Pneumatic Hose Coaxial Control Composite Cable | Integrated Air, Signal & Control Hybrid Cable Solution

Name: Pneumatic Hose Coaxial Control Composite Cable | Integrated Air, Signal & Control Hybrid Cable Solution
Rating: 4.5 (10 reviews)

The RST-PHC Series Pneumatic Hose Coaxial Control Composite Cable combines compressed air hose (PU 1.0 MPa or PA12 2.0 MPa), OFC power cores (300/500 V), and individually screened signal pairs (RS-485, EtherCAT, PROFIBUS, CANbus) in a single polyether TPU-jacketed cable rated for ≥5 million flex cycles in drag chain and robotic arm service. Available in single-hose and dual-hose configurations from 16 to 26 mm OD, with an optional fiber optic variant for vision-guided systems. CE, RoHS 2, ISO 9001 certified. HiPot and hose pressure test certificate per drum.

Description

Pneumatic Hose Coaxial Control Composite Cable | Integrated Air, Signal & Control Hybrid Cable Solution

Home › Products › Composite Hybrid Cables › Pneumatic Control Cable │ Series: RST-PHC │ Reviewed by: Rousheng Composite Engineering Team

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Air Hose

0.4–10 MPa rated

⚡

Power Core

300/500 V OFC

Signal Pair

Screened RS-485/IO

⊙

Control Pair

24 VDC / PLC logic

Pneumatic hose coaxial control composite cable solves one of the most persistent wiring problems in automated industrial systems: the need to route compressed air, electrical power, and control signals to the same moving end-effector, actuator, or gripper — through a single cable management track.

Running separate pneumatic hoses alongside electrical cables doubles the cable carrier fill ratio, increases failure points, and complicates installation significantly. The RST-PHC series combines all three media — compressed air, power, and signal — inside one outer jacket, designed specifically for continuous-flex drag chain and robotic arm applications.

Who specifies this cable

The RST-PHC series is specified by robotics system integrators, automotive OEM automation engineers, and packaging machine builders. Any end-effector that needs pneumatic actuation (grippers, suction cups, blow-off nozzles) alongside electrical power and PLC I/O signals is a direct application.

Page Contents

Why Composite: Air + Power + Signal in One Cable
Model Range & Specifications
Construction — Layer by Layer
Application Scenarios
Technical Parameters
Project References
FAQ — Engineers & System Integrators
Manufacturer Credentials
Request a Quote

Why Composite: The Case for Air + Power + Signal in One Jacket

The problem with separate hoses and cables

In a 6-axis welding robot, a typical end-effector cable package contains: one pneumatic hose (gripper), one power cable (servo), and two signal cables (encoder + I/O). That is four separate components competing for space in a single drag chain or cable arm conduit.

Separate routing causes three measurable problems. First, fill ratio: four separate items in a drag chain designed for two causes friction, heat buildup, and premature jacket wear. Second, installation time: routing, clamping, and labelling four items per robot takes 40–60% longer than routing one composite cable. Third, fault finding: when an intermittent fault occurs, maintenance engineers must test four cable paths rather than one.

What the composite design achieves

The RST-PHC composite cable replaces all four items with a single assembly. The outer diameter is typically 15–25% smaller than the combined outer diameter of the equivalent separate hose-and-cable bundle. The cable carrier fill ratio drops from ~70% to under 45% in typical installations.

Installation time reduces by an average of 35% based on field data from automotive OEM installations. Fault finding is simplified: a single HiPot test covers all electrical elements; a single pressure test covers the air hose. Both tests are conducted simultaneously on the same cable.

When separate cables remain preferable

Use RST-PHC composite when: air pressure is 0.4–10 MPa | electrical power is ≤16 mm² per core | cable run is ≤300 m | the end-effector combines pneumatic and electrical function in one body.

Continue with separate cables when: air pressure exceeds 10 MPa (dedicated high-pressure hose required) | power core exceeds 16 mm² (composite OD becomes impractical) | pneumatic and electrical terminations are on different structures more than 2 m apart.

RST-PHC Series — Model Specifications

Model	Air Hose(s)	Bore / Pressure	Power Cores	Signal / Control	OD	Flex Life	Primary Application
RST-PHC-1A-2P	1× PU hose	Ø6 mm / 1.0 MPa	2×1.0 mm²	2 signal pairs screened	16.0 mm	≥5 M cycles	Light gripper, small servo end-effector
RST-PHC-1A-4P	1× PU hose	Ø8 mm / 1.0 MPa	4×1.5 mm²	4 I/O pairs + RS-485	19.5 mm	≥5 M cycles	Standard gripper arm, PLC-controlled actuator
RST-PHC-2A-4P	2× PU hose	Ø6 mm / 1.0 MPa each	4×1.0 mm²	4 signal pairs screened	22.0 mm	≥5 M cycles	Dual-action gripper, push-pull pneumatic
RST-PHC-1A-4P-HP	1× PA12 hose	Ø8 mm / 2.0 MPa	4×1.5 mm²	4 I/O pairs + CAN pair	21.2 mm	≥5 M cycles	High-pressure gripper, injection moulding arm
RST-PHC-2A-6P	2× PA12 hose	Ø6 mm / 2.0 MPa each	6×1.5 mm²	8 I/O pairs + PROFIBUS	26.0 mm	≥3 M cycles	Multi-function end-effector, welding robot tool
RST-PHC-1A-4P-FO	1× PU hose	Ø8 mm / 1.0 MPa	4×1.5 mm²	2×SM fibre + 4 pairs	24.5 mm	≥3 M cycles	Vision-guided robot: camera + gripper + power
RST-PHC-OEM	1–4 hoses	Per spec	Per spec	Per spec	Per spec	Per spec	Automotive OEM, semiconductor, food industry

PU hose = polyurethane, flexible, −40°C to +60°C. PA12 hose = polyamide 12, higher pressure, −40°C to +100°C. HP = high-pressure variant. FO = fiber optic integrated. All models rated for drag chain and robotic arm dynamic flex service.

Construction — Layer by Layer

Air hose element

The pneumatic hose is the structurally dominant element in the RST-PHC cross-section and is positioned to exploit this: the hose runs along the cable’s neutral axis in single-hose models, or in a symmetric pair in dual-hose models.

Two hose materials are available. Polyurethane (PU) is the standard grade: Shore A 92, burst pressure 4× working pressure, excellent flexibility to −40°C. Polyamide 12 (PA12) is the high-pressure grade: rated to 2.0 MPa working pressure, chemical resistant to cutting fluids and hydraulic oil, rated to +100°C continuous.

Hose bore sizes: 4 mm, 6 mm, 8 mm, and 10 mm internal diameter. Hose wall is colour-coded per ISO 15552 convention: blue for supply, black for exhaust, red for pilot. Custom colour available on request.

Power and signal conductors

Power cores: oxygen-free copper (OFC), IEC 60228 Class 5 or Class 6 depending on cross-section. XLPE or flexible PVC insulation, colour-coded DIN VDE 0293. Cross-section range: 0.5 mm² to 6 mm² per core. Voltage: 300/500 V standard.

Signal and control pairs: individually foil-screened twisted pairs with drain wire. Characteristic impedance 120 Ω ±10 Ω (RS-485/PROFIBUS) or 100 Ω ±5 Ω (EtherCAT). Supported protocols: RS-485, Modbus RTU, PROFIBUS DP, CANbus, EtherCAT, 24 VDC discrete I/O.

Bundle geometry and outer jacket

The hose(s) and electrical elements are cabled together with a counter-helical lay optimised for the cable’s rated bend radius. A polyester fleece separator prevents the TPU jacket from bonding to the inner elements during extrusion — essential for flex life in drag chain service.

Outer jacket: polyether TPU, Shore A 85 ± 3, Taber abrasion ≥ 300 cycles (CS-17 wheel, 1 kg). Operating temperature: −40°C to +105°C. Oil and cutting fluid resistant. Colour: black standard; RAL colours on request.

Layer	Material	Standard / Test
Air hose bore	PU or PA12, colour-coded, 4–10 mm ID	ISO 15552; burst ≥4× working pressure
Hose fitting (factory-terminated option)	Push-in fittings, 316L SS or nickel-plated brass	ISO 14743
OFC power conductors	Class 5 or 6, 0.5–6 mm², XLPE insulation	IEC 60228; IEC 60502
Signal / control pairs	Foil-screened twisted pairs, 0.25–0.5 mm², drain wire	IEC 61156-5
Cabling separator	Polyester fleece binder tape	Internal specification
Outer jacket — polyether TPU	Shore A 85±3; Taber ≥300 cycles; −40°C to +105°C	ISO 37; ISO 9352; ISO 868

Application Scenarios

Robotic welding and assembly

In automotive body shops, each welding robot carries a pneumatic gripper for part positioning alongside servo-driven wrist axes. The RST-PHC-2A-6P replaces the separate hose bundle and multi-core cable in the upper arm drag chain, reducing the chain’s fill ratio and eliminating the hose-cable friction that causes premature jacket cracking at the chain’s minimum bend radius.

Pick-and-place and palletising

Delta robots and SCARA palletisers use suction cup grippers that require clean dry compressed air at 0.4–0.8 MPa. The RST-PHC-1A-2P provides the air supply alongside the encoder and I/O cables in a single lightweight assembly. Mass per metre is 15–20% lower than the equivalent separate hose-and-cable combination, reducing the dynamic load on the robot’s fourth axis.

CNC machine tool changer

Automatic tool changers (ATC) use pneumatic clamps and drawbars alongside servo feedback signals. The RST-PHC-1A-4P-HP high-pressure variant handles the 1.5–2.0 MPa clamp pressure while routing the tool identification and position signals through the same cable entry port — critical when the ATC has a single cable gland.

Vision-guided robotic systems

The RST-PHC-1A-4P-FO integrates two SM optical fibres alongside the pneumatic hose and electrical conductors. This enables a camera or structured-light sensor mounted on the end-effector to transmit high-bandwidth image data back to the vision processor without a separate fibre cable run through the drag chain.

Food and pharmaceutical automation

Food processing robots require cables that resist detergents, disinfectants, and washdown water. RST-PHC models with PA12 hose and white RAL 9010 TPU jacket meet EHEDG hygienic design guidelines for cable routing in wet food processing environments. FDA-compliant hose compound available on request.

Technical Parameters

Pneumatic element

Parameter	PU Hose (Standard)	PA12 Hose (High-Pressure)	Reference
Working pressure	1.0 MPa	2.0 MPa	ISO 15552; burst ≥4× WP
Bore sizes	4 / 6 / 8 / 10 mm	4 / 6 / 8 mm	Per model
Operating temp.	−40°C to +60°C	−40°C to +100°C	ISO 15552
Permeation rate	≤0.1 g/m·h at 0.6 MPa	≤0.05 g/m·h	Internal test
Chemical resistance	Oil, water, mild solvents	Cutting fluids, hydraulic oil, 10% NaOH	ISO 4080
Colour coding	Blue (supply) / Black (exhaust) / Red (pilot)	Same	ISO 15552

Electrical element

Parameter	Value	Reference
Power core voltage	300/500 V (standard); 450/750 V on request	IEC 60502-1
Power HiPot test	2,000 V AC / 5 min	IEC 60502-1 Cl.17
Insulation resistance	≥200 MΩ·km (power); ≥500 MΩ·km (signal pairs)	IEC 60502-1
Signal pair impedance	120 Ω±10 Ω (RS-485); 100 Ω±5 Ω (EtherCAT)	IEC 61156-5
NEXT @ 10 MHz	≤−40 dB (screened pairs in composite)	IEC 61156-5
Max conductor temp.	+90°C (XLPE insulation)	IEC 60502-1
Current derating (drag chain)	Factor 0.75 of free-air rating	IEC 60364-5-52

Mechanical and environmental

Parameter	Value	Standard
Dynamic bend radius	7.5× OD (drag chain); 10× OD (robotic arm torsion)	IEC 60794-1-2 E10 adapted
Minimum flex life	≥5 million cycles (standard); ≥3 M (FO and 2-hose models)	Internal flex rig
Jacket Shore A	85±3	ISO 868
Jacket tensile strength	≥48 MPa	ISO 37
Jacket elongation	≥360%	ISO 37
Jacket abrasion	≥300 cycles Taber CS-17, 1 kg	ISO 9352
Operating temp. (dynamic)	−40°C to +105°C	IEC 60811-501
Oil resistance	Mineral oil, cutting fluid, biodiesel — no swelling	IEC 60811-406
Flame retardancy	IEC 60332-1 (single wire, on request)	IEC 60332-1

Project References

Customer names withheld. Technical data verified and available under NDA.

Project	Application	Cable	Challenge	Result
Automotive body shop, Germany	82 welding robots, dual-gripper end-effectors, 18 m drag chain per robot	RST-PHC-2A-6P, 20 m per robot, 164 cables total	Separate hose/cable bundles were reaching 68% drag chain fill ratio, causing thermal damage to outer jackets at the chain’s tight bend. RST-PHC-2A-6P reduced fill ratio to 41%.	Zero thermal jacket failures in 18 months since installation. MTTR for cable faults reduced from 4.2 h to 1.8 h (single cable to locate and replace). 2023–ongoing.
Semiconductor packaging, Taiwan	48 pick-and-place arms, suction gripper + encoder + I/O, 3 m arm cable	RST-PHC-1A-2P, 3.5 m per arm	Previous separate PU hose + flat cable caused hose-to-cable friction at the arm pivot, wearing through hose wall within 8 months. Composite construction eliminates the relative motion between elements.	18 months service, 48 arms, zero hose failures. Cable replaced at scheduled PM interval (24 months). 2022–ongoing.
Palletising line, food industry, Netherlands	12 SCARA robots, suction cup palletiser, 4 m arm cable, daily washdown	RST-PHC-1A-4P, white RAL 9010 jacket, PA12 hose, food-grade compound	Standard black TPU jacket retained discolouration from food contact residues, failing hygiene audit. White RAL 9010 jacket allows visual inspection of jacket surface at daily hygiene check.	Passed EHEDG visual inspection 18 consecutive months. 2023–ongoing.
CNC machining centre OEM, Japan	Automatic tool changer arm, 1.8 MPa pneumatic clamp, servo encoder, 2.5 m cable	RST-PHC-1A-4P-HP, PA12 hose, 2.0 MPa rated	Single gland entry into ATC head required air and electrical signals in one cable. Previous PU hose compound swelled in cutting fluid at 0.9 MPa over 6 months. PA12 hose: no swelling after 12 months.	OEM adopted RST-PHC-1A-4P-HP as standard ATC cable across product line. 2023.
Vision robot integration, South Korea	6-axis vision-guided assembly robot, structured-light camera on end-effector, 6 m arm cable	RST-PHC-1A-4P-FO (SM fibre + 4 power cores + 1 PU hose)	Camera required SM fibre for 1 Gbit/s image data. Routing a separate fibre cable alongside the existing hose-and-power cable consumed the final drag chain slot. RST-PHC-FO integrated all three in existing chain.	Vision system latency: 1.2 ms (fibre link). No additional drag chain required. 2024.

FAQ — Engineers & System Integrators

Q1: What is the maximum air pressure the composite cable can handle?

Standard PU hose models are rated to 1.0 MPa working pressure with a burst pressure of ≥4.0 MPa. PA12 (polyamide 12) hose models handle 2.0 MPa working pressure. For working pressures between 2.0 MPa and 6.0 MPa, a hybrid construction with a separate high-pressure hose can be co-jacketed with the electrical elements — contact our engineering team for OEM specifications above 2.0 MPa.

Q2: Can the pneumatic hose and electrical conductors be separated at the termination end?

Yes. The standard termination approach at both ends is to strip the outer jacket, cut the polyester fleece separator, and route the hose and electrical elements separately to their respective connection points. The hose terminates to push-in or compression fittings; the electrical conductors terminate to terminal blocks or M12 circular connectors. Factory pre-terminated assemblies with push-in fittings and M12 connectors at both ends are available on request.

Q3: How is the cable’s flex life validated for the pneumatic element?

RST-PHC cables are flex-tested as a complete composite assembly on a motorised drag chain test rig at the rated dynamic bend radius (7.5× OD). After the rated cycle count, the pneumatic hose is pressurised to 1.5× working pressure and held for 30 minutes. A pressure drop of more than 0.01 MPa in 30 minutes is a test failure. The electrical elements are simultaneously tested with a HiPot retest and conductor resistance measurement. Both elements must pass to qualify the cable for the rated flex life.

Q4: Can RST-PHC composite cable be used in a rotary application (e.g., robot wrist rotation)?

Single-hose models (RST-PHC-1A variants) tolerate ±180° of torsion per metre of free cable length in the robot arm section, equivalent to standard robot cable performance. Multi-hose models (RST-PHC-2A variants) have a lower torsion tolerance (±90°/m) due to the asymmetric cross-section when two hoses are eccentric to the cable centre. For wrist applications with continuous rotation beyond ±180°, specify a slip ring or rotary joint for the pneumatic element and use RST-PHC for the non-rotating drag chain section only.

Q5: What is the minimum order quantity and lead time?

Standard models (RST-PHC-1A-2P, 1A-4P, 2A-4P): MOQ 50 m, lead time 2–3 weeks. HP and FO variants: MOQ 100 m, lead time 3–4 weeks. OEM custom cross-sections: MOQ 200 m, lead time 5–6 weeks. Cut-to-length assemblies with pre-terminated connectors: available from 1 m, lead time 2–3 weeks for stocked models. Contact Jerry@rstlkable.com for volume pricing and framework supply agreements.

Q6: Is the cable compatible with energy chain systems from specific manufacturers?

RST-PHC outer diameters are sized to standard energy chain inner heights from Igus, Tsubaki, Helukabel, and Murrplastik. The OD tolerance is ±0.3 mm to ensure reliable seating in chain clips. For critical fit requirements, request a certified dimensional report and a 0.5 m sample before finalising the chain clip size. We can also provide a cable-to-chain compatibility check if you supply the chain type and inner height specification.

Manufacturer Background — Shanghai Rousheng

Production capabilities

Dedicated composite extrusion line: simultaneous hose co-jacketing and electrical element cabling

In-house hose pressure test: 4× working pressure per batch

Motorised flex rig: continuous cycle testing at rated bend radius

100% HiPot test on all electrical cores per drum

Conductor resistance certificate per drum (IEC 60228)

Full batch traceability: hose compound lot + copper batch + TPU jacket lot

Certifications

ISO 9001:2015 quality management system

CE marking — LVD Directive 2014/35/EU

RoHS 2 / REACH SVHC compliance

EHEDG design guidance compliance (food-grade variants)

CNAS-accredited lab reports on request

AAA Enterprise Credit Rating (China)

Rousheng’s composite cable engineering team co-develops OEM cable cross-sections with system integrators. We review drag chain specifications, end-effector port layouts, and hose pressure requirements before proposing a cross-section — at no charge. We consider pre-sale engineering review as important as the cable itself.