Explosion-Proof Cobots: Automation for Hazardous Areas in Paint, Chemical and Pharma Plants

Some of the jobs that most need automation happen in places where an ordinary robot is not allowed: paint booths, solvent handling, chemical and pharmaceutical plants, and anywhere flammable gases, vapours or dust may be present. Explosion-proof collaborative robots are designed for these hazardous areas. This guide explains what “explosion-proof” means for a robot, where these cobots are used, and what to check before you buy.

What makes an area hazardous?

A hazardous (or “classified”) area is a place where an explosive atmosphere of gas, vapour, mist or combustible dust may be present. Any electrical equipment that could create a spark or a hot surface in such an area must be certified for it. In India, installations in hazardous areas must comply with the applicable regulations and standards, so always involve your safety team and certifying authority early.

How explosion-proof robots are protected

Several protection methods exist. One common method for robots is pressurisation (marked “p” in the protection code): the robot’s enclosure is kept at a slight positive pressure with clean air or inert gas, so the surrounding explosive atmosphere cannot get inside to reach electrical parts. The equipment’s marking describes the protection method, the gas or dust group and the temperature class it is certified for.

Reading the Elfin-Ex marking

The Elfin-Ex explosion-proof collaborative robot carries the markings Ex pxb IIC T6 Gb and Ex pxb IIIC T80°C Db. In general terms:

• Ex p: protection by pressurisation.
• IIC: suitable for the most demanding gas group, and IIIC: for conductive combustible dust.
• T6 / T80°C: low maximum surface temperature.
• Gb / Db: the equipment protection level for gas and dust atmospheres.

Always confirm with your safety engineer that the marking matches the zone classification of your specific area.

Elfin-Ex at a glance

From the Elfin-Ex specification table on our website:

• Models E05F, E10F, E10F-L, E12F and E15F
• Payload 5–15 kg, reach 800–1,800 mm
• Repeatability from ±0.02 mm
• IP66 protection and a working temperature of −20 to 40°C
• Six degrees of freedom, graphical programming and remote call interface
• TCP/IP and Modbus TCP communication (Profinet and EtherNet/IP optional)
• Customisable cable length of up to 15–20 m

Typical applications

• Spray painting and coating
• Solvent and chemical handling, dosing and sampling
• Pharmaceutical and fine-chemical processing
• Handling in areas with combustible dust, such as some powder processes
• Inspection and testing in hazardous zones

Benefits of a collaborative design in hazardous areas

• Removes people from exposure to solvents and vapours.
• Consistent quality on coating and dosing tasks.
• Flexible deployment and graphical programming, so process engineers can adjust tasks.

Checklist before you buy

• Confirm the zone classification and gas or dust group of your area.
• Check that the robot’s marking and certification match.
• Plan the pressurisation air supply and monitoring.
• Check that grippers, tools and sensors are also certified for the zone.
• Plan cable routing to the control cabinet outside the hazardous area.
• Carry out a risk assessment for the complete application.

Exploring automation for a hazardous process? Talk to MROBOTICS about the Elfin-Ex. See our guide to cobots in India for the wider range.