With the EcoRP4, Dürr is introducing a new generation of robots used to paint car bodies. The compact painting robot features an asymmetric architecture that improves access to the body for the applicator, enabling it to reliably reach even hard-to-access interior areas.
Its reduced number of components also lowers maintenance requirements and operational costs, especially benefiting car manufacturers with high production volumes.
Since 1998, Dürr has shipped almost 20,000 painting robots from the Ecopaint robotic family worldwide. The latest addition to the family, the EcoRP4, has been developed as the successor to the six-axis EcoRP E/L x33iC robot, and is specifically designed for painting lines that handle high volumes and standardised applications.
Different designs enable flexible integration into the paint shop, from floor mounting to tower installation as well as use on so-called linear rails.
“This fourth generation of robots is designed through and through for economy. Fewer components, a simplified mechanical system, and an easy-to-maintain design reduce the lifecycle costs when compared with previous generations, without affecting the process technology,” says Andreas Bokermann, product manager at Dürr.
Asymmetry moves the applicator closer to the interior
A central design feature of the EcoRP4 is the asymmetrical architecture of the robot arms. The tool center point (TCP), also known as the center point of the applicator, is offset laterally from the main axis by more than 200 millimeters. This increases the distance between the potential interference contour of the robot arm and the body.
As a result, the applicator can reach even hard-to-access areas such as door rebates, hinges, and transition zones much more easily. To support use on both sides of the body, Dürr offers the new robot in mirrored versions.
Slim design, high efficiency
In addition to the asymmetric arm geometry, arm 1 of the EcoRP4 is more compact. The slim design reduces the amount of space needed in the working area and increases clearance near the body.
Arm 2 still carries the applicator, colour changer, and metering pumps in close proximity to the paint outlet. As a result, the tubing lengths remain short. This enables fast valve switching times and minimises paint and rinsing agent loss during colour changes.
Easier access to the process technology
As in previous generations, most of the process control technology in the EcoRP4 is integrated in arm 1 – a characteristic feature of Dürr painting robots. As part of the redesign, the housing concept was revised.
Consequently, all process-related components can now be integrated into arm 1, that is, as close as possible to the atomiser for maximum efficiency. Arm 1 also features a continuous cover that can be accessed from the side.
“For the redesign, we placed great emphasis on making it easier to access the process technology,” explains Bokermann. “With fewer covers and side access, the new design simplifies maintenance and significantly shortens service times.”
Simplified drive technology for less maintenance
In addition to the above-mentioned changes, the design of the drive units for axis 2 and axis 3 has been simplified. Instead of utilising an angular gearbox with a reduction gear, the pinion gear drive of the respective motor now sits directly on the motor shaft.
Eliminating additional gear stages reduces both the number of components and the amount of wear and maintenance, further boosting the cost efficiency of the new robot generation.
The EcoRP4 also supports the HTE process and can be combined with Dürr’s latest application technology in a wide range of configurations. The market launch is planned for 2027.
