Wide-range Speed Control for Diaphragm Metering Pumps: LEWA ecodos sequence with new motor

In many functions, metering components within the pharmaceutical or meals trade for example, pumps are required that not solely may be precisely managed in phrases of move price and dosing time, but additionally convey the components significantly gently. To enable the confirmed pump items of the ecodos sequence from LEWA GmbH to fulfill this demanding activity with much more flexibility and energy effectivity in the future, the manufacturer is expanding the portfolio to incorporate a new type of wide-range velocity control. Alongside asynchronous motors and servomotors, everlasting magnet synchronous motors, or PMSMs for brief, are additionally used now. They are characterised by excessive energy efficiency and a control range larger than 1:200. This considerably expands the vary of functions. With PMSMs, it’s no longer essential to make use of a quantity of pumps for different move charges or oversize asynchronous motors for low speeds. Since PMSMs could be designed without a fan, they continue to be compact and simple to wash. The latter feature predestines them for hygienic functions. High efficiency ranking over the whole control range in accordance with power efficiency class IE5+ additionally reduces power costs, thus guaranteeing a decrease total cost of possession (TCO).
The diaphragm metering pumps in the LEWA ecodos series are notably well suited to applications within the food or pharmaceutical industries. All materials involved with the fluids used in the pump items meet the FDA and USP Class VI requirements, and the EU directives for the meals business. In the hygienic model, for example, the pump head is made from PP or electropolished stainless steel with a floor roughness < zero.5 µm. This facilitates cleaning of the surfaces involved with the product.
The motor technologies used so far have needed to make sacrifices: “For basic asynchronous motors whose rotor is a squirrel-cage rotor, the management vary stays limited to 1:10 (1:50 is possible in individual cases). With encoder suggestions, important expansion is feasible,” said Maurice Wirkner, an utility supervisor at LEWA. “In addition, the drive is comparatively inefficient outdoors the rated speed range – particularly at low speeds. This requires the drive to be oversized, which increases working prices.” Servomotors are optimized for highly dynamic necessities and also cover the entire management range (1-210 pump strokes), nonetheless, they are costlier to purchase and as nicely as, require a servo inverter for control.
Wide-range speed management with permanent magnet synchronous motor extends the range of functions
LEWA has now expanded its own portfolio with a drive know-how that doesn’t have these weaknesses. “Unlike the asynchronous motor, the rotor of this drive consists of everlasting magnets and rotates synchronously, i.e. without load-dependent slip,” Wirkner defined. “Among other things, it options an extreme management vary, which regularly makes using a number of pumps for various flow rates unnecessary.” Particularly in the case of multiple pumps, a further manual stroke adjustment or electrical stroke adjustment could be allotted with and the required move price could be realized by velocity control only. The PMSM additionally has a relentless torque. The complete torque may be applied from engine velocity zero rpm (standstill) up to the rated speed of the motor. This ensures particularly easy and delicate system start-up, since every process may be started with a pump capability of 1 p.c as an alternative of the identical old 10 %.
It additionally features a high short-term overload capacity, which enables a drive design with out oversizing for the starting torque. As a outcome, smaller, more cost-efficient sizes may be realized than with classic drives. “Like the asynchronous motor, the PMSM may be controlled via a normal frequency converter, so customers can rely on widespread parts,” Wirkner defined. “With the servomotor quite the opposite, it will be needed to purchase expensive servo controllers.” The compact drive may be simply cleaned because of its fanless design and presents excessive IP protection. If required an extra conversion process – called nsd tupH – may be utilized to the aluminum physique for FDA requirements. This makes the surface extraordinarily resistant and even simpler to wash – perfect for applications with stringent hygienic requirements, similar to aroma metering within the meals industry or additive dosing in the pharmaceutical business.
IE5+ PMSM permits cost reduction and decentralized options
The sole limitation of the at present used PMSM is that it is just available for secure areas. “Thanks to wide-range velocity control with IE5+ PMSM, we are able to meet the rising customer calls for for a wider adjustment range and decrease vitality consumption, as properly as overall costs,” mentioned Wirkner to sum up the state of affairs. “The matter of power effectivity specifically is becoming increasingly important for our customers. A decentralized solution in which the frequency converter is put in immediately on the PMSM, can now be implemented with Getriebebau NORD GmbH & Co. KG, LEWA’s motor associate for PMSM, too.”
LEWA GmbH was founded in 1952 by Herbert Ott and Rudolf Schestag as a household enterprise and is right now the world’s main producer of metering pumps and process diaphragm pumps as properly as full metering packages for process engineering. Headquartered in Leonberg, the company developed into a global group in just a few a long time. Since 2022, the company has been a part of the Atlas Copco Group, a globally leading Swedish producer of compressors, vacuum options, turbines, pumps, energy tools and assembly methods. Together with the new owner, LEWA will further broaden the industrial pumps business. As a analysis and manufacturing company, LEWA develops technologies and supplies options for the vast array of functions among its customers. Its products are used primarily in the chemical business, the cosmetics industry, prescribed drugs and biotechnology, food and beverage industry and energy utilities as nicely as within the manufacturing of plastics, detergents and cleaners. Additional utility areas embody refineries and petrochemicals, the oil and gas trade, and gasoline odorization. LEWA at present employs round 1,200 individuals and owns 14 subsidiaries around the world alongside having eighty representatives and gross sales workplaces in additional than 80 international locations.
Image material:
Image ID: LEWA ecodos LED3 WBR.jpg
Caption: LEWA ecodos LED3 with PMSM
Source: LEWA GmbH
Image ID: ecodos_NORD-IE5plus_opt.jpg
Caption: The PMSMs newly added to the portfolio feature a control vary of 1:200, enabling a wider vary of purposes to be coated by the same drive or pump.
Source: LEWA GmbH
Image ID: Baby food.jpg
Caption: The PMSM also has a constant torque, i.e. the entire torque could be called up at speed 0 rpm. This ensures particularly smooth and gentle system start-up, since each course of can be began with a conveyance price of 1 % as a substitute of the similar old 10 %. (Example: Metering omega 3 fatty acids in the manufacturing of child food)
Source: Adobe Stock
Image ID: Torque.jpg
Caption: In contrast to the ASMs shown, the constant torque of the PMSM allows steady operation at low speeds. ชนิดของpressuregauge for the required pump starting torque has turn out to be pointless due to the excessive overload capability of the PMSM.
Source: LEWA GmbH
Image ID: Baugrößen_530PWebJPG.jpg
Caption: Like the asynchronous motor, the PMSM may be managed via a normal frequency converter (NORD, Danfoss, etc.) with special parameterization, so that users can depend on common components.
Source: Getriebebau NORD GmbH & Co. KG
Image ID: NORDAC ON Wandmontage BG2_806x502Web.jpg / Nordac ON+ with frequency converter on an IE5 PMSM.jpg
Caption: Decentralized solutions by which the frequency converter is installed directly on the PMSM are additionally already attainable with the PMSMs chosen by LEWA.
Source: Getriebebau NORD GmbH & Co. KG
Image ID: Functional testing.jpg
Caption: As early as 2020, LEWA carried out initial functional testing with the NORD PMSM prototype and an ecodos pump on the pump take a look at bench. In the lower velocity vary above all, the PMSM efficiently demonstrated the benefits of constant torque: the ecodos take a look at pump could possibly be driven in a variety of 1:480 up to 5 bar.
Source: LEWA GmbH
More info for readers/viewers/interested parties:
LEWA GmbH
Ulmer Straße 10, 71229 Leonberg, Germany
Phone: +49 7152 14-0, Fax: +49 7152 14-1303
Email: lewa@lewa.de
Internet: www.lewa.de
More data for members of the press
ABOPR Pressedienst B.V.
Stefan-George-Ring 19, 81929 Munich, Germany
Phone: +49 89 500315-20, Fax: +49 89 500315-15
Email: info@abopr.de
Internet: www.abopr.de
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