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

In many functions, metering components in the pharmaceutical or food industry for instance, pumps are required that not only can be precisely managed in terms of move rate and dosing time, but also convey the ingredients notably gently. To allow the proven pump units of the ecodos series from LEWA GmbH to fulfill this demanding activity with even more flexibility and vitality efficiency sooner or later, the manufacturer is increasing the portfolio to include a brand new form of wide-range pace control. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for short, are additionally used now. They are characterised by high vitality efficiency and a control range higher than 1:200. This significantly expands the range of functions. With PMSMs, it’s now not essential to use several pumps for various circulate rates or oversize asynchronous motors for low speeds. Since PMSMs can be designed with no fan, they remain compact and simple to wash. The latter function predestines them for hygienic functions. High efficiency score over the whole control vary in accordance with energy effectivity class IE5+ additionally reduces energy costs, thus guaranteeing a lower total price of ownership (TCO).
The diaphragm metering pumps in the LEWA ecodos sequence are notably properly suited to purposes in the meals or pharmaceutical industries. All materials in contact with the fluids used within the pump models meet the FDA and USP Class VI requirements, and the EU directives for the meals business. In the hygienic model, for instance, the pump head is made from PP or electropolished stainless steel with a surface roughness < zero.5 µm. ไดอะแฟรม facilitates cleaning of the surfaces involved 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 stays restricted to 1:10 (1:50 is feasible in particular person cases). With encoder feedback, important expansion is possible,” stated Maurice Wirkner, an utility supervisor at LEWA. “In addition, the drive is relatively inefficient outdoors the rated pace range – especially at low speeds. This requires the drive to be oversized, which will increase operating costs.” Servomotors are optimized for highly dynamic requirements and in addition cowl the whole control vary (1-210 pump strokes), however, they’re costlier to purchase and in addition, require a servo inverter for management.
Wide-range speed management with everlasting magnet synchronous motor extends the range of purposes

LEWA has now expanded its personal portfolio with a drive expertise that doesn’t have these weaknesses. “Unlike the asynchronous motor, the rotor of this drive consists of everlasting magnets and rotates synchronously, i.e. with out load-dependent slip,” Wirkner explained. “Among different things, it options an excessive control vary, which frequently makes using multiple pumps for different flow rates pointless.” Particularly in the case of a quantity of pumps, an additional manual stroke adjustment or electric stroke adjustment can be dispensed with and the required move rate may be realized by speed management only. The PMSM also has a relentless torque. The full torque can be utilized from engine speed zero rpm (standstill) up to the rated speed of the motor. This ensures significantly smooth and gentle system start-up, since every course of may be began with a pump capacity of 1 p.c instead of the standard 10 %.
It additionally features a excessive short-term overload capability, which allows a drive design without oversizing for the starting torque. As a outcome, smaller, extra cost-efficient sizes can be realized than with classic drives. “Like the asynchronous motor, the PMSM may be managed via a regular frequency converter, so customers can rely on widespread parts,” Wirkner defined. “With the servomotor on the contrary, it would be essential to buy costly servo controllers.” The compact drive could be simply cleaned because of its fanless design and offers excessive IP protection. If required a further conversion process – called nsd tupH – may be applied to the aluminum physique for FDA necessities. This makes the floor extraordinarily resistant and even simpler to scrub – ideal for functions with stringent hygienic requirements, corresponding to aroma metering in the food trade or additive dosing within the pharmaceutical industry.
IE5+ PMSM allows cost discount and decentralized options

The sole limitation of the at present used PMSM is that it is just obtainable for protected areas. “Thanks to wide-range pace management with IE5+ PMSM, we are ready to meet the increasing customer demands for a wider adjustment range and decrease vitality consumption, as nicely as total costs,” said Wirkner to sum up the situation. “The subject of vitality efficiency in particular is changing into more and more necessary for our clients. A decentralized resolution during which the frequency converter is installed directly on the PMSM, can now be implemented 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 business and is right now the world’s leading producer of metering pumps and process diaphragm pumps in addition to complete metering packages for process engineering. Headquartered in Leonberg, the company developed into a world group in only a few a long time. Since 2022, the company has been part of the Atlas Copco Group, a globally main Swedish producer of compressors, vacuum options, mills, pumps, energy instruments and meeting techniques. Together with the brand new owner, LEWA will further broaden the industrial pumps business. As a analysis and manufacturing company, LEWA develops technologies and provides solutions for the vast array of applications amongst its clients. Its products are used mainly within the chemical business, the cosmetics trade, pharmaceuticals and biotechnology, food and beverage industry and power utilities as nicely as in the manufacturing of plastics, detergents and cleaners. Additional utility areas embody refineries and petrochemicals, the oil and gas trade, and gas odorization. LEWA currently employs round 1,200 individuals and owns 14 subsidiaries around the world alongside having eighty representatives and sales offices in more than 80 nations.
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 control vary of 1:200, enabling a wider range of purposes to be covered 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 may be called up at speed 0 rpm. This ensures notably easy and mild system start-up, since each process could be started with a conveyance rate of 1 p.c as a substitute of the usual 10 p.c. (Example: Metering omega 3 fatty acids within the production of child food)

Source: Adobe Stock

Image ID: Torque.jpg

Caption: In distinction to the ASMs proven, the fixed torque of the PMSM permits steady operation at low speeds. Oversizing for the required pump starting torque has turn into unnecessary as a result of high overload functionality of the PMSM.
diaphragm seal : LEWA GmbH

Image ID: Baugrößen_530PWebJPG.jpg

Caption: Like the asynchronous motor, the PMSM may be managed through a regular frequency converter (NORD, Danfoss, and so on.) with particular parameterization, in order that users can depend on frequent parts.
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 in which the frequency converter is installed instantly on the PMSM are additionally already possible 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 functional testing with the NORD PMSM prototype and an ecodos pump on the pump test bench. In the decrease pace range above all, the PMSM efficiently demonstrated some great advantages of fixed torque: the ecodos take a look at pump might be driven in a range of 1:480 up to 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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