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

In many applications, metering components within the pharmaceutical or food business for instance, pumps are required that not only can be exactly controlled when it comes to flow price and dosing time, but additionally convey the elements notably gently. To enable the proven pump units of the ecodos series from LEWA GmbH to meet this demanding task with even more flexibility and vitality efficiency in the future, the manufacturer 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 short, are additionally used now. They are characterised by high vitality effectivity and a control vary larger than 1:200. This considerably expands the vary of applications. With PMSMs, it is now not essential to use a quantity of pumps for different move rates or oversize asynchronous motors for low speeds. Since PMSMs may be designed with no fan, they remain compact and straightforward to wash. The latter function predestines them for hygienic purposes. High effectivity rating over the entire control range in accordance with vitality effectivity class IE5+ additionally reduces power costs, thus guaranteeing a decrease complete price of possession (TCO).
The diaphragm metering pumps within the LEWA ecodos sequence are notably properly fitted to functions within the meals or pharmaceutical industries. All supplies involved with the fluids used within the pump items meet the FDA and USP Class VI requirements, and the EU directives for the food trade. In the hygienic model, 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 involved with the product.
The motor technologies used thus far have had to make sacrifices: “For classic asynchronous motors whose rotor is a squirrel-cage rotor, the control vary stays restricted to 1:10 (1:50 is possible in particular person cases). With encoder suggestions, vital expansion is possible,” mentioned Maurice Wirkner, an utility supervisor at LEWA. “In เพรสเชอร์เกจ , the drive is relatively inefficient outdoors the rated pace range – especially at low speeds. This requires the drive to be oversized, which will increase working costs.” Servomotors are optimized for extremely dynamic requirements and in addition cover the complete control vary (1-210 pump strokes), nevertheless, they’re costlier to purchase and in addition, require a servo inverter for management.
Wide-range velocity control with permanent magnet synchronous motor extends the range 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. without load-dependent slip,” Wirkner defined. “Among other things, it features an extreme control range, which frequently makes the use of multiple pumps for different move charges pointless.” Particularly within the case of a number of pumps, an additional handbook stroke adjustment or electric stroke adjustment may be allotted with and the required circulate price can be realized by speed control only. The PMSM also has a relentless torque. The complete torque could be utilized from engine pace 0 rpm (standstill) as much as the rated velocity of the motor. This ensures significantly clean and delicate system start-up, since every process could be began with a pump capability of 1 percent as an alternative of the identical old 10 percent.
It also includes a high short-term overload capability, which allows a drive design without oversizing for the beginning torque. As a outcome, smaller, extra cost-efficient sizes could be realized than with classic drives. “Like the asynchronous motor, the PMSM can be managed through a normal frequency converter, so users can depend on widespread parts,” Wirkner defined. “With the servomotor on the contrary, it would be needed to purchase costly servo controllers.” The compact drive may be easily cleaned because of its fanless design and presents excessive IP safety. If required an extra conversion course of – referred to as nsd tupH – could be applied to the aluminum physique for FDA necessities. This makes the floor extraordinarily resistant and even easier to clean – ideal for applications with stringent hygienic necessities, corresponding to aroma metering within the meals industry or additive dosing in the pharmaceutical trade.
IE5+ PMSM allows value reduction and decentralized solutions

The sole limitation of the presently used PMSM is that it is only obtainable for secure areas. “Thanks to wide-range velocity control with IE5+ PMSM, we can meet the rising customer demands for a wider adjustment range and lower energy consumption, as nicely as total prices,” mentioned Wirkner to sum up the situation. “The subject of power effectivity in particular is turning into more and more necessary for our customers. A decentralized answer by which the frequency converter is installed directly on the PMSM, can now be applied 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 enterprise and is at present the world’s leading manufacturer of metering pumps and process diaphragm pumps as properly as full metering packages for course of engineering. Headquartered in Leonberg, the corporate developed into a global group in just some a long time. Since 2022, the corporate has been a part of the Atlas Copco Group, a globally main Swedish producer of compressors, vacuum solutions, generators, pumps, energy tools and assembly methods. Together with the model new owner, LEWA will further expand the commercial pumps enterprise. As a research and manufacturing company, LEWA develops applied sciences and supplies solutions for the vast array of applications among its clients. Its products are used mainly within the chemical business, the cosmetics business, prescription drugs and biotechnology, meals and beverage business and power utilities in addition to in the production of plastics, detergents and cleaners. Additional application areas include refineries and petrochemicals, the oil and fuel industry, and fuel odorization. LEWA currently employs around 1,200 people and owns 14 subsidiaries around the globe alongside having eighty representatives and gross sales offices in more 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 management vary of 1:200, enabling a wider vary of applications to be covered by the same drive or pump.
Source: LEWA GmbH

Image ID: Baby food.jpg

Caption: The PMSM also has a relentless torque, i.e. the entire torque can be referred to as up at pace zero rpm. This ensures notably clean and delicate system start-up, since each course of could be started with a conveyance fee of 1 % as a substitute of the usual 10 p.c. (Example: Metering omega 3 fatty acids within the manufacturing of child food)

Source: Adobe Stock

Image ID: Torque.jpg

Caption: In distinction to the ASMs proven, the constant torque of the PMSM permits continuous operation at low speeds. Oversizing for the required pump starting torque has turn out to be pointless because of the excessive overload functionality of the PMSM.
Source: LEWA GmbH

Image ID: Baugrößen_530PWebJPG.jpg

Caption: Like the asynchronous motor, the PMSM could be controlled through a regular frequency converter (NORD, Danfoss, etc.) with special parameterization, so that users can depend on common 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 during which the frequency converter is installed directly on the PMSM are also already possible 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 decrease pace range above all, the PMSM efficiently demonstrated some nice advantages of fixed torque: the ecodos take a look at pump could be pushed in a variety of 1:480 up to 5 bar.
Source: LEWA GmbH

More info for readers/viewers/interested parties:

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Phone: +49 7152 14-0, Fax: +49 7152 14-1303

Email: lewa@lewa.de

Internet: www.lewa.de

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Phone: +49 89 500315-20, Fax: +49 89 500315-15

Email: info@abopr.de

Internet: www.abopr.de


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