Explosion proof wall lights: to protect the battery factory safety production of intelligent lighting to handle the program

First, why the battery factory must choose Explosion proof wall lights?

In the lithium-ion battery production workshop, the electrolyte volatile combustible gas concentration can reach the explosion limit of 30% -50%, ordinary lighting equipment to produce sparks probably cause serious accidents.

Explosion proof wall lights approved intrinsically safe design, the light source, power supply and other components are completely sealed in the impact-resistant alloy shell [often made of ADC12 die-cast aluminum], combined with the explosion-proof surface gap control technology [guideline gap ≤ 0.15mm], the success of the internal arc will probably be generated with the external physical isolation of the hazardous environment.

According to the requirements of ATEX 94/9/EC directive, it is suitable for II 2G Ex db IIC T6 Gb grade Explosion proof wall lights, which can work continuously under the ambient temperature from -40℃ to +55℃.

A power battery leading enterprises measured data show that the electrolyte subassembly workshop after the installation of Explosion proof wall lights, the lighting system triggered a reduction of 97% of the potential safety hazards, the equipment failure rate fell 63% year-on-year.

Second, Explosion proof wall lights three major technological breakthroughs

1. Intelligent constant current drive technology

The use of PWM dimming chip [such as TILM3409HV] with temperature compensation circuit to ensure that the voltage fluctuations of ± 20% can still be stable output.

A model Explosion proof wall lights test shows that in the input voltage range of 180-265VAC, luminous flux fluctuation control within ± 3%, effectively avoiding strobe phenomenon.

2. Composite heat dissipation structure

Innovative use of finned heat sink + thermally conductive silicone filling program, so that the LED junction temperature is always below 85 ℃. Laboratory data shows that the LED junction temperature is always below 85℃ compared with traditional structure.

Laboratory data show that, compared with the traditional structure, the new explosion-proof wall light decay rate of 5% from 3000 hours to 1.8%, extending the service life to 50,000 hours.

3. Modular high-speed maintenance

The unique snap-on lens design shortens the maintenance time to 15 minutes, which is 80% more efficient than the traditional bolt fixing method.

A customer case shows that 2,000 Explosion proof wall lights to reduce annual maintenance costs of 420,000 yuan.

Third, the battery factory typical scene Explosion proof wall lights configuration program

Area Name	Illumination Requirement(lx)	Mounting Height(m)	Protection Class	Explosion-proof Class	Recommended Power
Electrolyte preparation room	300	3.5-4.0	IP66	Ex d IIC T6	60W
Chemistry workshop	500	5.0-6.0	IP67	Ex de IIC T4	100W
Raw material warehouse	200	6.0-8.0	IP65	Ex tb IIIC T135℃	40W
pack assembly line	750	3.0-3.5	IP68	Ex d e IIC T6 Gb	80W

Note: According to EN 60079-10-1 guidelines, hazardous area classification and equipment selection needs to be certified by professional organizations.

Fourth, Explosion proof wall lights selection of 5 major gold standard

1. Certification compliance: must obtain IECEx, ATEX and local explosion-proof certificates [such as China PCEC], the certificate number should be able to verify the official website in real-time

2. Optical performance matching: the bat-wing light distribution curve [half-peak angle 110 °], to ensure that the uniformity of illumination on the work surface ≥ 0.7

3. Emergency function integration: Configuration of dual-channel power supply + lithium battery pack [endurance of 90 minutes], switching time ≤ 0.3 seconds Intelligent control system: support DALI2.0 protocol, the implementation of the group dimming [10% -100% stepless adjustment] and energy consumption monitoring

4. Expandable design: reserved dust sensor interface to meet the needs of future upgrades to the smart factory.

Fifth. Full life cycle cost analysis

An annual output of 10GWh battery factory as an example:

Traditional explosion-proof lamp program: the initial investment of 1.8 million yuan, the annual power consumption of 680,000 yuan, 5-year maintenance cost of 950,000 yuan

Intelligent Explosion proof wall lights program: the initial investment of 2.3 million yuan, the annual power consumption of 320,000 yuan [energy saving 53%], 5 years of maintenance costs 380,000 yuan

ROI analysis: although the initial investment is 28% higher, but the total cost of 5 years to reduce 36%, the payback period of only 2.3 years!

Sixth, the industry’s development momentum forward

1. digital twin technology applications: approval of 3D modeling to implement Explosion proof wall lights layout simulation, improved program design performance by 40%.

2. Predictive maintenance system: built-in vibration sensor + temperature monitoring module, failure warning accuracy of 92%.

3. New energy integration and innovation: R & D photovoltaic + super capacitor power supply off-grid Explosion proof wall lights, has been implemented in the pilot project 72 hours of battery life

A head battery manufacturer application data show that the deployment of intelligent explosion-proof wall light system:

Lighting-related safety accidents to zero production line illuminance pass rate increased from 78% to 99% annual integrated energy consumption by 1.2 million kWh equipment inspection efficiency increased by 65%.

Please visit Amasly Lighting or call +86 13732643699, our engineers will provide you with professional selection proposition within 24 hours.

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