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

In many applications, metering elements in the pharmaceutical or food trade for instance, pumps are required that not only could be exactly controlled in terms of circulate fee and dosing time, but in addition convey the components significantly gently. To enable the confirmed pump models of the ecodos series from LEWA GmbH to satisfy this demanding process with even more flexibility and power efficiency sooner or later, the manufacturer is expanding the portfolio to include a new form of wide-range velocity control. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for brief, are additionally used now. They are characterised by excessive energy efficiency and a control range greater than 1:200. This considerably expands the range of functions. With PMSMs, it’s not essential to make use of a number of pumps for different move rates or oversize asynchronous motors for low speeds. Since PMSMs can be designed and not using a fan, they proceed to be compact and simple to scrub. The latter characteristic predestines them for hygienic functions. High effectivity rating over the whole control range in accordance with energy efficiency class IE5+ additionally reduces vitality costs, thus ensuring a decrease complete value of ownership (TCO).
The diaphragm metering pumps in the LEWA ecodos series are notably properly suited for functions in the food or pharmaceutical industries. All materials in contact with the fluids used within the pump models 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 manufactured from 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 thus far have needed to make sacrifices: “For basic asynchronous motors whose rotor is a squirrel-cage rotor, the control vary remains restricted to 1:10 (1:50 is feasible in particular person cases). With encoder suggestions, significant growth is feasible,” mentioned Maurice Wirkner, an utility supervisor at LEWA. “In addition, the drive is comparatively inefficient exterior the rated pace range – especially at low speeds. This requires the drive to be outsized, which increases working costs.” Servomotors are optimized for extremely dynamic requirements and in addition cover the entire control vary (1-210 pump strokes), nonetheless, they are costlier to purchase and as well as, require a servo inverter for management.
Wide-range speed control with everlasting magnet synchronous motor extends the range of applications
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 permanent magnets and rotates synchronously, i.e. with out load-dependent slip,” Wirkner defined. “Among different issues, it features an excessive management vary, which often makes the usage of a number of pumps for various move charges pointless.” Particularly within the case of a number of pumps, an extra handbook stroke adjustment or electrical stroke adjustment can be allotted with and the required move rate could be realized by pace control solely. The PMSM also has a relentless torque. The full torque can be utilized from engine velocity zero rpm (standstill) as a lot as the rated speed of the motor. This ensures notably smooth and mild system start-up, since each process can be began with a pump capacity of 1 percent instead of the usual 10 %.
It additionally includes a excessive short-term overload capability, which allows a drive design without oversizing for the beginning torque. As a result, smaller, more cost-efficient sizes can be realized than with basic drives. “Like the asynchronous motor, the PMSM could be controlled through a normal frequency converter, so customers can depend on frequent parts,” Wirkner defined. “With the servomotor on the contrary, it will be necessary to purchase expensive servo controllers.” The compact drive could be easily cleaned due to its fanless design and presents excessive IP safety. If required an extra conversion course of – known as nsd tupH – may be applied to the aluminum physique for FDA requirements. This makes the floor extraordinarily resistant and even easier to clean – best for applications with stringent hygienic necessities, corresponding to aroma metering in the food industry or additive dosing within the pharmaceutical trade.
IE5+ PMSM allows value reduction and decentralized options
The sole limitation of the presently used PMSM is that it is only available for safe areas. ที่วัดแรงดัน to wide-range pace control with IE5+ PMSM, we can meet the increasing customer calls for for a wider adjustment vary and lower power consumption, in addition to total costs,” mentioned Wirkner to sum up the situation. “The topic of energy efficiency specifically is changing into increasingly important for our customers. A decentralized solution in which the frequency converter is installed directly on the PMSM, can now be implemented with Getriebebau NORD GmbH & Co. KG, LEWA’s motor partner for PMSM, too.”
LEWA GmbH was founded in 1952 by Herbert Ott and Rudolf Schestag as a family business and is at present the world’s main producer of metering pumps and course of diaphragm pumps in addition to complete metering packages for process engineering. Headquartered in Leonberg, the company developed into a global group in just a few decades. Since 2022, the corporate has been part of the Atlas Copco Group, a globally main Swedish producer of compressors, vacuum solutions, mills, pumps, energy instruments and meeting techniques. Together with the new owner, LEWA will further expand the economic pumps enterprise. As a research and manufacturing company, LEWA develops applied sciences and offers options for the vast array of applications amongst its prospects. Its products are used primarily in the chemical industry, the cosmetics trade, pharmaceuticals and biotechnology, food and beverage trade and power utilities as nicely as within the production of plastics, detergents and cleaners. Additional software areas embrace refineries and petrochemicals, the oil and gas business, and gas odorization. LEWA presently employs around 1,200 individuals and owns 14 subsidiaries all over the world alongside having eighty representatives and gross sales offices in additional than 80 countries.
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 feature a control vary of 1:200, enabling a wider vary 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 continuing torque, i.e. all the torque may be known as up at pace zero rpm. This ensures particularly smooth and gentle system start-up, since every process can be began with a conveyance rate of 1 p.c instead of the identical old 10 p.c. (Example: Metering omega three fatty acids within the manufacturing of baby food)
Source: Adobe Stock
Image ID: Torque.jpg
Caption: In contrast to the ASMs proven, the constant torque of the PMSM allows steady operation at low speeds. Oversizing for the required pump beginning torque has turn out to be unnecessary due to the excessive overload functionality of the PMSM.
Source: LEWA GmbH
Image ID: Baugrößen_530PWebJPG.jpg
Caption: Like the asynchronous motor, the PMSM may be managed via a regular frequency converter (NORD, Danfoss, etc.) with special parameterization, in order that customers can depend on common 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 options by which the frequency converter is put in directly 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 preliminary useful testing with the NORD PMSM prototype and an ecodos pump on the pump test bench. In the lower pace vary above all, the PMSM efficiently demonstrated some great benefits of constant torque: the ecodos check pump could probably be pushed in a range of 1:480 as much as 5 bar.
Source: LEWA GmbH
More data for readers/viewers/interested events:
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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