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

In many applications, metering ingredients in the pharmaceutical or food trade for example, pumps are required that not only can be precisely controlled when it comes to move fee and dosing time, but additionally convey the ingredients notably gently. To allow the confirmed pump models of the ecodos collection from LEWA GmbH to meet this demanding activity with much more flexibility and energy efficiency sooner or later, the producer is increasing the portfolio to incorporate a new form of wide-range speed management. Alongside asynchronous motors and servomotors, everlasting magnet synchronous motors, or PMSMs for brief, are also used now. They are characterized by excessive vitality effectivity and a management vary greater than 1:200. This considerably expands the vary of purposes. With PMSMs, it is no longer essential to use a quantity of pumps for different circulate charges or oversize asynchronous motors for low speeds. Since PMSMs can be designed without a fan, they proceed to be compact and easy to clean. The latter function predestines them for hygienic applications. High effectivity score over the complete control range in accordance with vitality efficiency class IE5+ additionally reduces energy prices, thus guaranteeing a lower whole cost of possession (TCO).
The diaphragm metering pumps within the LEWA ecodos sequence are notably nicely suited to applications in the meals or pharmaceutical industries. All materials in contact with the fluids used in the pump units 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 made from PP or electropolished stainless-steel with a floor roughness < zero.5 µm. This facilitates cleansing of the surfaces in touch with the product.
The motor applied sciences used thus far have had to make sacrifices: “For classic asynchronous motors whose rotor is a squirrel-cage rotor, the control vary remains restricted to 1:10 (1:50 is feasible in particular person cases). With encoder feedback, significant enlargement is feasible,” said Maurice Wirkner, an software supervisor at LEWA. “In addition, the drive is relatively inefficient exterior the rated speed vary – especially at low speeds. This requires the drive to be oversized, which increases working prices.” Servomotors are optimized for extremely dynamic requirements and in addition cover the whole management range (1-210 pump strokes), however, they’re dearer to buy and as nicely as, require a servo inverter for control.
Wide-range speed control with permanent magnet synchronous motor extends the range of purposes
LEWA has now expanded its personal portfolio with a drive technology that does not have these weaknesses. “Unlike the asynchronous motor, the rotor of this drive consists of permanent magnets and rotates synchronously, i.e. with out load-dependent slip,” Wirkner defined. “Among other issues, it features an excessive management range, which frequently makes the utilization of multiple pumps for different move charges pointless.” Particularly in the case of a number of pumps, a further guide stroke adjustment or electric stroke adjustment could be dispensed with and the required flow fee can be realized by speed management solely. The PMSM additionally has a relentless torque. The full torque could be utilized from engine pace zero rpm (standstill) up to the rated pace of the motor. This ensures notably easy and delicate system start-up, since each course of could be started with a pump capability of 1 % instead of the standard 10 percent.
It additionally contains a high short-term overload capacity, which allows a drive design without oversizing for the beginning torque. As a outcome, smaller, extra cost-efficient sizes may be realized than with classic drives. “Like the asynchronous motor, the PMSM can be controlled through a normal frequency converter, so users can rely on frequent parts,” Wirkner explained. “With the servomotor quite the opposite, it might be needed to buy expensive servo controllers.” The compact drive may be simply cleaned because of its fanless design and provides excessive IP safety. If required a further conversion course of – referred to as nsd tupH – can be applied to the aluminum body for FDA necessities. This makes the surface extraordinarily resistant and even simpler to scrub – perfect for applications with stringent hygienic necessities, corresponding to aroma metering in the meals trade or additive dosing within the pharmaceutical trade.
IE5+ PMSM enables xp2i and decentralized options
The sole limitation of the presently used PMSM is that it is only available for secure areas. “Thanks to wide-range velocity control with IE5+ PMSM, we will meet the growing customer demands for a wider adjustment range and decrease vitality consumption, as properly as total costs,” mentioned Wirkner to sum up the situation. “The subject of power effectivity in particular is becoming increasingly necessary for our customers. A decentralized answer by which the frequency converter is installed directly on the PMSM, can now be carried out with Getriebebau NORD GmbH & Co. KG, LEWA’s motor partner for PMSM, too.”
LEWA GmbH was founded in 1952 by Herbert Ott and Rudolf Schestag as a family business and is at present the world’s leading manufacturer of metering pumps and process diaphragm pumps as well as full metering packages for course of engineering. Headquartered in Leonberg, the corporate developed into a world group in only a few decades. Since 2022, the corporate has been a part of the Atlas Copco Group, a globally main Swedish manufacturer of compressors, vacuum solutions, generators, pumps, energy tools and assembly techniques. Together with the new proprietor, LEWA will additional expand the commercial pumps business. As a analysis and manufacturing company, LEWA develops technologies and supplies options for the huge array of applications among its clients. Its products are used mainly within the chemical trade, the cosmetics trade, prescription drugs and biotechnology, meals and beverage trade and vitality utilities in addition to within the production of plastics, detergents and cleaners. Additional software areas include refineries and petrochemicals, the oil and gasoline trade, and gasoline odorization. LEWA at present employs around 1,200 folks and owns 14 subsidiaries around the globe alongside having eighty representatives and sales workplaces in more 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 function a control range of 1:200, enabling a wider vary of purposes to be covered by the same drive or pump.
Source: LEWA GmbH
Image ID: Baby food.jpg
Caption: The PMSM also has a constant torque, i.e. all of the torque could be known as up at speed zero rpm. This ensures particularly easy and delicate system start-up, since each process could be started with a conveyance price of 1 percent instead of the usual 10 p.c. (Example: Metering omega 3 fatty acids in the production of baby food)
Source: Adobe Stock
Image ID: Torque.jpg
Caption: In distinction to the ASMs shown, the fixed torque of the PMSM allows continuous operation at low speeds. Oversizing for the required pump beginning torque has turn out to be pointless because of the excessive overload functionality of the PMSM.
Source: LEWA GmbH
Image ID: Baugrößen_530PWebJPG.jpg
Caption: Like the asynchronous motor, the PMSM could be managed via a normal frequency converter (NORD, Danfoss, and so on.) with special parameterization, in order that customers can rely 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 solutions during which the frequency converter is installed directly on the PMSM are also already possible with the PMSMs selected by LEWA.
Source: Getriebebau NORD GmbH & Co. KG
Image ID: Functional testing.jpg
Caption: As early as 2020, LEWA carried out initial practical testing with the NORD PMSM prototype and an ecodos pump on the pump take a look at bench. In the decrease speed range above all, the PMSM efficiently demonstrated some nice benefits of fixed torque: the ecodos check pump could be pushed in a range of 1:480 as much as 5 bar.
Source: LEWA GmbH
More data for readers/viewers/interested events:
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 info 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

Scroll to Top