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

In many applications, metering ingredients in the pharmaceutical or meals industry for example, pumps are required that not only can be precisely controlled by way of circulate fee and dosing time, but in addition convey the elements particularly gently. To allow the proven pump units of the ecodos collection from LEWA GmbH to satisfy this demanding task with much more flexibility and power efficiency sooner or later, the producer is expanding the portfolio to incorporate a new type of wide-range pace management. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for short, are also used now. They are characterized by excessive power efficiency and a management range greater than 1:200. This considerably expands the range of purposes. With PMSMs, it’s not necessary to use a number of pumps for various flow rates or oversize asynchronous motors for low speeds. Since PMSMs can be designed with no fan, they remain compact and straightforward to scrub. The latter feature predestines them for hygienic functions. High efficiency score over the complete management vary in accordance with energy efficiency class IE5+ also reduces vitality costs, thus ensuring a lower whole price of possession (TCO).
The diaphragm metering pumps in the LEWA ecodos collection are particularly nicely suited for applications within the meals or pharmaceutical industries. All supplies in touch with the fluids used in the pump items meet the FDA and USP Class VI necessities, and the EU directives for the food business. In the hygienic model, for instance, the pump head is made of PP or electropolished stainless-steel with a surface roughness < 0.5 µm. This facilitates cleansing of the surfaces in touch with the product.
The motor applied sciences used so far have needed to make sacrifices: “For basic asynchronous motors whose rotor is a squirrel-cage rotor, the control range remains limited to 1:10 (1:50 is feasible in particular person cases). With encoder suggestions, significant enlargement is possible,” said Maurice Wirkner, an software supervisor at LEWA. “In addition, the drive is comparatively inefficient exterior the rated velocity vary – particularly at low speeds. This requires the drive to be oversized, which increases operating prices.” Servomotors are optimized for highly dynamic requirements and likewise cowl the entire control vary (1-210 pump strokes), however, they’re dearer to buy and in addition, require a servo inverter for control.
Wide-range velocity management with everlasting magnet synchronous motor extends the range of functions
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 control vary, which regularly makes the use of a quantity of pumps for different flow charges pointless.” Particularly within the case of a number of pumps, an additional guide stroke adjustment or electrical stroke adjustment can be dispensed with and the required move price could be realized by pace control solely. The PMSM additionally has a continuing torque. The full torque can be utilized from engine pace 0 rpm (standstill) up to the rated velocity of the motor. This ensures notably easy and mild system start-up, since every course of may be began with a pump capability of 1 p.c instead of the usual 10 %.
It additionally contains a high short-term overload capability, which permits a drive design without oversizing for the starting torque. As a result, smaller, extra cost-efficient sizes could be realized than with traditional drives. “Like the asynchronous motor, the PMSM may be controlled via a regular frequency converter, so users can depend on frequent elements,” Wirkner explained. “With the servomotor quite the opposite, it will be essential to buy expensive servo controllers.” The compact drive may be easily cleaned because of its fanless design and presents excessive IP safety. If required an additional conversion process – known as nsd tupH – can be applied to the aluminum physique for FDA necessities. This makes the surface extremely resistant and even simpler to wash – ideal for functions with stringent hygienic requirements, similar to aroma metering within the meals business or additive dosing in the pharmaceutical trade.
IE5+ PMSM enables 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 control with IE5+ PMSM, we are able to meet the rising buyer demands for a wider adjustment vary and lower vitality consumption, in addition to overall prices,” mentioned Wirkner to sum up the scenario. “The subject of energy efficiency particularly is turning into increasingly necessary for our clients. A decentralized solution by which the frequency converter is installed directly on the PMSM, can now be applied 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 today the world’s leading manufacturer of metering pumps and course of diaphragm pumps in addition to complete metering packages for course of engineering. Headquartered in Leonberg, the corporate developed into an international group in just some a long time. Since 2022, the company has been a half of the Atlas Copco Group, a globally leading Swedish producer of compressors, vacuum solutions, mills, pumps, power instruments and meeting systems. Together with the brand new owner, LEWA will additional broaden the industrial pumps enterprise. As a analysis and manufacturing firm, LEWA develops technologies and supplies options for the huge array of functions among its customers. Its products are used primarily in the chemical industry, the cosmetics trade, pharmaceuticals and biotechnology, meals and beverage industry and vitality utilities as well as within the production of plastics, detergents and cleaners. Additional utility areas embrace refineries and petrochemicals, the oil and gasoline business, and gasoline odorization. LEWA at present employs around 1,200 individuals and owns 14 subsidiaries around the globe alongside having eighty representatives and sales places of work in additional 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 function a management range of 1:200, enabling a wider range of functions to be lined by the same drive or pump.
Source: LEWA GmbH
Image ID: Baby food.jpg
Caption: The PMSM additionally has a relentless torque, i.e. all the torque may be known as up at pace zero rpm. This ensures notably clean and delicate system start-up, since each process could be started with a conveyance price of 1 percent instead of the standard 10 percent. (Example: Metering omega three fatty acids in the manufacturing of baby food)
Source: Adobe Stock
Image ID: Torque.jpg
Caption: In distinction to the ASMs shown, the fixed torque of the PMSM permits steady operation at low speeds. Oversizing for the required pump beginning torque has turn into unnecessary because of the high overload functionality of the PMSM.
เกจวัดแรงดันpsi : LEWA GmbH
Image ID: Baugrößen_530PWebJPG.jpg
Caption: Like the asynchronous motor, the PMSM may be controlled by way of a standard frequency converter (NORD, Danfoss, and so on.) with particular parameterization, so that customers can rely on frequent elements.
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 attainable 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 test bench. In the lower velocity vary above all, the PMSM efficiently demonstrated the benefits of fixed torque: the ecodos take a look at pump could be pushed in a variety of 1:480 as much as 5 bar.
Source: LEWA GmbH
More data 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 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
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