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

In many applications, metering components within the pharmaceutical or food industry for instance, pumps are required that not solely could be precisely managed when it comes to circulate fee and dosing time, but also convey the components significantly gently. To enable the proven pump units of the ecodos collection from LEWA GmbH to meet this demanding activity with even more flexibility and power effectivity sooner or later, the manufacturer is increasing the portfolio to include a new type of wide-range speed control. Alongside asynchronous motors and servomotors, everlasting magnet synchronous motors, or PMSMs for short, are additionally used now. They are characterised by excessive vitality efficiency and a control vary larger than 1:200. This significantly expands the range of purposes. With PMSMs, it is no longer essential to use several pumps for various move rates or oversize asynchronous motors for low speeds. Since PMSMs could be designed and not using a fan, they proceed to be compact and easy to scrub. The latter feature predestines them for hygienic applications. High efficiency score over the complete control range in accordance with vitality efficiency class IE5+ additionally reduces energy costs, thus guaranteeing a decrease complete cost of ownership (TCO).
The diaphragm metering pumps within the LEWA ecodos series are notably well fitted to applications in the food or pharmaceutical industries. All supplies in contact with the fluids used in the pump models meet the FDA and USP Class VI necessities, and the EU directives for the food trade. 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 cleaning of the surfaces in touch with the product.
The motor applied sciences used to date have needed to make sacrifices: “For classic asynchronous motors whose rotor is a squirrel-cage rotor, the management range remains restricted to 1:10 (1:50 is feasible in individual cases). With encoder suggestions, vital growth is possible,” stated Maurice Wirkner, an utility supervisor at LEWA. “In addition, the drive is relatively inefficient outdoors the rated velocity vary – especially at low speeds. This requires the drive to be oversized, which increases working costs.” Servomotors are optimized for highly dynamic necessities and in addition cowl the entire management range (1-210 pump strokes), however, they are costlier to buy and as nicely as, require a servo inverter for management.
Wide-range speed management with permanent magnet synchronous motor extends the vary of purposes
LEWA has now expanded its personal portfolio with a drive technology 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 issues, it options an excessive management vary, which frequently makes the use of multiple pumps for different move rates pointless.” Particularly within the case of a quantity of pumps, an extra guide stroke adjustment or electrical stroke adjustment could be allotted with and the required flow price could be realized by pace control solely. The PMSM additionally has a constant torque. The full torque may be utilized from engine speed zero rpm (standstill) as a lot as the rated velocity of the motor. This ensures significantly smooth and delicate system start-up, since each process could be started with a pump capacity of 1 % instead of the similar 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 result, smaller, more cost-efficient sizes could be realized than with traditional drives. “Like the asynchronous motor, the PMSM can be managed through a regular frequency converter, so users can rely on common components,” Wirkner defined. “With the servomotor quite the opposite, it would be necessary to buy expensive servo controllers.” The compact drive could be simply cleaned as a end result of its fanless design and provides high IP protection. If required an extra conversion process – known as nsd tupH – could be utilized to the aluminum physique for FDA requirements. This makes the surface extremely resistant and even easier to wash – perfect for functions with stringent hygienic necessities, similar to aroma metering in the meals trade or additive dosing in the pharmaceutical trade.
IE5+ PMSM permits value discount and decentralized options
The sole limitation of the currently used PMSM is that it is only available for secure areas. “Thanks to wide-range pace control with IE5+ PMSM, we are ready to meet the increasing customer demands for a wider adjustment range and decrease energy consumption, in addition to total costs,” said Wirkner to sum up the state of affairs. “The matter of power efficiency specifically is becoming more and more essential for our customers. A decentralized answer during which the frequency converter is put in directly 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 household enterprise and is right now the world’s main manufacturer of metering pumps and process diaphragm pumps as nicely as full metering packages for course of engineering. Headquartered in Leonberg, the corporate developed into a world group in just some many years. Since 2022, the company has been part of the Atlas Copco Group, a globally main Swedish producer of compressors, vacuum solutions, generators, pumps, energy instruments and meeting methods. Together with the new owner, LEWA will additional increase the commercial pumps enterprise. As a analysis and manufacturing firm, LEWA develops applied sciences and provides options for the huge array of purposes amongst its clients. Its products are used primarily within the chemical trade, the cosmetics industry, prescribed drugs and biotechnology, meals and beverage trade and energy utilities as properly as in the production of plastics, detergents and cleaners. Additional software areas embody refineries and petrochemicals, the oil and gas trade, and fuel odorization. LEWA currently employs round 1,200 people and owns 14 subsidiaries around the world alongside having 80 representatives and sales workplaces in additional than eighty countries.
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 characteristic a management vary of 1:200, enabling a wider range of applications to be lined by the identical drive or pump.
Source: LEWA GmbH
Image ID: Baby meals.jpg
Caption: The PMSM also has a relentless torque, i.e. the entire torque may be known as up at velocity 0 rpm. This ensures significantly easy and delicate system start-up, since each course of could be started with a conveyance fee of 1 p.c as an alternative of the identical old 10 %. (Example: Metering omega 3 fatty acids within the production of baby food)
Source: Adobe Stock
Image ID: Torque.jpg
Caption: In distinction to the ASMs proven, the constant torque of the PMSM allows continuous operation at low speeds. Oversizing for the required pump beginning torque has turn out to be pointless due to the high overload functionality of the PMSM.
เพรสเชอร์เกจน้ำ : LEWA GmbH
Image ID: Baugrößen_530PWebJPG.jpg
Caption: Like the asynchronous motor, the PMSM can be controlled by way of a normal frequency converter (NORD, Danfoss, and so forth.) with special parameterization, so that customers can rely on widespread 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 solutions by which the frequency converter is installed immediately 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 functional testing with the NORD PMSM prototype and an ecodos pump on the pump check bench. In the decrease pace range above all, the PMSM successfully demonstrated the 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 info for readers/viewers/interested parties:
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 information 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