527 AWG28 Thin Diameter φ0.60mm Black 300m Bobbin

--A Comprehensive Analysis of Commercial and Passenger Vehicles, Industrial Structure, and Social Impact-

The Japanese government has set a goal of deploying 10,000 Level 4 autonomous commercial vehicles by fiscal year 2030. This is an important initiative to address social issues such as the growing driver shortage, maintaining logistics infrastructure, and ensuring local transportation. While fewer than 1,000 vehicles are expected to be deployed by fiscal year 2027, a plan has been put in place to rapidly promote deployment from that point toward fiscal year 2030. Support measures for local governments and development companies are also expected to be strengthened, accelerating policies toward the societal implementation of autonomous driving.

Overseas, the United States and China have progressed from the demonstration phase to the commercial phase, and in China, autonomous taxis are already operating in several cities. Japan has taken a cautious approach, but advances in policy and technological development are expected to significantly expand commercial services over the next five to ten years. Demand for autonomous trucks is particularly likely to increase in the logistics sector, and autonomous buses are expected to play an important role as a regional transportation provider in depopulated areas.

In the passenger car sector, the Honda Legend is currently the only commercially available vehicle with Level 3 technology. Going forward, it is expected that Japanese manufacturers will gradually add Level 3 technology to their lineup. In five years, Level 3 will be available on multiple vehicle models, and in ten years, it is likely to become widespread, primarily in flagship and luxury models from major manufacturers. However, Level 4 will require significant regulatory and social acceptance, as well as infrastructure development, and widespread adoption in passenger vehicles will require a longer timeframe.

The key factors in determining whether Level 3 or higher autonomous driving will become commonplace in private vehicles will be its compatibility with the living environment and cost. Five years from now, it is expected to be limited to a limited number of high-priced models, expanding to mid-range models in ten years. In 30 years, highly automated driving may become a common option, with autonomous vehicles likely to become a primary means of transportation in urban areas. However, the rate of adoption in rural areas may vary due to differences in road conditions and population density.

In terms of the relationship between autonomous driving and powertrains, EVs are considered to be the most compatible with autonomous driving due to their compatibility with software control. While hybrid vehicles will continue to play a role, the future widespread adoption of autonomous driving is expected to increase the proportion of EVs due to the integration of control and ease of maintenance. Gasoline-powered vehicles will gradually decline in the future, and the industry as a whole will see significant increases in demand in areas such as electrical and software development, sensors, and semiconductors, potentially significantly restructuring the entire automotive industry.

The slow progress of autonomous driving in Japan is due to factors such as high societal demand for safety, complex road environments, cautious legal system development, and infrastructure disparities between rural and urban areas. Additionally, clarifying the scope of responsibility in the event of an accident, improving communication infrastructure, and establishing a system for continuous data collection and improvement are also essential. Progress in autonomous driving could help alleviate labor shortages in the logistics and transportation sectors, but replacing everything with autonomous driving is difficult. Therefore, autonomous driving will likely play a complementary role in specific areas, particularly long-distance transportation and nighttime delivery.

The benefits of introducing autonomous driving include fewer traffic accidents, improved logistics efficiency, maintaining regional transportation, and expanding mobility opportunities for people with mobility restrictions. On the other hand, there are also anticipated disadvantages, such as risks in the event of system malfunction, cybersecurity issues, changes to employment in driving-related occupations, and disparities in adoption due to high costs. Given these factors, the introduction of autonomous driving is not just a technical challenge; it is a theme that will have an impact on the entire social structure, making gradual and sustained efforts essential.

Japan's autonomous driving market is expected to expand steadily in the future, backed by policy support and technological innovation. As adoption progresses from the commercial sector and spreads to passenger cars, the automotive industry is predicted to shift from being centered on hardware to being a multi-disciplinary industry that includes software and services. Advances in autonomous driving are expected to contribute to resolving social issues while shaping a new direction for Japan's mobility industry.

1. Introduction

In environments like aerospace, where space, weight, and thermal loads are unforgiving, conventional hardware solutions are often inadequate. This briefing analyzes two advanced board-level technologies—Flexible Printed Circuits (FPCs) and Copper Coin Printed Wiring Boards (PWBs)—engineered to provide robust performance, three-dimensional wiring, and superior thermal management under these extreme operational constraints.

2. Flexible Printed Circuit Boards (FPCs) for High-Reliability Applications

2.1. Overview and Core Characteristics

A Flexible Printed Circuit Board (FPC) is a circuit board made by applying a copper wire pattern to a thin, flexible insulating material. Unlike traditional rigid boards, FPCs offer distinct advantages in form factor and application.

The three primary characteristics of FPCs are:

• Flexibility and 3D Wiring: FPCs can be bent and folded, which allows for free arrangement within confined areas and enables complex three-dimensional wiring configurations.
• Thin and Lightweight: FPCs are extremely thin, typically 0.1 to 0.2 mm, and lightweight, weighing approximately one-fifth as much as traditional cables. This contributes directly to the miniaturization and weight reduction of electronic devices.
• Dynamic Movement: FPCs can be formed into specific shapes, such as a bellows, to accommodate dynamic movement, including repeated bending and extension. For applications involving simple, repeated flexion, they can be engineered to withstand over 100 million cycles.

2.2. Suitability for Harsh Environments

FPCs are highly suitable for use in harsh environments, such as space and aviation, where high reliability is a critical requirement. Their material composition is key to this durability. FPCs use a thin insulating material like polyimide, which provides excellent heat resistance (above 120°C), radiation resistance, and superior electrical insulation properties, making them robust enough for the rigors of space.

2.3. Case Study: The Ikaros Solar Sail

The history of FPCs dates back to the late 1960s, following the mass production of polyimide film, which led to their adoption by NASA for aerospace applications. The same fundamental material properties that made FPCs valuable for early space missions—namely polyimide's resilience—are precisely what enabled the success of ambitious modern missions decades later, demonstrating the technology's enduring relevance.

A significant application of this technology was the use of OKI's FPCs in the JAXA "Ikaros" small solar power sail demonstrator, launched in 2010. The FPC was chosen for this mission after being evaluated for its key attributes: being lightweight, heat-resistant, and radiation-resistant. In the Ikaros craft, a continuous 14-meter FPC was used as the wiring for thin-film solar cells and various sensors attached to the sail's surface. The mission was a success, marking the world's first successful demonstration of a solar power sail.

3. Copper Coin Printed Wiring Boards (PWBs) for Enhanced Thermal Management

3.1. Functional Principle

A Copper Coin Printed Wiring Board (PWB) is a product where a solid copper coin is embedded directly into the board to conduct heat away from electronic components. The primary function of the coin is to transfer thermal energy from a component on one side of the PWB to the backside, where it can be dissipated through direct contact with a chassis or heat sink. This method is particularly advantageous for components where heat cannot be dissipated from the top surface.

3.2. Innovation: The Convex Copper Coin

To improve thermal performance, a convex (凸型, totsugata) copper coin was developed. The purpose of this design is to increase the surface area on the heat dissipation side of the board, thereby improving the efficiency of heat transfer away from the component and into the chassis.

3.3. Manufacturing Challenge and Solution

The Challenge: The introduction of the convex coin presented a manufacturing challenge. The traditional method—using pressure to deform a cylindrical coin into a through-hole—is unsuitable for convex coins. The varying diameters of the convex shape result in uneven deformation under pressure. This non-uniform deformation prevents the formation of a secure mechanical interlock, compromising the coin's stability and thermal interface within the board.

The Developed Method: A new manufacturing process was developed to reliably secure the convex coins. This method involves the following steps:

1. Create two separate multi-layer board sections (e.g., layers L1-L4 and L5-L8).
2. Drill holes in each board section that correspond to the different diameters of the convex coin.
3. Stack the board sections with a layer of prepreg material placed between them.
4. Insert the convex copper coin into the aligned holes.
5. Laminate the entire assembly. During this process, the prepreg material's resin melts and flows into the gaps, encapsulating the coin. As the thermosetting resin cures during lamination, it forms a robust, void-free bond that mechanically locks the coin in place and ensures a stable thermal pathway.

This new method has been validated through reliability evaluations, including heat cycle tests, confirming sufficient durability for demanding applications. Its true ingenuity lies in its use of existing, space-qualified materials and processes—namely multi-layer lamination and prepreg resin—to solve a novel mechanical problem. This approach minimizes qualification risk by leveraging proven manufacturing infrastructure.

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Robots are no longer confined to the realms of science fiction—they are becoming an integral part of society and industry. With the evolution of AI and robotics, the demand for robot cables, which are indispensable for connecting and transmitting power and data, is also expected to grow rapidly.

Why Robots Will Continue to Proliferate

The spread of robots is driven by several key factors.

• Labor shortages caused by declining birthrates and aging populations in many developed countries.

• Rising labor costs and the growing need for automation in manufacturing.

• Healthcare and welfare demands, such as supporting caregivers and medical professionals.

• Logistics and delivery services, which face increasing demand in e-commerce.

• Safety and disaster response, where robots can work in hazardous environments in place of humans.

As robots become more capable, society will gradually rely on them not only for industrial purposes but also in everyday life.

The Future of Human–Robot Coexistence

• 5 years from now: AI-powered robots will become more common in factories, logistics, hospitals, and restaurants. Humans will begin to see robots as teammates rather than mere tools.

• 10 years from now: Robots will play a central role in solving social issues such as labor shortages and disaster response. In some workplaces, collaboration between humans and robots will be seamless.

• 30 years from now: A society where robots coexist with humans as part of daily life will be established. Service robots, caregiving robots, and home-support robots will be widespread, with robots embedded into urban infrastructure itself.

Robot Cables: Demand Forecast

Currently, global demand for robot cables is estimated to be in the hundreds of millions of meters per year, primarily in factory automation.

• 5 years from now: As robotics spreads into logistics and healthcare, demand will grow by about 1.5 times.

• 10 years from now: With humanoid robots and service robots entering daily life, demand is expected to double.

• 30 years from now: Robots will be embedded in nearly all industries and households, leading to 3–5 times the current demand.

How Robot Cables Will Evolve

Robot cables, which must withstand bending, twisting, and high data transmission, will evolve alongside robots:

• Higher durability: Capable of withstanding hundreds of millions of bending cycles.

• Lighter and thinner designs: Supporting the miniaturization and weight reduction of robots.

• Multi-core and multifunctionality: Handling power, signal, and even optical transmission in a single cable.

• High-speed data transmission: Supporting AI-driven real-time control.

• Smart cables: Equipped with sensors for self-diagnosis and predictive maintenance.

• Wireless and hybrid integration: Some functions may shift to wireless transmission, with cables serving as the backbone for stable power and key data connections.

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Robots will continue to expand their roles in society due to clear needs: solving labor shortages, improving efficiency, and enhancing quality of life. Robot cables, though often unnoticed, are essential infrastructure supporting this growth. As the world heads toward a future where humans and robots live together, the cables that connect them will also evolve in ways we cannot yet fully imagine.

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This table shows the correspondence between AWG (American Wire Gauge), a standard used primarily in the United States, and SQ (square millimeters), which is commonly used in countries like Japan. In the AWG system, a smaller number indicates a thicker wire, while SQ represents the cross-sectional area of the conductor in mm². This table is useful for comparing and converting wire sizes between different standards.

 

AWG	Equivalent SQ Size	Cross-Sectional Area (mm²)
AWG 30	0.05 SQ	0.0507
AWG 28	0.08 SQ	0.0804
AWG 26	0.12 SQ	0.128
AWG 24	0.2 SQ	0.205
AWG 22	0.3 SQ	0.324
AWG 20	0.5 SQ	0.519
AWG 18	0.75 SQ	0.823
AWG 16	1.25 SQ	1.31
AWG 14	2 SQ	2.08
AWG 12	3.5 SQ	3.31
AWG 10	5.5 SQ	5.261
AWG 8	8 SQ	8.368
AWG 6	14 SQ	13.30
AWG 4	22 SQ	21.15
AWG 2	38 SQ	33.63
AWG 1	38 SQ	42.41
AWG 1/0	60 SQ	53.49
AWG 2/0	60 SQ	67.42
AWG 3/0	80 SQ	85.3
AWG 4/0	100 SQ	107.2

The video explains the technical features of each cable, specific use cases, and benefits of introducing OKI Electric Cable's Gigabit Ethernet Cable, as well as the areas in which it is used, with a focus on OKI IDS's i-Series high-speed data transmission solution for FPGA/SoC.

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Supporting the AI/IoT/DX Era: OKI IDS’s High-Speed Data Transmission Solutions and Advanced Cable Technology

In today’s world, where AI, IoT, and digital transformation (DX) are deeply integrated into society, systems are becoming increasingly advanced in areas such as factory automation, surveillance, and autonomous vehicles. As a result, high-speed and large-capacity data transmission has become essential. Traditional data transmission methods struggle with real-time processing as data volumes increase, leading to performance bottlenecks. To address these challenges, OKI IDS offers high-speed data transmission solutions using FPGA technology.

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Why High-Speed Data Transmission Is Needed and the Advantages of FPGAs

Modern systems demand features such as low power consumption, real-time capability, low latency, robustness (durability and long life), high flexibility, and compactness. For example, in autonomous vehicles, real-time responsiveness and minimal latency are critical for avoiding accidents.

To meet these needs, OKI IDS proposes solutions that utilize Field Programmable Gate Arrays (FPGAs), which are programmable logic devices. Compared to CPUs or GPUs, FPGAs can reduce power consumption by 20% to 50% while offering superior real-time performance, robustness, low latency, high flexibility, and compact design—making them indispensable for high-speed communications.

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OKI IDS’s Three High-Speed Data Transmission Solutions

OKI IDS provides the following three solutions to meet diverse customer needs. All of these achieve transmission speeds close to their theoretical maximums.

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1. I-Gig (GigE Vision-Compatible Solution)

I-Gig is compatible with GigE Vision, a widely adopted standard for industrial Ethernet image transmission.

Features and Capabilities

• Supports transmission speeds up to 10 Gbps

• Durable Ethernet cables allow long-distance transmission

• Uses the UDP protocol with a retransmission function to ensure reliable communication

• Utilizes standard interfaces and cables, enabling low-cost system configuration

• Supports GenICam for generic camera control via applications

Use Cases

• Real-time road monitoring systems: Transmits high-volume video data from cameras installed every few hundred meters to central control centers without data loss, enabling detailed monitoring and rapid response to incidents

• Medical X-ray equipment: Transfers uncompressed X-ray images quickly to external PCs via Ethernet for diagnostics and patient data management

Product Lineup

• "I-Gig TX" (camera side) with options such as lightweight/high-precision PTP versions and customizable versions

• "I-Gig RX" (monitor side)

Demo Example

• Demonstrated with AMD’s Kria K26 SOM, achieving high-speed transmission of 5.1MP 60FPS color images at 5.1 Gbps—ideal for AI inference applications

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2. I-TE (TCP/IP Offloading Engine)

I-TE is a TCP Offloading Engine (TOE) that offloads TCP/IP protocol processing from the CPU to the FPGA for enhanced speed.

Features and Capabilities

• Frees CPU resources and achieves near-theoretical maximum speeds (e.g., 920 Mbps for 1 Gbps links, 99 Gbps for 100 Gbps links)

• Provides two communication functions in a single IP: high-speed TCP and general-purpose control communication

• Supports 1GbE, 10GbE, 25GbE, and 100GbE networks

• Parallel processing on the FPGA accelerates time-consuming tasks like checksum calculation

Use Cases

• Imaging systems and surveillance cameras: Supports the increasing bandwidth needs of 4K and 8K high-resolution video transmission

• In-vehicle networks and AI data processing: Transfers data between vehicle units and from edge devices to the cloud

Development Support

• Supports application development on MicroBlaze soft-core processors and Linux applications on Zynq MPSoCs

• Provides design services for MAC/PHY integration and physical device control

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3. I-DMAC (PCI Express DMA Controller)

I-DMAC is an intelligent DMA controller optimized for AMD’s integrated PCI Express blocks, enabling high-speed data transfers between main memory and local FPGA/SOC memory without CPU intervention.

Features and Capabilities

• Maximizes PCIe performance without requiring specialized knowledge

• Includes platform-integrated protocol handling, DMA functionality, target access, and peripheral circuits, reducing development time

• Compatible with Windows and Linux device drivers

• Uses a Command Descriptor Table (CDT) for continuous DMA transfer under virtual memory environments without CPU interruption

• Offers two DMA modes: "Normal Transfer" and "Capture Transfer" (the latter enables autonomous continuous transfers ideal for large image data streams)

Use Cases

• Imaging and video production equipment: Transfers large volumes of high-resolution data efficiently

• Data communication equipment: Integrates with OKI IDS’s 100GbE I-TE for high-performance smart NIC solutions

• Now supports PCIe Gen4 x8, improving both bandwidth and energy efficiency

Development Support

• Provides IPs, reference designs, Vivado projects, manuals, and evaluation tools

• Customization available for specific customer needs, such as multi-channel support or PCIe SR-IOV

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Cable Technology Supporting High-Speed Data Transmission

OKI Electric Cable supports these high-speed data solutions with high-performance network cables compatible with GigE Vision.

Features

• Environmental resistance: Durable in harsh conditions including oil, dust, vibration, and temperature changes

• Noise resistance: Ensures stable communication even under external interference—ideal for machine vision applications

• Flexibility: Designed for industrial robots, allowing easy routing in tight spaces while maintaining signal integrity

Product Lineup

• Supports standards such as EtherCAT, MECHATROLINK, CC-Link

• Offers a full range of cables from Category 5 to 7, including non-RJ45 connector options

Customer Applications

• High-speed communication and precise control for industrial robots

• Real-time image processing in surveillance systems

• Efficient network configuration in smart factories through IoT integration

• Custom cable development and tailored proposals for specific field requirements

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Conclusion

With its three powerful solutions—I-Gig, I-TE, and I-DMAC—combined with OKI Electric Cable’s advanced technologies, OKI IDS meets the diverse high-speed data transmission needs of the AI/IoT/DX era.

If you’re envisioning a new system or seeking the optimal solution, feel free to contact OKI IDS for expert consultation and support.

◇OKI Electric Cable　Gigabit Ethernet Cable
https://www.okidensen.co.jp/jp/prod/cable/mv/index_gigab.html?lfpeid=e5ElX34UtcpZ&lfmaid=1000339978-1

― Application of UL11527 AWG28 φ0.60mm for Next-Generation Devices ―

1. Background: Increasing Demand for Miniaturization and High-Density Wiring

In recent years, the trend toward miniaturization and weight reduction in electronic devices has intensified, along with a growing need for high-density and reliable internal wiring. In compact applications where flexibility and space-saving are essential, the combination of ultra-fine flexible wire and low-profile board-to-wire connectors is becoming increasingly important.

In response to these market demands, we would like to introduce the UL11527 AWG28 φ0.60mm single-core robot cable manufactured by OKI Electric Cable, which demonstrates excellent compatibility with various compact connectors.

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2. Product Overview: UL11527 AWG28 φ0.60mm

The UL11527 AWG28 φ0.60mm cable offers the following key features:

• Conductor structure: 49 strands of 0.05mm wires (49/0.05) for excellent flexibility

• Insulation outer diameter: Just 0.60mm for space-efficient routing

• Insulation material: Polyester elastomer with high flex and heat resistance

• Rated temperature: 105°C / Rated voltage: 30V

• Certifications: UL compliant (UL11527), RoHS2 compliant

With its ultra-thin diameter and excellent bend resistance, this cable is well-suited for applications involving repeated motion or constrained spaces.

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3. High Compatibility with Low-Profile Connectors

This cable is ideally suited for use with low-profile, small-pitch board-to-wire connectors such as:

• JST ACH Series (SACH-003G-P0.2)

• JST SUH Series (SSUH-003T-P0.15)

• Hirose Electric DF52, DF57, DF58 Series

These connectors are designed for use in compact spaces and feature secure locking mechanisms. The UL11527 cable meets the size and flexibility requirements of these terminals, ensuring excellent crimpability and mating reliability, even in tight installations.

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4. Target Applications and Future Demand

The combination of UL11527 cable and low-profile connectors is expected to be especially useful in the following areas, with projected growth in the next 5 to 10 years:

■ Automotive

• Increasing electronic content in EVs, ADAS, and in-vehicle sensors is driving demand for compact and vibration-resistant wiring.

• Ideal for battery management systems and space-limited ECUs.

■ Medical & Wearable Devices

• Widely applicable in compact and portable diagnostic devices and wearable monitors.

• Its high flexibility makes it suitable for on-body or textile-integrated sensors.

■ Robotics & Humanoid Systems

• Suitable for joints and articulated parts where repeated flexing occurs.

• The combination with locking connectors helps ensure stable connections during movement.

■ Drones / UAVs

• Lightweight and flexible wiring is highly desirable for small drones and gimbal control systems.

• UL11527 is well-suited for compact flight control boards and servo wiring.

■ Consumer, IoT, AR/VR Devices

• Increasing need for fine wiring in smart glasses, AR headsets, and IoT sensors.

• Excellent fit for dense internal connections where space and weight are critical.

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5. Flexible Supply for Prototyping and Small Lots

Cables with outer diameters of 0.60mm or less are generally produced in bulk quantities by many manufacturers, making small-lot procurement difficult for prototyping or R&D.

To address this, we offer the UL11527 AWG28 φ0.60mm cable in black and white, starting from just 1 meter. This allows for:

• Rapid prototyping with minimal procurement hurdles

• Reduced lead times and inventory risk

• Flexible response to small-volume and specialized development needs

We hope this offering will support engineers working in early-stage development or evaluation.

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6. Conclusion

The UL11527 AWG28 φ0.60mm robot cable demonstrates strong compatibility with low-profile, narrow-pitch connectors, and is highly suitable for use in compact and moving parts of next-generation devices. From automotive systems to wearables, robotics, drones, and consumer electronics, we believe this cable can contribute to reliable and space-saving wiring solutions.

We are pleased to offer small-lot sales and short delivery times to support your development activities. If you have any questions or would like to request samples or datasheets, please feel free to contact us.

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◇Product page https://nisho-en.ocnk.net/product/168

Laser processing is one method for cutting out (processing) the outer shape of an FPC. This laser processing has two main advantages compared to using a mold.

The cost of preparation (initial cost) is low
To process the outer shape of an FPC, there are two methods: using a dedicated mold called a "mold" and using a laser processing machine. When using a mold, it is necessary to create a special mold that matches the shape of the product. It costs money to create this mold (this is part of the initial cost). On the other hand, with laser processing, there is no need to prepare such a mold. You can simply prepare the shape you want to process as data on a computer. Therefore, there is a great advantage in that you can keep the initial preparation cost (initial cost) for making the product low because there is no cost to make a mold.

Easy to respond when you want to change the shape
In the initial stage of product development (prototype stage), it is often necessary to change the specifications, such as "I want to change the shape of this part a little more" after using the actual FPC. If you use a mold for processing, you must create a new mold from scratch to fit the new shape in order to change the shape. This takes time and money again. However, with laser processing, even if you want to change the shape, you can do so simply by editing the processing data on a computer. This has the advantage of being able to respond flexibly to specification changes quickly and without incurring large additional costs.

Because of these advantages, laser processing is a very effective method, especially when prototyping FPCs, as it reduces initial costs and also makes it easy to change the shape later. Laser processing takes longer to process than using a mold, so it is mainly used for small-scale production such as prototyping. Please choose the optimal processing method depending on the final specifications of the FPC and the quantity to be made.

◇Manufacturer's site
https://www.okidensen.co.jp/en/prod/fpc/

OKI Electric Cable FPC Catalog PDF