The Smart-Ex® 03 from Pepperl+Fuchs is an explosion-proof smartphone that, according to the manufacturer, offers the same capabilities as an Ex-camera.
Industrial inspection and maintenance tasks in hazardous environments, such as explosion zones (Ex-zones), pose complex challenges. Workers operating in these zones require specialized, certified devices such as Ex-cameras. Traditionally, Ex-cameras have been essential for documenting equipment damage or recording maintenance work. However, these cameras often function as standalone tools and require workers to carry multiple devices on-site.
Pepperl+Fuchs has designed a smartphone that they say can be an alternative to explosion-proof cameras.
A High-Performance Camera Built for Industrial Use
The Smart-Ex® 03 is equipped with a 13-megapixel main camera, LED flash, and autofocus, enabling workers to capture high-resolution images and Full HD videos. It also supports automatic object recognition and barcode scanning, adding extra functionality beyond simple image capture.
“The main camera with 13 MP, LED flash, and autofocus is capable of recording videos up to Full HD resolution (1080p). Images can be captured in resolutions up to 3120 x 4160 pixels. In bad lighting conditions, the LED flash ensures that images remain clear and rich in detail,” explains Sebastian Kaul, Product Portfolio Manager MCC.
Unlike traditional Ex-cameras with small, low-resolution screens, the Smart-Ex® 03 features a large 6-inch display, allowing users to review images in detail directly on-site, eliminating the need to transfer files for verification.
For companies requiring a more controlled environment, the Smart-Ex® 03 is available in a camera-only mode, where all smartphone functionalities are disabled via kiosk mode. This prevents users from installing unauthorized applications or modifying system settings. However, this restriction is reversible, ensuring the device remains future-proof.
Advanced Communication and Data Management
For Pepperl+Fuchs, one of the major advantages of the Smart-Ex® 03 over conventional Ex-cameras is its real-time connectivity.
“Thanks to 5G support, workers can instantly transfer large files to the cloud, company network, or email, if authorized, eliminating the need for manual SD card data transfers,” Kaul emphasizes.
The desktop mode allows the smartphone to function as a fully operational computer in an office setting, simplifying data handling. Another key feature is the front-facing 5-megapixel camera, which enables live video calls for remote support, ensuring quick decision-making in critical situations.
To enhance safety, a programmable side button can be customized for push-to-talk communication or as an emergency call button, providing an instant response option for field workers.
Built for Harsh Industrial Conditions
The Smart-Ex® 03 is designed to perform optimally even in extreme environments. It has all the functions of a modern 5G smartphone and a higher temperature range in which it can be used, from -20 °C to +60 °C. Besides, its glove mode enhances touchscreen sensitivity, allowing seamless operation while wearing gloves.
“To accommodate use under the harsh conditions that usually exist in industrial settings, the Smart-Ex 03 has several features to boost usability. The smartphone’s glove mode, for example, increases the sensitivity of the touchscreen to help the user operate it precisely, even when wearing gloves. The double-tap feature allows the user to lock the device by simply double-tapping on the home screen. Hence, users don’t have to feel for the on/off button on the side, which can be a challenge when wearing gloves.”
Left- and right-handed workers are benefiting from this feature similarly. If a mobile worker puts the smartphone in one of their pockets, for example, the pocket mode automatically locks the display to prevent unintentional interactions with the device.
“Additionally, S Pen support and speech-to-text are additional input modes that can be used under difficult conditions. The 6-inch display allows mobile workers to immediately check the images they have taken and to zoom in on details while still out in the field.”
Advanced Scanning and Augmented Reality Capabilities
Beyond its camera functions, the Smart-Ex® 03 excels in scanning and data retrieval. The eBARCODE-ML app leverages machine learning for fast and precise barcode and QR code scanning. The smartphone’s NFC functionality allows RFID data to be read directly on the device, ensuring all information remains stored locally.
The high-performance camera enables augmented reality (AR) applications, which are becoming increasingly valuable in industrial settings.
“Mobile workers can scan an object within the plant, sensors can identify the object and show all relevant technical data on the screen. Another application is change identification, which allows mobile workers to scan an object at two different points in time. The software then identifies what has changed between those two scans and highlights the changes,” explains Kaul.
AR can also play a vital role in inspection and predictive maintenance tasks. And it can improve worker safety.
“In case of an emergency mobile workers can scan their immediate area and immediately see the location of the closest fire extinguisher or a secure escape route.”
Security and Long-Term Software Support
The Smart-Ex 03 is certified for use in ATEX/IECEx and NEC/CEC Zone 1/21 and Division 1 and mining.
“Next to that we also obtained several regional specific Ex-certifications like for Brazil, South Africa, South Korea or Japan. Optionally, there is a variant certified for use in Zone 2/22 and Division 2 only.”
The Smart-Ex® 03 is also Google-certified under the Android Enterprise Recommended program, ensuring regular security updates, multiple Android version upgrades, and global customer support.
Starting in mid-2025, the device will come preloaded with Android 15, guaranteeing compatibility with the latest industrial software applications.
Applications
Industries beyond oil and gas can recognize the value of this technology.
“Every industry dealing with hazardous areas, such as mining, petrochemicals, food & beverage, medtech, or the hydrogen supply chain, benefits from an intrinsically safe 5G smartphone. Our customer Kalundborg leveraged the Smart-Ex® 03 for digitalization projects within their refinery, particularly valuing its camera, macro function, and compact form factor,” shares Kaul.
So, could such smartphones definitely replace ex-cams in the future? While some specialized Ex-cameras offer thermal imaging and longer battery life, Kaul believes that smartphones like the Smart-Ex® 03 will replace them in many use cases.
“Dedicated Ex-cameras still have advantages in specific scenarios, such as thermal imaging. However, in most cases, they are gradually being phased out in favor of smartphones like the Smart-Ex® 03, which combines Ex-camera functionality with smartphone capabilities,” he says.
Combining the features of an Ex-camera with smartphone capabilities allows mobile workers to reduce the number of tools they must carry in the field. A reduction in tools and therefore weight allows them to move more freely and fulfill their tasks unhindered.
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