EPX Series EtherCAT Box: Empowering Spray Painting Robots with Smart Control

In the field of industrial spray painting, precision, reliability, and compliance with explosion-proof standards are critical. b+m surface systems, a German specialist in integrated spray systems, has upgraded its T1 X6 and T2 X6 six-axis articulated robots with Beckhoff’s EPX series EtherCAT boxes, achieving remarkable improvements in performance, maintenance, and space efficiency.

b+m focuses on full-process spray solutions from workpiece feeding to final inspection, with a vertically integrated product portfolio covering spray guns, robot motion control, and paint delivery systems. The X6 series robots feature a hollow wrist design for internal media routing, with the T1 X6 optimized for automotive plastic parts and the compact T2 X6 ideal for space-constrained applications. These robots meet ATEX requirements with pressurized enclosures (Ex p), making them suitable for hazardous explosive environments.

Intrinsically Safe Signals Integrated Seamlessly

The adoption of Beckhoff’s IP67-rated EP/EPX series I/O boxes simplifies cabling and enhances maintainability. Unlike traditional robots with complex external wiring, the EPX series is directly integrated inside the robot, drastically reducing the number of cables leading to the application cabinet and saving space in the cable assembly.

For the T2 X6 robot, the configuration typically includes 4 pieces of EPX1058 (8-channel digital input) and one or more EPX3158 (8-channel analog input) EtherCAT coupler boxes. Both modules support direct connection of intrinsically safe field devices from explosive zones 0/20 and 1/21, enabling safe and reliable signal acquisition without extra safety barriers.

This upgrade replaces discrete wiring with EtherCAT-based integration. About 40 process sensors—including encoders and pressure sensors—are now connected via EtherCAT, eliminating bulky external cable harnesses and reducing material and labor costs.

Tailored Connection Technology for Harsh Environments

Spray robots impose strict demands on I/O and connectivity. Traditional IP20 ELX modules require additional IP54 enclosures and active air purification, which conflicts with pressurized explosion-proof requirements. The EPX series resolves this issue with native high protection ratings.

Beckhoff developed a custom cable solution with single-wire injection molding for M12 connectors, delivering IP65/IP67 protection, EMC shielding, and compact dimensions. This eight-in-one cable design saves space, enables fast installation, and supports easy maintenance without disassembling the robot.

Flexible PC-based Control Architecture

Beckhoff’s PC- and EtherCAT-based control system offers outstanding openness and scalability. Along with EPX modules, the robots use EP series boxes such as the EP2338-1002 digital I/O and EP5151-0002 encoder interface for spray valve control and atomizer speed monitoring.

The comprehensive I/O portfolio, including EL series terminals and TwinSAFE safety modules in the cabinet, simplifies third-party integration and eliminates expensive external safety barriers. b+m has relied on Beckhoff’s control technology since 1996, valuing TwinCAT’s flexibility and EtherCAT’s high performance and compatibility.

Conclusion

By integrating Beckhoff EPX series EtherCAT boxes, b+m’s X6 series spray robots achieve intrinsically safe signal acquisition, simplified cabling, and improved maintainability while complying with ATEX explosion-proof standards. This cooperation demonstrates how advanced EtherCAT I/O technology enhances efficiency and reliability in precision spray applications for automotive, commercial vehicle, and aerospace industries.