3‑Axis Explosion‑Proof Scissor Lift for Paint Booth (USA)

POSTED: 5/19/2026

Overview

Project type: 3‑axis explosion‑proof scissor lift (X‑axis travel + Y‑axis lift + Z‑axis extension)
Client: LPG John (USA)
End use: Personnel spraying operations inside a large paint booth
Industry: Aerospace, heavy machinery, automotive – large workpiece coating

Industry Pain Points

1. Low efficiency & high risk of traditional access methods – scaffolding, boom lifts or conventional platforms only provide point access; workers must frequently reposition, leading to uneven coating and long cycle times.
2. Flammable/explosive atmosphere inside paint booths – solvents (toluene, xylene, ethyl acetate) create explosive environments. Standard electrical equipment can cause ignition, requiring IIC class (hydrogen/acetylene) highest explosion‑proof rating.
3. Need for 3D access on complex workpieces – curved surfaces, recesses and edges demand precise positioning in X (horizontal), Y (vertical) and Z (depth) axes. Ordinary lifts only offer vertical movement.
4. Multi‑operator collaboration – large workpieces often require several painters working simultaneously, with anti‑collision logic and centralised management.

Core Specifications

Parameter	Value
Load capacity	225 kg (person + tools)
X‑axis travel length	22,000 mm (three units) / 17,000 mm (one unit)
X‑axis travel speed	0‑12 m/min (VFD adjustable)
Y‑axis lift range	550 – 4,200 mm
Y‑axis lift speed	1.5‑4.5 m/min (VFD adjustable)
Z‑axis extension range	folded 1,600 mm → extended 4,000 mm (net 2,400 mm)
Z‑axis extension speed	1.5‑4.5 m/min (VFD adjustable)
Personnel platform (L×W)	900 × 800 mm
Guardrail height	1,050 mm + 100mm toe‑plate
Platform deck	Perforated grid
Explosion‑proof rating	Ex db IIC T4 Gb (full system)
Motors	ABB (explosion‑proof)
Gearboxes	SEW (explosion‑proof)
Hydraulic cylinders	Hebei Hengyu (with bellows)
Hydraulic power unit	Anshan Lisheng (with motor fixing bracket)
Control PLC	Siemens S7‑1200
HMI	Siemens touch screen
Inverters / main electrical	ABB
Main control cabinet	IP54 (outside paint booth)
Button boxes / remote control	Longtong (explosion‑proof)
Voltage / frequency	480V / 60Hz three‑phase
Noise level	≤70 dB
Colour	RAL 1021 (bright yellow)
Quantity	4 units

Solutions

Three‑axis motion system: horizontal travel + vertical lift + forward/backward extension

X‑axis horizontal travel:

• Each lift runs on its own rail. Total track length 22m (for three units) and 17m (for one unit), each split into two sections for shipping.
• Drive: ABB explosion‑proof motor (0.75kW) + SEW explosion‑proof gearbox, four‑wheel drive (2 driving + 2 idler wheels), speed 0‑12 m/min adjustable.
• Rails: upper rail 12# channel steel, lower rail 15kg light rail. Brushes installed in front of wheels to clean dust.
• Limit switches: 8 explosion‑proof limit switches per unit (both ends of travel), rubber bumpers at rail ends.

Y‑axis vertical lift:

• Scissor mechanism, stroke 550mm to 4,200mm (net lift 3,650mm), capacity 225kg (person + tools).
• Drive: ABB 2.2kW explosion‑proof motor + SEW gearbox, chain drive, speed 1.5‑4.5 m/min adjustable.
• Safety: fall‑arrest device (mechanical), drive chain covered with dust‑proof bellows (round).
• Limit switches: top & bottom explosion‑proof limit switches, motor with thermal protector and external brake.

Z‑axis scissor extension (forward/backward movement):

• Scissor arms made of 120×60×4mm rectangular tube, hydraulically driven. Extension range: folded – platform front edge 1.6m from wall, extended – 4.0m (net extension 2.4m).
• Drive: 1.5kW explosion‑proof motor + hydraulic power unit (Anshan Lisheng), speed 1.5‑4.5 m/min adjustable.
• Limit switches: front & rear explosion‑proof limit switches, cylinder with bellows cover.

Personnel platform:

• Platform size 900×800mm, guardrail height 1,050mm, plus 100mm toe‑plate below side guardrails (prevents tools from falling).
• Deck: perforated grid (anti‑slip, ventilated).
• Door lock: spring latch (same type as self‑propelled scissor lifts). Additional stopper inside the door side to reduce door swing.

Explosion‑proof design – fully Ex db IIC T4 Gb

Paint booths are classified as Zone 1 or Zone 2 explosive gas atmospheres (flammable gas present continuously or occasionally). The highest requirement is IIC (covers hydrogen, acetylene and other extremely hazardous gases) and temperature class T4 (≤135°C). The whole system meets this rating:

Component	Explosion‑proof requirement	Implementation
All motors (X/Y/Z)	Ex db IIC T4 Gb	ABB explosion‑proof motors + SEW explosion‑proof gearboxes, with metal guards
Limit switches (travel/lift/extend/door)	Ex db IIC T4 Gb	28 units, with dedicated brackets
Push‑button control boxes (upper & lower)	Ex db IIC T4 Gb	Longtong brand, IP65, buttons marked with white letters (L/R/Up/Down/F/B)
Wireless remote control	Ex db IIC T4 Gb	8 buttons, same functions
Explosion‑proof conduits	Ex db IIC T4 Gb	DN20/DN15, all cables routed through conduits
Main electrical cabinet	Non‑explosion‑proof (located outside paint booth)	IP54, CCC certified, ABB components, Siemens PLC + HMI

Key details:

• Motor external brakes and thermal protectors also explosion‑proof.
• All cables routed through explosion‑proof conduits + cable trays + energy chains. Moving energy chain (45×49mm) follows the unit.
• Equipment grounding complies with SKJ8‑79, meeting I(Q‑2) fire protection requirements.

Centralised control system: 4‑unit coordination + safety interlocks

Hardware:

• One main control cabinet (IP54, outside the booth): contains Siemens S7‑1200 PLC, ABB frequency inverters (control all motors), ABB MCCB moulded‑case circuit breakers, protection relays.
• HMI: Siemens touch screen, four pages showing real‑time status of each lift (position, speed, faults).
• Each lift: upper control box (on platform) + lower control box (ground) + wireless remote + 5‑stack tower light with buzzer (85dB, illuminates when running).

Control logic:

• Two operation modes:
  • Manual mode: via HMI or remote control, following preset safety protocols and interlocks.
  • Maintenance mode: for technicians, allows unlocking a single unit without disabling others.
• Safety features:
  • Button interlock: X/Y/Z motions cannot be activated simultaneously (PLC interlock).
  • Time delay: after releasing “Up” button, wait 2 seconds before “Down” button becomes active (delay adjustable on HMI).
  • Limit protection: motion stops automatically when reaching limit switches.
  • Anti‑collision: PLC logic prevents adjacent units from colliding on the track.
  • Emergency stop: each unit has an E‑stop button; main cabinet also has E‑stop.
• Alarm feedback: fault, over‑travel, safety confirmation displayed on HMI, triggering tower light/buzzer.

Programming & documentation:

• Siemens programming software (license version V18), full source code provided.
• Complete electrical schematics, list of all components (including screws, rail brackets, cable carriers, etc.).
• 3C certificates for electrical components (though for export to the US, the client requested them as quality evidence).

Power supply & special requirements

• Voltage/frequency: 480V / 60Hz (US standard), three‑phase.
• Noise: ≤70 dB (required inside paint booth).
• Colour: RAL 1021 (bright yellow, safety colour for paint booths).
• Rail segmentation: 22m rails for three units (cut into two 11m sections), 17m rail for one unit (cut into two 8.5m sections) – easy transport.

Shipping & accessories

• Each unit ships with all installation parts: screws (extra long to leave 5‑10mm after tightening), rail fixing brackets, steel plates, energy chains, cable trays, etc.
• Extra cables supplied to avoid shortage on site.
• Full explosion‑proof conduits, energy chains, etc., included.

Details

FAQ

If you want to customize your material handling equipment, please contact us →.

Downloadable Documents