Contacts are the unsung backbone of industrial robotics hardware. You can assemble the most advanced robots with cutting-edge capabilities, but without high-quality contacts, reliability suffers. Motors may not turn, sensors can drop out, and systems may grind to a halt. Well-designed contacts ensure that robots work together flawlessly, transmitting power and data without interruption.
Electrical contacts are the conductive elements that make or break a circuit within a connector or device. They can be made from materials such as electrographite, copper alloys, silver, or composite blends. In robotics, contacts bridge circuit boards, sensors, actuators, and controllers — enabling modular, maintainable designs. With quality contacts, components can be replaced or upgraded without major disassembly.
Industrial robots operate in environments where repetitive motion, vibration, temperature swings, and contamination are common. Under these conditions, poorly chosen contacts can loosen, corrode, or wear down, leading to costly downtime. Advanced contact materials and designs withstand high cycle counts, maintain low electrical resistance, and resist mechanical degradation over time.
Different robotic systems use different contact designs depending on motion patterns, space constraints, and electrical requirements:
In industrial robotics, electrical contacts aren’t just chosen from a catalog — they’re engineered for the specific environment, duty cycle, and performance requirements of the application. The wrong choice can lead to premature wear, excessive resistance, or outright failure, resulting in costly downtime.
Common issues include pitting or erosion from arcing, fretting corrosion from vibration, and material wear from mechanical cycles. Solutions involve using harder contact materials, applying protective coatings, and designing contact geometries that maintain consistent pressure over the product’s life.
Even the best-designed contacts can fail if they’re not integrated properly into the robotic system. Installation practices, cable management, and maintenance schedules all influence long-term performance. Poor routing or strain relief can introduce mechanical stress that leads to wear, while improper handling during assembly can damage delicate contact surfaces.
Electrical contacts are present in nearly every part of an industrial robot, from its high-power drive systems to the smallest sensor connections. Their design and material composition often vary by application, depending on movement cycles, environmental exposure, and precision requirements.
As robotics technology advances, so too must the components that make them possible. The push for smaller, faster, and more capable robots is driving the need for miniaturized contacts that can carry more power and data in less space.
Electrical contacts may be small, but their impact on robotic performance is huge. The right material and design choices can extend service life, reduce downtime, and improve efficiency. At St. Marys Carbon, we specialize in contacts that stand up to the toughest industrial environments, bridging the gap between concept and reliable, scalable automation.