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

In many applications, metering components within the pharmaceutical or food industry for instance, pumps are required that not solely may be exactly controlled in phrases of circulate price and dosing time, but in addition convey the elements particularly gently. To enable the proven pump models of the ecodos sequence from LEWA GmbH to fulfill this demanding activity with even more flexibility and energy efficiency in the future, the manufacturer is increasing the portfolio to include a new form of wide-range pace management. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for short, are additionally used now. They are characterized by high power efficiency and a management vary larger than 1:200. This significantly expands the vary of functions. With PMSMs, it is now not necessary to use several pumps for different circulate rates or oversize asynchronous motors for low speeds. Since PMSMs may be designed without a fan, they remain compact and simple to scrub. The latter characteristic predestines them for hygienic functions. High effectivity rating over the complete control range in accordance with energy effectivity class IE5+ additionally reduces power prices, thus making certain a decrease total price of ownership (TCO).
The diaphragm metering pumps within the LEWA ecodos series are notably nicely fitted to functions within the food or pharmaceutical industries. All supplies in contact with the fluids used within the pump units meet the FDA and USP Class VI necessities, and the EU directives for the food business. In the hygienic model, for example, the pump head is made of PP or electropolished chrome steel with a floor roughness < zero.5 µm. This facilitates cleaning of the surfaces in touch with the product.
The motor technologies used to date have needed to make sacrifices: “For basic asynchronous motors whose rotor is a squirrel-cage rotor, the management range remains limited to 1:10 (1:50 is possible in particular person cases). With encoder feedback, significant expansion is feasible,” mentioned Maurice Wirkner, an application manager at LEWA. “In addition, the drive is comparatively inefficient outside the rated speed vary – especially at low speeds. This requires the drive to be oversized, which increases operating costs.” Servomotors are optimized for extremely dynamic necessities and likewise cowl the whole control range (1-210 pump strokes), nevertheless, they’re more expensive to buy and in addition, require a servo inverter for control.
Wide-range pace management with everlasting magnet synchronous motor extends the range of applications
LEWA has now expanded its own portfolio with a drive know-how that does not 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 defined. “Among other issues, it options an excessive control vary, which regularly makes using multiple pumps for various circulate rates unnecessary.” Particularly within the case of a number of pumps, an additional guide stroke adjustment or electric stroke adjustment could be distributed with and the required flow rate can be realized by speed management only. The PMSM additionally has a relentless torque. The complete torque could be applied from engine velocity 0 rpm (standstill) up to the rated pace of the motor. This ensures significantly easy and gentle system start-up, since every course of can be started with a pump capability of 1 percent as an alternative of the similar old 10 p.c.
It also contains a excessive short-term overload capacity, which enables a drive design without oversizing for the beginning torque. As a result, smaller, more cost-efficient sizes may be realized than with basic drives. “Like the asynchronous motor, the PMSM could be controlled via a normal frequency converter, so customers can rely on common parts,” Wirkner explained. “With the servomotor on the contrary, it will be needed to buy expensive servo controllers.” The compact drive can be simply cleaned because of its fanless design and presents high IP safety. If required a further conversion process – called nsd tupH – can be utilized to the aluminum body for FDA necessities. This makes the floor extraordinarily resistant and even simpler to scrub – best for functions with stringent hygienic necessities, such as aroma metering within the meals business or additive dosing in the pharmaceutical trade.
IE5+ PMSM enables value discount and decentralized solutions
The sole limitation of the presently used PMSM is that it’s only available for secure areas. “Thanks to wide-range velocity control with IE5+ PMSM, we are able to meet the growing customer demands for a wider adjustment range and lower vitality consumption, in addition to total costs,” mentioned Wirkner to sum up the scenario. “The matter of power efficiency specifically is becoming more and more essential for our customers. A decentralized answer by which the frequency converter is put in instantly on the PMSM, can now be applied with Getriebebau NORD GmbH & Co. KG, LEWA’s motor companion for PMSM, too.”
LEWA GmbH was based in 1952 by Herbert Ott and Rudolf Schestag as a household enterprise and is at present the world’s main manufacturer of metering pumps and process diaphragm pumps in addition to full metering packages for process engineering. Headquartered in Leonberg, the company developed into a world group in just a few a long time. Since 2022, the company has been part of the Atlas Copco Group, a globally leading Swedish producer of compressors, vacuum solutions, mills, pumps, power instruments and assembly systems. Together with the new proprietor, LEWA will additional broaden the industrial pumps business. As a analysis and manufacturing company, LEWA develops technologies and provides options for the huge array of purposes amongst its clients. Its merchandise are used primarily within the chemical business, the cosmetics industry, pharmaceuticals and biotechnology, meals and beverage industry and power utilities in addition to within the manufacturing of plastics, detergents and cleaners. Additional software areas embrace refineries and petrochemicals, the oil and fuel business, and fuel odorization. LEWA presently employs round 1,200 people and owns 14 subsidiaries around the globe alongside having 80 representatives and gross sales workplaces in more than eighty nations.
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 characteristic a control range of 1:200, enabling a wider range of purposes to be coated by the same drive or pump.
Source: LEWA GmbH
Image ID: Baby meals.jpg
Caption: The PMSM additionally has a constant torque, i.e. all the torque may be referred to as up at velocity zero rpm. Bizarre ensures significantly easy and delicate system start-up, since every process may be began with a conveyance rate of 1 p.c instead of the usual 10 percent. (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 fixed torque of the PMSM allows continuous operation at low speeds. Oversizing for the required pump beginning torque has turn into 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 through a standard frequency converter (NORD, Danfoss, and so forth.) with special parameterization, so that users can rely on frequent 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 instantly 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 useful testing with the NORD PMSM prototype and an ecodos pump on the pump test bench. In the decrease speed range above all, the PMSM successfully demonstrated some nice benefits of fixed torque: the ecodos take a look at pump could presumably be pushed in a variety 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 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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