Industry
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Hazardous Locations and Explosive Atmospheres
Innovative Solutions for the Most Demanding Environments
A cornerstone of IPS’s expertise is safety-critical engineering for Explosive Atmospheres (ATEX/ IECEX) and Hazardous Locations (HazLoc) following Intrinsically Safe and Explosion Proof approaches.
Designing for Hazardous Environments
Intelligent Product Solutions delivers innovative design and engineering solutions for Explosive Atmospheres and Hazardous Locations. We have well over 10 years of experience in delivering safe, reliable, and manufacturable designs within ATEX, IECEX, and HAZLOC regulatory frameworks. Our design experience includes both Intrinsically Safe and Explosion-Proof approaches.
Our track record speaks to our technical versatility and commitment to excellence. Highlights of our work include:
- Designing the world’s first ATEX-certified mobile phone, meeting rigorous intrinsic safety standards for safe operation in hazardous zones.
- Partnering with Chesterton to deliver an ATEX-certified product by addressing system, mechanical, and electrical design challenges.
At IPS, we work closely with our clients to address their engineering challenges as well as facilitating regulatory approvals and transition to production. Our designs have provided innovative, practical, and reliable solutions for applications in aerospace, agriculture, gas, milling, and mining to achieve breakthrough performance while maintaining uncompromising safety.
From concept to certification, IPS delivers custom solutions prioritizing safety, compliance, and functionality across diverse industries and applications.
Chesterton Connect
The Chesterton Connect is an equipment monitoring sensor for industrial pumps, sealing systems, motors and gearboxes. It monitors process temperature and pressure as well as bearing housing temperature and vibration. It logs 30 days of data internally, uploads to a gateway or mobile app and provides visual indications for alert/alarm conditions with up to 3 years of battery life.
IPS developed this product for Chesterton from a clean slate to production in under 10 months. IPS performed Architecture, Electrical, Embedded SW, ID, Manufacturing, Mechanical, Packaging and pilot production. The Intrinsically Safe design was subsequently shepherded through Notified Body (SGS) certification with only minor modifications. Design challenges included aggressive schedule, extended battery life, extended temperature range, Intrinsically Safe design and radio range.
Certifications/Nomenclature
ATEX/IECEx:
- II 1 G Ex iaIIB T4 Ga
- II 1 D Ex iaIIIB T200 166°C Da
Zone:
- Class I Zone0 AEx ia IIB T4 Ga
- Zone 20 AExia IIIB T166°C Da
Division:
- Class I Div 1Groups C D T4
- Class II Div1 Groups F G T4
Rated Temp:
- -20°C ≤ Ta ≤+85°C
Freewave Fusion Bridge
Fusion Bridge is a dual-radio Wi-Fi Bridge that adds seamless Wi-Fi access point connectivity to remote 900 MHz networks. Fusion Bridge lets you connect multiple wireless devices and sensors in the field with a range of up to 60 miles. The device can also function as an edge computer.
IPS performed the System Architecture, Electrical, Embedded SW (Linux BSP), SW (configuration control panel), DFM/DTUPC and Intrinsic Safety design practices for certain external interfaces. IPS also supported FCC, UL, and Ex Veritas evaluation. The design incorporated FreeWave’s proprietary radio and OTS mPCIe Wi-Fi card. Design challenges included power conditioning for automotive power, driver customization, configuring Linux for reliable unattended operation while maintaining budget and schedule through initial COVID shutdown.
Certification/Nomenclature
- NFPA 70 NEC (National Fire Protection Association)
- Class I, Division 2, Groups A, B, C, D
Librestream Ecom Cube 800
Intrinsically Safe Wearable Camera Ecom Cube 800 is the first intrinsically safe portable infrared and HD camera. It simplifies inspection and maintenance in hazardous areas. It holds both ATEX and IECEx certifications (ATEX Zone 1/21) demonstrating adherence to the EU and International directives for equipment operating in explosive atmospheres. Its flexible design allows mounting on a helmet, handheld, or monopod so industrial workers can perform tasks safely and hands-free.
IPS provided industrial design, mechanical engineering, human factors, and analysis services for the project. Our work encompassed industrial design, mechanical engineering, packaging, prototyping, manufacturing support, thermal and mechanical analysis, and intrinsic safety design practices. A key challenge was maintaining a lightweight design for a head-mounted device while ensuring robust performance in drop and puncture tests, as well as meeting stringent thermal requirements. IPS also assisted with the transition to manufacturing and developed various prototypes to evaluate and refine the design.
Certification/Nomenclature
- ATEX: Zone1/21, HazLoc: Class 1 Division 1
- 2G Ex ib op isIIC T4 Gb IP64
- 2D Ex ib op isIIIC T135°C Db IP64
Aerospace Oxygen Sensor
This project involved the development of a gas sensor for an aerospace application operating in a potentially explosive atmosphere, with the sensor running at temperatures exceeding 600°C. The goal was to consolidate four existing designs into a single alternate source that met the requirements of multiple applications. The project complied with aerospace standards such as DO-178, DO-160E, and ISO 2669. An automated test equipment system was also designed to calibrate the sensor.
IPS led the entire design project, in collaboration with our client, to develop a single drop-in replacement for 4 different sensors, while ensuring compliance with stringent aerospace regulations.
Certification/Nomenclature
Compliance with DO-178, DO-160E, ISO 2669, and explosion-proof enclosure validation.
AiroWireless I-Safe 28
Globally Certified, Intrinsically Safe, Super-Rugged Smart Phone.
IPS designed the world’s first Globally Certified, Intrinsically Safe mobile phone. With a patented design and independent certification for both the phone and battery pack, this device ensures safety in hazardous environments. The Airo Wireless I-Safe™ 28 sets a new standard in safety and durability. IPS performed the electrical engineering and shepherded the phone and battery-pack through the certification process using SGS S.A as the Notified Body.
Patent: AU2017239629B2
Certification/Nomenclature
- ATEX Category 2 Marking: ATEX II 2G Ex ib IIC T4 (IECEx Gb)
- Underwriter Laboratories UL 913 7th Edition Standard - Zone 1
- Canadian Standards Authority CSA-C22.2 No. 157-92
Solutions in Action
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Capabilities & Expertise
Electrical Hardware Design
Our hardware engineers are closely coupled with the software team and are tuned for integrating hardware and software to create a sustainable system. IPS Electrical Engineers are all proficient in PCB design, serving Commercial, Industrial, Medical and Military markets.
Risk Management Planning
A critical component of the overall risk management process is development of the risk management plan. This typically occurs at the leading edge of product development, concurrent with development of product requirements. The IPS team can lend their expertise to guide selection of the elements of the risk management plan, such as assessment methods and cadence, acceptance criteria, and milestones, packaging that plan into a formal document.
Highly Rugged Devices
Does your product need to operate in the most challenging environments? Our team is well versed in producing comprehensive designs to meet the most demanding specifications. From 6-foot drop tests to IP67 sealing and Intrinsically Safe designs, we have met the challenges of highly rigorous specifications.
Electronic Packaging and IOT Integration
Challenging geometries and complex electronic packaging are a routine task for our experienced mechanical engineering team. We are well versed in integrating diverse technologies into tight packages, including wireless connectivity, rechargeable batteries and camera and sensor integrations. We are prepared to turn your vision into tangible parts that are designed for manufacturing repeatability and meet both your functional and cosmetic needs.
Risk Mitigation & Monitoring
At each iteration of risk assessment, value is gained by applying mitigation strategies to the most significant risks. The IPS team has extensive experience in risk mitigation strategies for a wide variety of risk classes and will guide the product development team toward the most effective strategies for the application. Crucial to the risk management process is documentation of risk assessment and resultant mitigation strategy, captured as formal risk management reports.