Maximum safety and reliability for demanding drive technology in explosion-hazardous areas.
What does an ATEX certification mean for a gear box in our chemical facility?
An ATEX certification ensures that your gear box is designed and tested so that it does not represent an ignition source in explosion-hazardous areas.. This means that sparking or excessive heat generation is avoided,, which could ignite flammable gases, vapors, or dust present in chemical plants, and it meets EU safety regulations.
What ATEX zone is relevant for our chemical process area and how does it affect the selection of gear boxes?
The specific ATEX zone (e.g., Zone 1 for frequent gas hazards, Zone 21 for frequent dust hazards) is determined by your individual risk assessment.. Areas with higher risk require gear boxes with stricter protective measures and a more robust design. ATEK Drive Solutions supports you in the correct zoning classification and the selection of the appropriate gear box.
Our chemical environment is very corrosive. What materials are best suited for ATEX gear boxes?
For use in corrosive chemical environments, stainless steel, particularly grades like 316L, is often the material of choice for ATEX gear boxes. It offers excellent corrosion resistance and prevents material degradation that could compromise safety or create ignition sources.
Can we combine an ATEX-certified gear box with our existing motors or do we need a complete ATEX system?
Although individual components can be ATEX certified, it is strongly recommended to consider the entire drive system (motor and gear box).Using a pre-certified ATEX motor-gear box unit from a provider like ATEK ensures compatibility and safety of the overall system. This simplifies regulatory compliance and can reduce commissioning time by up to 25%..
How important is a “hygienic design” for an ATEX gear box in chemical or pharmaceutical production?
A hygienic design with smooth surfaces and minimized gaps is crucial.It prevents the accumulation of dust or product residues that could pose an explosion risk, and facilitates more thorough and quicker cleaning.This is essential for both safety and product purity in chemical and pharmaceutical facilities and can reduce inspection times by about 20%..
We need high reduction ratios and high torque. Is a gear box suitable for ATEX applications in chemical plants?
Yes, gear boxes are very well suited for applications that require high torques and good efficiency. For very high reduction ratios, they can also be combined with other types of gear boxes (e.g., worm gears) in an ATEX-compliant design. ATEK offers modular solutions to meet such specific requirements. werden. ATEK bietet modulare Lösungen, um solche spezifischen Anforderungen zu erfüllen.
What maintenance do ATEX-certified gear boxes require in a chemical plant?
Maintenance typically includes regular inspections for wear, checking seals, and the condition of lubricants. Using high-quality synthetic long-term lubricants can extend maintenance intervals. Customized solutions with special seals can potentially extend these intervals by up to 30%.Always follow the specific ATEX maintenance guidelines of the manufacturer.
Our application requires variable speeds. Can we use a frequency converter with an ATEX gear box?
Yes, ATEX-certified gear boxes can be used with frequency converters for speed control. However, the frequency converter itself must typically be installed outside the explosion-hazard (Ex) zone or housed in a suitable Ex-protection enclosure. The motor coupled with the gear box must also be suitable for operation with the converter and ATEX certified.
Choosing an ATEX-certified gear box is essential for chemical plants to minimize explosion risks and ensure plant safety. Proper zoning and material selection, like stainless steel 316L for corrosion resistance,, are crucial.
Technical specifications such as torque, speed, and design must be precisely matched to the application. Optimized gear box combinations can increase efficiency by up to 8%,, while custom seals can extend maintenance intervals by up to 30%. können.
The integration into the overall system, including ATEX-compliant motors and control components such as frequency converters (outside the Ex zone), is critical for safety. Certified motor-gear box units can reduce commissioning times by up to 25% and increase reliability..Discover how ATEX-certified gear boxes from ATEK Drive Solutions make your chemical plants safer, more efficient, and more reliable. Learn more about the benefits, applications, and technical details!
Extreme conditions prevail in chemical plants. ATEX-certified gear boxes from ATEK Drive Solutions ensure maximum safety and efficiency. Our gear boxes are specially designed for explosion-hazardous areas. Contact us at this link for a personalized consultation.
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Introduction to ATEX-certified gear boxes for chemical plants
ATEX certification and its significance.
ATEX certification prevents explosions caused by sparks. The EU ATEX directives are fundamental for the safety of equipment in explosion-hazardous areas of chemical plants. Certification is mandatory; Zone 1 requires stricter measures than Zone 2. More on ATEX gear boxes..
What does ATEX mean?
“ATEX” (Atmosphères Explosibles) protects against explosions from gases/dust in chemical plants. An ATEX-certified gear box does not form an ignition source. Tests according to EN 60079 confirm this. Explore ATEX gear motors..
Why are ATEX-certified gear boxes used in chemical plants?
Standard gear boxes are risky in chemical plants with explosive substances. Gear boxes certified for explosive-hazardous areas minimize the risk of explosion as they do not form ignition sources and can reduce downtime by up to 15%.Technical requirements and design of ATEX gear boxes.
Material selection and corrosion resistance.
Material choice is critical for media resistance and ATEX safety. Stainless steel 316L is often optimal for durability and safety; unsuitable materials corrode and cause sparks. ATEK Drive Solutions provides advice on this. Corrosion-resistant units..
- The right material choice is fundamental for media resistance and ATEX compliance.
- Stainless steel 316L is frequently the preferred material to ensure longevity and safety and to avoid sparking through corrosion.
- A hygienic design with smooth surfaces and minimized gaps is essential to prevent dust accumulation in ATEX areas.
- A hygienic design facilitates cleaning and can significantly reduce inspection times.
- Gear boxes offer high torques and efficiencies, ideal for energy-intensive applications in chemistry.
- Combining gear boxes with other types of gears, such as worm gears, allows for high overall reductions in a compact design and can increase efficiency.
Hygienic design and cleaning.
Dust accumulation in gear boxes is dangerous in ATEX areas. Hygienic design with smooth surfaces and minimal gaps is important. It reduces dust, facilitates cleaning, and can shorten inspection times by 20%. Information on gear box motors..
Gear combinations and efficiency.
A chemical corporation increased agitator efficiency by 8% with optimized spur-worm gear combinations. Gear boxes provide high torques/efficiencies for energy-intensive chemical applications. Combined, for example, with worm gears, they enable compact high reductions.Selection criteria for ATEX gear boxes in chemical plants.
ATEX zones and categories.
The distinction of ATEX zones (gases: Zone 1/2; dusts: Zone 21/22) is fundamental. Correct zoning determines gear box selection. Requirements for Zone 22 (dust, rare) vs. Zone 1 (gas, frequent) affect design/costs. Expert advice helps with classification. Inline gear boxes for mills..
Technical specifications.
A pharmaceutical company shut down a line because a gear box could not sustain 1200 Nm starting torque. Torque, power, speed, and reduction must be precisely matched to the application, to avoid risks.
Application-specific adjustments.
If standard seals do not withstand chemicals, adjustments are needed. Special seals and chemical-resistant lubricants (e.g., synthetic oils) prevent leaks/contaminations in ATEX areas. Custom solutions can extend maintenance intervals by 30%.Integration of ATEX gear boxes into drive systems.
Motor-gear combinations.
Motors and gear boxes must be ATEX certified and matched. Certified motor-gear units avoid compatibility/safety risks. This can reduce commissioning by 25%. Multistage gear boxes..
- Motors and gear boxes must both be ATEX certified and optimally matched as a unit.
- Using certified motor-gear units is crucial to avoid compatibility and safety risks and to accelerate commissioning.
- Frequency converters enable flexible and energy-efficient control of drives, which can lead to significant energy savings.
- Frequency converters must always be installed outside of hazardous areas, while the ATEX Gear Box operates safely within this zone.
- Modern ATEX drives should have integrated safety features such as STO (Safe Torque Off) to ensure safe shutdown in emergencies.
- The STO function reliably prevents unwanted starting of the drive and stops it immediately in case of danger, which increases machine safety.
Frequency converters and control
A chemical company saved 18% energy through frequency converters for pump speed control. Frequency converters enable flexible, efficient control but must be installed outside of the Ex zone, while the explosion-protected Gear Box operates within it. Correct installation is critical for safety.
Safety features
Safe shutdown in emergencies is critical. Modern ATEX drives can include STO (Safe Torque Off). STO prevents unwanted starting and stops drives immediately in case of danger, minimizing risks and supporting, for example, the Machinery Directive 2006/42/EC.Manufacturers and suppliers of ATEX bevel gear drives
Diversity of manufacturers
The ATEX Gear Box market ranges from global players like Bonfiglioli to specialists. Choosing a partner is crucial; expertise, delivery capability, and consulting count alongside price. Experience and portfolio are advantageous.
Certifications and standards
ISO 9001 certification signals reliable quality management. For ATEX components, valid ATEX certificates and standards such as ISO 9001 are important at the supplier. They ensure product conformity.
Custom solutions
If standard ATEX Gear Boxes do not fit, custom solutions are often necessary. Many manufacturers, including ATEK Drive Solutions, specialize in customized ATEX bevel gear drives for complex requirements in the chemical industry, even in small series. One customer reduced equipment size by 15%. Customized Gear Boxes.
The choice of the right explosion-protected bevel Gear Box is crucial for safety and productivity in chemical industry facilities. Material, design, and system integration are key aspects. ATEK Drive Solutions offers consulting for tailored, reliable drive solutions.
