With the EcoRP4, Dürr is introducing a new generation of robots for painting car bodies.
The compact painting robot features an asymmetric architecture that improves the applicator's access to the body, 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 standardized 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,” says Andreas Bokermann, product manager at Dürr. “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.”
Asymmetry Moves The Applicator Closer To The Interior
Dürr’s new EcoRP4 robot impresses with fewer components, a simplified mechanical system, and an easy-to-maintain design.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 robot arm's potential interference contour 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.
In addition to the asymmetric arm geometry, arm 1 of the EcoRP4 is more compact. The slim design reduces the space required in the working area and increases clearance around the body. Arm 2 still carries the applicator, color changer, and metering pumps in proximity to the paint outlet. As a result, the tubing lengths remain short. This enables fast valve switching and minimizes loss of paint and rinsing agents during color 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 atomizer 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. “With fewer covers and side access, the new design simplifies maintenance and significantly shortens service times,” explains Mr. Bokermann.
In addition to the above-mentioned changes, the design of the drive units for axis 2 and axis 3 has been simplified. Instead of utilizing 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 wear and maintenance requirements, 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.
Dürr Systems USA has been present in the United States since 1970 and operates multiple locations, including facilities in Michigan and Wisconsin. The largest site is in Southfield, Michigan, with operations serving as the main center. As of 2025, Dürr employs approximately 660 people nationwide who serve a wide range of market segments. Dürr Systems USA plans, builds, and installs complete, state-of-the-art paint shops and final assembly facilities, supported by DXQ, Dürr’s digital products suite.
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