Comprehensive guide to ATEX-compliant brake solutions for industrial applications
What exactly is an ATEX brake and why is it vital for my operation?
An ATEX brake is specifically designed for use in hazardous locations to prevent ignition sources such as sparks or hot surfaces. It is vital, as it protects people, equipment, and the environment from explosions and ensures the compliance with legal regulations (ATEX Directive 2014/34/EU).
How do I select the appropriate ATEX brake for my specific zone and application?
The selection depends on the ATEX zone (e.g., 0, 1, 2 for gases; 20, 21, 22 for dusts), the type of explosive atmosphere, the environmental conditions (temperature, humidity), and the mechanical requirements (brake torque, duty cycle) . A thorough analysis of your application is crucial.
What is the difference between ATEX Zone 21 and Zone 22 in terms of dust explosion hazard?
ATEX Zone 21 designates areas where, under normal operating conditions, often or occasionally an explosive atmosphere can occur due to combustible dust. ATEX Zone 22 concerns areas where such an atmosphere occurs only rarely and temporarily. The requirements for brakes are stricter in Zone 21.
My operation has very specific requirements. Can ATEK also provide customized ATEX brake solutions?
Yes, ATEK Drive Solutions specializes in custom ATEX special solutions to develop. This includes adjustments in braking torque, mounting flanges, materials, or controls to precisely address your individual application needs, even for small series. einzugehen, auch für Kleinserien.
What role do ATEX markings and the IECEx certification play?
Die ATEX marking on a brake provides detailed information about its suitability for specific zones, equipment categories, temperature classes, and types of explosion protection. The IECEx certification is an internationally recognized system that facilitates global trade in explosion-protected devices and signals worldwide compliance. signalisiert.
How do ATEX spring-applied brakes contribute to plant safety?
ATEX spring-applied brakes operate on the fail-safe principle: they are safely closed by spring force when power is off.This means that in case of a power failure or emergency shutdown, the braking effect is activated immediately and reliably, which is crucial for safety in critical applications.
In which industries are ATEX brakes typically used?
ATEX brakes are essential in industries such as the oil and gas industry, mining, chemical industry, food and pharmaceutical industry, as well as in woodworking, painting facilities, and anywhere combustible gases, vapors, or dust may occur.
Does ATEK provide support for the design and integration of ATEX brakes into existing or new systems?
Yes, ATEK offers comprehensive technical consulting and engineering support.Our experts analyze your specific application and environmental conditions in order to design the optimal ATEX brake or complete drive solution and ensure its seamless integration.
The correct selection and implementation of an ATEX brake ist are crucial for operational safety in hazardous areas and prevent costly outages as well as dangerous accidents, which significantly increases the availability of the plant..
ATEK Drive Solutions offers not only individual ATEX brakes, but also integrated drive solutions (gear boxes, motors, brakes) that are made possible by the modular system millions of configurations und enable fast delivery times. Through
Durch custom adjustments and comprehensive technical consulting, ATEK ensures that your ATEX brake solution is optimally designed, which can lead to an improved system efficiency and a reduction in interface complexity by up to 30% .Learn everything about ATEX brakes: From the basics of ATEX certification to the latest technologies and applications. Find the optimal solution for your hazardous areas.
In hazardous environments, ATEX brakes are essential. They ensure safety and reliability. ATEK Drive Solutions offers you a wide range of ATEX-compliant brake solutions. Do you need individual consulting? Contact us now! Contact with us now!
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Understand: Basics and necessity of ATEX brakes
What are ATEX brakes and why are they indispensable?
ATEX brakes are designed for safe operation in explosive atmospheres by avoiding ignition sources. In painting facilities (Zone 1, solvent vapors), electrical components, including brakes, must be ATEX-compliant to prevent explosions. The importance of the ATEX directive for your operational safety
Die Bedeutung der ATEX-Richtlinie für Ihre Betriebssicherheit
The ATEX Directive 2014/34/EU is binding for equipment in Ex-areas; compliance protects people and secures processes. In the food industry (Zone 21, flour dust), conveyor brakes often require dust explosion protection certification. This must be considered when choosing compliant In der Lebensmittelindustrie (Zone 21, Mehlstaub) erfordern Förderanlagenbremsen oft Staubexplosionsschutz-Zertifizierung. Dies ist bei Wahl konformer industrial brakes. Distinction: ATEX versus ‘explosion-protected’
‘Explosion-protected’ is general; ATEX defines specific protection levels/zones (e.g., 1, 2, 21, 22) for gas/dust.
For Zone 1 (gas), a higher protection class is required than for Zone 22 (dust). The ATEX definiert spezifische Schutzniveaus/Zonen (z.B. 1, 2, 21, 22) für Gas/Staub. An ATEX brake für Zone 1 (Gas) braucht höhere Schutzart als für Zone 22 (Staub). Die safety brake must match the zone.Analyze: Operating principles and designs of ATEX brakes in detail
How do ATEX spring-applied brakes work?
ATEX spring-applied brakes (YBF) utilize mechanical spring force and are safely closed in the power-off state (fail-safe). Brakes such as the DEX series (up to 3200 Nm) hold immediately during power loss, for example in conveying systems for combustible bulk materials. Electromagnetic release when powered.
- ATEX spring-applied brakes (e.g., YBF) are securely closed by mechanical spring force when power is off (fail-safe principle).
- These brakes, like the DEX series, ensure immediate holding during power loss, ideal for conveying systems of combustible bulk materials.
- The release occurs electromagnetically as soon as voltage is applied.
- Electromagnetic ATEX brakes brakes are characterized by precise switching through encapsulated, spark-cutting systems.
- Pneumatic ATEX brakes brakes use compressed air as the actuating medium and are often made of stainless steel.
- A variety of designs exists, including ATEX motor brakes for direct mounting on explosion-protected motors.
- For specific applications such as shipbuilding or stage technology, customized special brakes are also developed.
Electromagnetic and pneumatic ATEX brakes
Electromagnetic ATEX brakes switch precisely through encapsulated, spark-cutting systems. Pneumatic ATEX brakes (e.g., DEPRAG) use compressed air and often stainless steel. Example: 3-bar air line with safety valve. See ATEX certified electromagnetic brakes.
Variety of designs: From motor brakes to special solutions
ATEX motor brakes are available for direct mounting on Ex motors. For specific requirements (shipbuilding, stage), special brakes are developed. ATEK supplies ATEX brake motors as integrated units, optimized for design/system integrity.Navigate: Applying ATEX guidelines and certifications safely
The ATEX Directive 2014/34/EU in detail
The ATEX Directive classifies areas according to the frequency/duration of explosive atmospheres. Gases: Zones 0, 1, 2; Dusts: Zones 20, 21, 22. A wood pellet plant may comprise Zones 21 (frequent dust) and 22 (rare dust), which impose different requirements for the used equipment. ATEX brake The ATEX Directive 2014/34/EU classifies explosive areas based on the frequency and duration of explosive atmospheres.
- For gases, the zones 0 (permanent danger), 1 (occasional danger under normal operation), and 2 (rare and temporary danger) are distinguished.
- Für Gase werden die Zonen 0 (ständige Gefahr), 1 (gelegentliche Gefahr im Normalbetrieb) und 2 (seltene und kurzzeitige Gefahr) unterschieden.
- For dusts, zones 20 (permanent danger), 21 (occasional danger under normal operation), and 22 (rare and temporary danger) apply.
- The correct zoning is fundamental for selecting the appropriate equipment category and the required protection level.
- The ATEX marking on devices gives information about suitability for specific zones, the equipment category, the temperature class, and the type of explosion protection.
- In addition to the ATEX Directive, IECEx certification is often relevant, especially for the international use of equipment.
- Understanding these classifications and markings is essential to ensure safety in explosive areas.
Difference between ATEX Zone 21 and Zone 22
Zone 21: High risk due to frequent explosive dust under normal operation. Zone 22: Areas with only temporarily explosive dust atmosphere. A spice mill (daily dust) is typically Zone 21 and requires ATEX brakes category 2D.
Understanding ATEX marking and IECEx certification
ATEX marking indicates equipment category, zone suitability, temperature class. IECEx is the international counterpart for global trade. Example: II 2G Ex db IIC T4 Gb = Zone 1 (gas), pressure-resistant encapsulation (db), gases IIC, T4 (max. 135°C).Selecting: Finding optimal ATEX brakes for specific applications
The right selection criteria for your ATEX brake
Selection criteria beyond the ATEX zone for your ATEX brake: environmental conditions (temperature, e.g. -50/+55°C VIS brakes; humidity; chemistry). Also, braking torque, duty cycle (S1), options (manual release, microswitch) are relevant. Refineries (Zone 1) often require special coatings, IP66.
Typical application areas for ATEX brakes
ATEX brakes are in oil/gas, mining (brakes for mining machinery), and chemicals. They are also central in food processing and the pharmaceutical industry. Example: Filling systems for flammable liquids, where pump motor brakes ensure emergency stops.
Specific requirements in different industries
Industries have specific requirements: mining often requires Group I M2 brakes. The food industry often requires hygienic design/stainless steel for ATEX gear boxes and associated explosion-proof brakes. ATEK offers solutions for this ATEX braking solutions such as the INTORQ BFK458 ATEX for braking torques of 1.5-600 Nm.Benefit: Utilize ATEK system solutions for maximum ATEX safety
Our claim as a system provider for ATEX solutions
ATEK Drive Solutions GmbH is a system provider for industrial drive systems. We supply ATEX brakes integrated with our servo motors/gear boxes into complete solutions. This increases system efficiency and reduces interfaces (e.g., one ATEX brake with servo bevel gear boxes for Zone 2).
- ATEK considers itself a system provider that offers complete ATEX-compliant drive solutions from a single source.
- The portfolio includes the supply of ATEX brakes, seamlessly integrated with ATEK servo motors and gear boxes into complete systems.
- These integrated solutions increase system efficiency and minimize interface risks.
- ATEK develops customized ATEX special solutions that are precisely tailored to the individual requirements of the application.
- Adjustments include specific braking torques, optimized mounting flanges, and tailored controls.
- Experienced ATEK engineers provide comprehensive advice on the design and selection of ATEX-compliant drives.
- In addition to individual consulting, an online configurator supports the selection of standard solutions.
Custom ATEX brake solutions
ATEK develops customized ATEX special solutions. Braking torques, mounting, and controls are specifically adjusted. Example: a special ATEX spring-applied brake for a packaging machine (Zone 22, 25 Nm), also for small series.
Consultation and service for your ATEX application
ATEK engineers advise on the design of ATEX-compliant drives. Application/environment are analyzed to define the optimal ATEX brake. Online configurator helps with standard solutions. A solution is developed for specific requirements (chemicals, gases IIC).Forecasting: Recognizing future trends and innovations in ATEX brakes
Digitalization and intelligent ATEX brakes
Industry 4.0 influences safety in Ex areas. Sensors for condition monitoring in ATEX brakes is a trend. This enables predictive maintenance, reduces failures, and increases safety. Such intelligent ATEX brakes could report wear before critical conditions (Zone 1). ATEK develops such solutions.
New materials and constructions for increased safety
Research focuses on more resistant materials (corrosion, temperature) and more compact ATEX brakes. Lighter, more robust brake components for Ex areas improve integration and energy efficiency. New composite materials/coatings could extend the lifespan of these safety brakes in aggressive environments (offshore).
Challenges and opportunities for ATEX systems
Increasing safety requirements and complex standards require continuous development in the ATEX sector. Innovative system solutions/digital services optimize safety/efficiency. ATEK invests in R&D for future-proof ATEX technology (e.g., hydrogen applications IIC).
The correct ATEX brake selection is crucial for plant safety/efficiency. ATEK provides system solutions. Contact us for advice on securing your Ex areas.
