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

In many functions, metering elements in the pharmaceutical or meals trade for instance, pumps are required that not only could be precisely managed by method of circulate fee and dosing time, but additionally convey the components particularly gently. To allow the confirmed pump units of the ecodos series from LEWA GmbH to meet this demanding process with even more flexibility and energy effectivity in the future, the producer is expanding the portfolio to incorporate a brand new form of wide-range speed control. Alongside asynchronous motors and servomotors, everlasting magnet synchronous motors, or PMSMs for brief, are also used now. They are characterised by excessive vitality effectivity and a control range greater than 1:200. This significantly expands the range of purposes. With PMSMs, it’s no longer needed to make use of several pumps for various flow rates or oversize asynchronous motors for low speeds. Since PMSMs can be designed with no fan, they continue to be compact and easy to scrub. The latter function predestines them for hygienic functions. High efficiency ranking over the whole management vary in accordance with power efficiency class IE5+ also reduces power prices, thus making certain a decrease complete cost of ownership (TCO).
The diaphragm metering pumps within the LEWA ecodos sequence are particularly nicely suited to purposes within the meals or pharmaceutical industries. All materials in contact with the fluids used within the pump items meet the FDA and USP Class VI requirements, and the EU directives for the food industry. In the hygienic model, for instance, the pump head is manufactured from PP or electropolished stainless steel with a floor roughness < 0.5 µm. This facilitates cleaning of the surfaces in touch with the product.
The motor technologies used so far have had to make sacrifices: “For basic asynchronous motors whose rotor is a squirrel-cage rotor, the control vary remains limited to 1:10 (1:50 is possible in individual cases). With encoder feedback, significant enlargement is possible,” stated Maurice Wirkner, an application supervisor at LEWA. “In addition, the drive is relatively inefficient exterior the rated velocity vary – particularly at low speeds. This requires the drive to be oversized, which increases operating costs.” Servomotors are optimized for extremely dynamic requirements and in addition cowl the whole management range (1-210 pump strokes), nonetheless, they’re dearer to purchase and in addition, require a servo inverter for management.
Wide-range speed management with permanent magnet synchronous motor extends the vary of applications

LEWA has now expanded its personal portfolio with a drive know-how that doesn’t have these weaknesses. “Unlike the asynchronous motor, the rotor of this drive consists of permanent magnets and rotates synchronously, i.e. without load-dependent slip,” Wirkner explained. “Among other things, it features an excessive control range, which frequently makes the utilization of multiple pumps for different circulate rates pointless.” Particularly within the case of multiple pumps, a further guide stroke adjustment or electric stroke adjustment may be dispensed with and the required circulate fee could be realized by pace management solely. The PMSM also has a constant torque. The complete torque could be utilized from engine velocity 0 rpm (standstill) up to the rated pace of the motor. This ensures significantly easy and mild system start-up, since every course of may be began with a pump capability of 1 p.c instead of the standard 10 percent.
It additionally features a excessive short-term overload capability, which allows a drive design with out oversizing for the beginning torque. As a outcome, smaller, extra cost-efficient sizes could be realized than with traditional drives. “Like the asynchronous motor, the PMSM may be managed by way of a regular frequency converter, so users can depend on frequent components,” Wirkner explained. “With the servomotor on the contrary, it would be necessary to purchase costly servo controllers.” The compact drive can be easily cleaned as a result of its fanless design and offers high IP safety. If required an extra conversion process – referred to as nsd tupH – can be utilized to the aluminum physique for FDA necessities. This makes the surface extraordinarily resistant and even simpler to clean – best for functions with stringent hygienic necessities, similar to aroma metering in the meals industry or additive dosing within the pharmaceutical trade.
IE5+ PMSM enables cost discount and decentralized options

The sole limitation of the currently used PMSM is that it is only obtainable for protected areas. “Thanks to wide-range speed control with IE5+ PMSM, we will meet the rising customer calls for for a wider adjustment vary and lower vitality consumption, in addition to overall costs,” stated Wirkner to sum up the situation. “The topic of power efficiency specifically is becoming increasingly necessary for our customers. A decentralized resolution in which the frequency converter is installed directly on the PMSM, can now be carried out with Getriebebau NORD GmbH & Co. KG, LEWA’s motor companion for PMSM, too.”

LEWA GmbH was founded in 1952 by Herbert Ott and Rudolf Schestag as a household enterprise and is today the world’s leading producer of metering pumps and process diaphragm pumps as nicely as full metering packages for course of engineering. Headquartered in Leonberg, the company developed into a world group in just some decades. Since 2022, the corporate has been a half of the Atlas Copco Group, a globally main Swedish manufacturer of compressors, vacuum options, turbines, pumps, power tools and assembly methods. Together with the model new owner, LEWA will additional expand the economic pumps business. As a research and manufacturing firm, LEWA develops technologies and offers options for the vast array of functions amongst its clients. Its products are used primarily in the chemical business, the cosmetics trade, prescribed drugs and biotechnology, meals and beverage trade and power utilities as properly as in the production of plastics, detergents and cleaners. Additional application areas embrace refineries and petrochemicals, the oil and fuel industry, and fuel odorization. LEWA presently employs round 1,200 folks and owns 14 subsidiaries around the globe alongside having 80 representatives and gross sales workplaces in more than 80 countries.
Image materials:
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 management vary of 1:200, enabling a wider vary of applications to be coated by the same drive or pump.
Source: LEWA GmbH

Image ID: Baby food.jpg

Caption: The PMSM additionally has a constant torque, i.e. the entire torque could be referred to as up at speed 0 rpm. ไดอะแฟรม ซีล ensures particularly easy and gentle system start-up, since each process could be started with a conveyance price of 1 percent as a substitute of the standard 10 percent. (Example: Metering omega three fatty acids within the production of child food)

Source: Adobe Stock

Image ID: Torque.jpg

Caption: In distinction to the ASMs shown, the fixed torque of the PMSM permits continuous operation at low speeds. Oversizing for the required pump starting torque has turn into pointless as a end result of excessive overload functionality of the PMSM.
Source: LEWA GmbH

Image ID: Baugrößen_530PWebJPG.jpg

Caption: Like the asynchronous motor, the PMSM can be managed through a regular frequency converter (NORD, Danfoss, etc.) with special parameterization, in order that users can depend on widespread 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 options during which the frequency converter is put in directly on the PMSM are also already potential 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 preliminary useful testing with the NORD PMSM prototype and an ecodos pump on the pump check bench. In the decrease pace vary above all, the PMSM efficiently demonstrated the benefits of fixed torque: the ecodos take a look at pump could presumably be pushed in a range of 1:480 as a lot as 5 bar.
Source: LEWA GmbH

More data for readers/viewers/interested events:
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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