What changes on 20 January 2027?

From 20 January 2027 the Machinery Regulation (EU) 2023/1230 applies and replaces the previous Machinery Directive.

May I use an inspection robot in an Ex zone?

Only with ATEX or IECEx approval for the zone concerned. Most systems commonly available on the market have none.

Do I have to register the robot anywhere?

As an operator, generally not. As an importer or economic operator placing on the market, yes – and before the first delivery.

Why is IP67 not an Ex approval?

Because the two markings cover different risks – IP67 protects the device from the environment, explosion protection protects the environment from the device.

Who is liable if I import a robot directly from abroad?

Whoever places a product from a third country on the EU market for the first time legally becomes the importer and takes on far-reaching obligations.

Are the radio modules of foreign robots permitted in Germany?

Not automatically. Radio modules must comply with the Radio Equipment Directive and may only be operated on frequencies allocated in Europe.

Is “TÜV-tested” relevant for robots?

There is no TÜV approval for inspection robots. What counts is CE conformity.

Does an inspection robot need CE marking?

Yes. An inspection robot is a machine and may only be placed on the market in the EU with CE marking and an EU declaration of conformity.

Is an inspection robot a high-risk AI system?

In most cases not – what matters is whether a safety function is based on machine learning.

What must an EU declaration of conformity contain?

The manufacturer with address, an unambiguous product designation, all legal acts applied, the harmonised standards used, the notified body where applicable, and place, date and signature.

Does the robot need an operating manual in German?

Yes. The operating manual must be available in the official language of the Member State in which the machine is placed on the market.

How do employees react to a robot in the workplace?

In our experience, with considerably more attention than other technology – and with three recurring concerns.

Does an inspection robot replace jobs?

In practice to date, predominantly not – it replaces the walk-through, not maintenance.

How do I communicate the introduction in the workplace?

Early, concretely and before the device is on site.

How long will spare parts be available?

That is a commitment you should get in writing – it cannot be taken for granted.

What happens if the robot breaks down?

This should be settled in the contract before it happens – response time, place of repair, turnaround time and replacement device.

What does an inspection robot cost?

The range is wide, and the platform alone is rarely the largest item – on top come sensors, charging infrastructure, set-up and service.

What does ongoing operation cost?

Budget for maintenance, spare batteries, wear parts, licences, insurance, training and the staff time needed for supervision and evaluation.

Buy, lease or rent – what makes sense?

That depends less on price than on who is to bear the risk of breakdown and loss of value.

When does an inspection robot pay for itself?

The calculation rarely works out on staff savings alone – eliminated journeys to site, avoided exposure to hazards and anomalies detected earlier are more reliable.

Does deploying a robot require the works council's consent?

As a rule, yes. Under Section 87(1) no. 6 BetrVG, the introduction of technical equipment suitable for monitoring conduct or performance is subject to enforceable works council co-determination.

Can an inspection robot be operated without an external connection?

With many systems, yes – operation without any external connection is technically possible and is increasingly offered as a configuration option.

Where does the robot's camera data go?

That depends on the system and is one of the most important questions to check before procurement.

When is a data protection impact assessment required?

When the processing is likely to result in a high risk to the rights and freedoms of the persons concerned – for mobile camera systems this is regularly to be assumed.

What belongs in a works agreement on robot deployment?

Purpose, areas and times, types of data recorded, retention period, persons with access, exclusion of monitoring of performance and conduct, and a provision on evaluation.

May employees be recorded by the robot?

Only under strict conditions and never for monitoring of conduct or performance.

Can a robot be deployed in a substation?

Yes, this is currently the most advanced field of application.

Does the robot work in tunnels without reception?

Yes. Navigation is based on LiDAR mapping and requires no satellite signal.

For which plants is an inspection robot worthwhile?

When three conditions come together – the inspection round is repeated frequently, it is demanding or dangerous, and the inspection points are stable.

What structural requirements does the charging station have?

Level ground, a power connection, sufficient clearance all round and, depending on the model, anchoring in the floor.

How can I tell whether a model may be operated in Europe?

By the EU declaration of conformity – not by the CE sticker and not by the product brochure.

Which manufacturers offer inspection robots?

The market falls roughly into three groups – European and North American suppliers, Chinese manufacturers and specialised suppliers for hazardous areas.

Can the robot be used in the rain?

With ingress protection IP67, yes – the robot itself is designed for wet conditions, the charging station often is not.

How loud is an inspection robot?

Electrically driven legged systems are considerably quieter than combustion engines, but not silent.

Which sensors does an inspection robot need?

That follows from the question of what your employees check on their inspection round today.

What does IP67 mean for a robot?

IP67 means complete dust-tightness and protection against temporary immersion, usually tested at a water depth of one metre for 30 minutes.

At what temperatures can a robot work?

Industrial models are typically specified for minus 20 to plus 55 degrees Celsius.

How much payload can a four-legged robot carry?

Industrial models typically carry 10 to 20 kilograms, compact research platforms 3 to 8 kilograms.

How many kilometres can an inspection robot cover per charge?

Depending on the model, between approx. three and ten kilometres.

What is the difference between remotely operated and automated?

A remotely operated system is operated by a person throughout; an automated system follows a previously taught route on its own.

How does a robot find its way without GPS?

Through LiDAR-based mapping – during teach-in, the robot creates a three-dimensional map and continuously compares its position against it.

Can an inspection robot climb stairs?

Yes, industrial legged systems manage industrial stairs with angles of inclination up to approx. 45 degrees.

How long does an inspection robot's battery last?

Industrial systems typically achieve two to four hours of operating time per charge, more compact models one to two hours.

How long does charging take?

Usually one to three hours, depending on battery capacity and charging power.

Frequently asked questions about inspection robots

Law and regulation

What changes on 20 January 2027?
May I use an inspection robot in an Ex zone?
Do I have to register the robot anywhere?
Why is IP67 not an Ex approval?
Who is liable if I import a robot directly from abroad?
Are the radio modules of foreign robots permitted in Germany?
Is “TÜV-tested” relevant for robots?
Does an inspection robot need CE marking?
Is an inspection robot a high-risk AI system?
What must an EU declaration of conformity contain?
Does the robot need an operating manual in German?

Acceptance and responsibility

How do employees react to a robot in the workplace?
Does an inspection robot replace jobs?
How do I communicate the introduction in the workplace?

Cost-effectiveness and procurement

How long will spare parts be available?
What happens if the robot breaks down?
What does an inspection robot cost?
What does ongoing operation cost?
Buy, lease or rent – what makes sense?
When does an inspection robot pay for itself?

Data protection and works council

Does deploying a robot require the works council's consent?
Can an inspection robot be operated without an external connection?
Where does the robot's camera data go?
When is a data protection impact assessment required?
What belongs in a works agreement on robot deployment?
May employees be recorded by the robot?

Areas of application

Can a robot be deployed in a substation?
Does the robot work in tunnels without reception?
For which plants is an inspection robot worthwhile?
What structural requirements does the charging station have?

Market and manufacturers

How can I tell whether a model may be operated in Europe?
Which manufacturers offer inspection robots?

Fundamentals and technology

Can the robot be used in the rain?
How loud is an inspection robot?
Which sensors does an inspection robot need?
What does IP67 mean for a robot?
At what temperatures can a robot work?
How much payload can a four-legged robot carry?
How many kilometres can an inspection robot cover per charge?
What is the difference between remotely operated and automated?
How does a robot find its way without GPS?
Can an inspection robot climb stairs?
How long does an inspection robot's battery last?
How long does charging take?