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

In many functions, metering components within the pharmaceutical or food business for example, pumps are required that not only can be precisely managed by way of circulate fee and dosing time, but in addition convey the ingredients particularly gently. To enable the proven pump units of the ecodos series from LEWA GmbH to satisfy this demanding activity with much more flexibility and power efficiency sooner or later, the producer is expanding the portfolio to include a brand new form of wide-range speed control. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for brief, are additionally used now. They are characterised by excessive power effectivity and a control vary higher than 1:200. This significantly expands the range of applications. With PMSMs, it is now not needed to use a number of pumps for different move rates or oversize asynchronous motors for low speeds. Since PMSMs can be designed and not utilizing a fan, they continue to be compact and easy to wash. The latter function predestines them for hygienic functions. High efficiency score over the entire control vary in accordance with power effectivity class IE5+ also reduces energy prices, thus ensuring a decrease complete cost of possession (TCO).
The diaphragm metering pumps in the LEWA ecodos collection are significantly nicely fitted to purposes within the food or pharmaceutical industries. All supplies in contact with the fluids used in the pump models meet the FDA and USP Class VI requirements, and the EU directives for the meals trade. In the hygienic version, for example, the pump head is made of PP or electropolished stainless steel with a surface roughness < zero.5 µm. This facilitates cleansing of the surfaces in touch with the product.
The motor applied sciences used to date have had to make sacrifices: “For traditional asynchronous motors whose rotor is a squirrel-cage rotor, the control vary remains restricted to 1:10 (1:50 is feasible in individual cases). With encoder feedback, vital expansion is possible,” mentioned Maurice Wirkner, an software supervisor at LEWA. “In addition, the drive is relatively inefficient outside the rated speed vary – particularly at low speeds. This requires the drive to be oversized, which will increase working prices.” Servomotors are optimized for highly dynamic requirements and likewise cover the entire control range (1-210 pump strokes), nonetheless, they are costlier to purchase and in addition, require a servo inverter for management.
Wide-range pace management with everlasting magnet synchronous motor extends the range of applications

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 everlasting magnets and rotates synchronously, i.e. without load-dependent slip,” Wirkner defined. “Among other issues, it features an excessive control vary, which frequently makes the utilization of multiple pumps for different circulate charges pointless.” Particularly within the case of a quantity of pumps, a further manual stroke adjustment or electric stroke adjustment may be dispensed with and the required flow rate can be realized by speed control solely. The PMSM additionally has a relentless torque. The full torque could be applied from engine speed 0 rpm (standstill) up to the rated speed of the motor. This ensures particularly easy and gentle system start-up, since every process could be began with a pump capacity of 1 percent as a substitute of the same old 10 percent.
It additionally contains a excessive short-term overload capacity, which permits a drive design without oversizing for the beginning torque. As a outcome, smaller, more cost-efficient sizes could be realized than with basic drives. “Like the asynchronous motor, the PMSM can be controlled by way of a standard frequency converter, so users can rely on widespread parts,” Wirkner explained. “With the servomotor quite the opposite, it might be necessary to buy expensive servo controllers.” digital pressure gauge can be easily cleaned because of its fanless design and offers high IP protection. If required an additional conversion course of – referred to as nsd tupH – can be applied to the aluminum physique for FDA necessities. This makes the floor extremely resistant and even easier to scrub – ideal for applications with stringent hygienic requirements, corresponding to aroma metering in the meals business or additive dosing in the pharmaceutical business.
IE5+ PMSM allows price discount and decentralized solutions

The sole limitation of the presently used PMSM is that it is only available for protected areas. “Thanks to wide-range pace management with IE5+ PMSM, we will meet the rising customer calls for for a wider adjustment vary and lower energy consumption, in addition to general costs,” stated Wirkner to sum up the situation. “The matter of energy efficiency particularly is turning into increasingly necessary for our customers. A decentralized answer in which the frequency converter is put in immediately on the PMSM, can now be carried out with Getriebebau NORD GmbH & Co. KG, LEWA’s motor associate for PMSM, too.”

LEWA GmbH was based in 1952 by Herbert Ott and Rudolf Schestag as a family enterprise and is right now 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 company developed into a global group in just a few decades. Since 2022, the company has been a part of the Atlas Copco Group, a globally leading Swedish producer of compressors, vacuum options, generators, pumps, energy tools and assembly techniques. Together with the new proprietor, LEWA will further expand the economic pumps business. As a research and manufacturing company, LEWA develops applied sciences and supplies solutions for the vast array of applications amongst its prospects. Its merchandise are used mainly within the chemical industry, the cosmetics business, prescribed drugs and biotechnology, meals and beverage business and energy utilities as nicely as in the manufacturing of plastics, detergents and cleaners. Additional software areas include refineries and petrochemicals, the oil and gas industry, and gasoline odorization. LEWA at present employs around 1,200 folks 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 function a management range of 1:200, enabling a wider range of functions 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. the entire torque can be referred to as up at pace 0 rpm. This ensures particularly clean and gentle system start-up, since every course of can be started with a conveyance fee of 1 p.c instead of the similar old 10 %. (Example: Metering omega three fatty acids within the production of baby food)

Source: Adobe Stock

Image ID: Torque.jpg

Caption: In contrast to the ASMs proven, the constant torque of the PMSM enables steady operation at low speeds. Oversizing for the required pump beginning torque has become unnecessary due to the high overload capability of the PMSM.
Source: LEWA GmbH

Image ID: Baugrößen_530PWebJPG.jpg

Caption: Like the asynchronous motor, the PMSM can be controlled through a standard frequency converter (NORD, Danfoss, and so on.) with particular parameterization, in order that customers can rely 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 solutions by which the frequency converter is installed instantly on the PMSM are also 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 preliminary 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 efficiently demonstrated some great advantages of fixed torque: the ecodos check pump could be pushed in a variety of 1:480 up to 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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