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

In many purposes, metering components in the pharmaceutical or food business for instance, pumps are required that not only could be precisely managed in terms of flow fee and dosing time, but also convey the components notably gently. To enable the proven pump models of the ecodos collection from LEWA GmbH to meet this demanding task with even more flexibility and power effectivity sooner or later, the manufacturer is increasing the portfolio to incorporate a model new type of wide-range velocity management. Alongside asynchronous motors and servomotors, everlasting magnet synchronous motors, or PMSMs for brief, are additionally used now. They are characterised by excessive vitality effectivity and a control vary larger than 1:200. This significantly expands the vary of functions. With PMSMs, it’s now not essential to use several pumps for various flow charges or oversize asynchronous motors for low speeds. Since PMSMs can be designed and not using a fan, they remain compact and easy to scrub. The latter function predestines them for hygienic functions. High effectivity score over the complete control vary in accordance with energy effectivity class IE5+ additionally reduces power prices, thus guaranteeing a lower complete cost of possession (TCO).
The diaphragm metering pumps in the LEWA ecodos collection are notably properly suited for applications in the food or pharmaceutical industries. All supplies involved with the fluids used in the pump items meet the FDA and USP Class VI necessities, and the EU directives for the meals trade. In the hygienic version, for instance, the pump head is manufactured from PP or electropolished stainless-steel with a floor roughness < zero.5 µm. This facilitates cleaning of the surfaces in contact with the product.
The motor applied sciences used to date have needed to make sacrifices: “For traditional asynchronous motors whose rotor is a squirrel-cage rotor, the management range remains limited to 1:10 (1:50 is possible in individual cases). With encoder suggestions, important growth is feasible,” stated Maurice Wirkner, an application supervisor at LEWA. “In addition, the drive is relatively inefficient outdoors the rated speed vary – especially at low speeds. This requires the drive to be outsized, which increases operating costs.” Servomotors are optimized for highly dynamic necessities and in addition cowl the whole control vary (1-210 pump strokes), however, they are costlier to purchase and in addition, require a servo inverter for control.
Wide-range pace management with everlasting magnet synchronous motor extends the vary of functions
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. with out load-dependent slip,” Wirkner explained. “Among different things, it features an excessive management vary, which regularly makes using a number of pumps for different circulate charges unnecessary.” Particularly in the case of a number of pumps, an extra manual stroke adjustment or electric stroke adjustment could be dispensed with and the required move price could be realized by velocity management solely. The PMSM additionally has a continuing torque. The complete torque can be utilized from engine velocity zero rpm (standstill) as much as the rated speed of the motor. This ensures significantly clean and delicate system start-up, since each course of could be started with a pump capacity of 1 p.c as a substitute of the standard 10 %.
It additionally features a excessive short-term overload capacity, which enables a drive design without oversizing for the starting torque. As a end result, smaller, extra cost-efficient sizes can be realized than with traditional drives. “Like the asynchronous motor, the PMSM could be managed through a standard frequency converter, so users can rely on widespread components,” Wirkner explained. “With the servomotor quite the opposite, it might be necessary to purchase costly servo controllers.” The compact drive could be simply cleaned because of its fanless design and provides excessive IP protection. If required an additional conversion process – known as nsd tupH – may be utilized to the aluminum physique for FDA necessities. This makes the surface extraordinarily resistant and even easier to wash – best for purposes with stringent hygienic necessities, corresponding to aroma metering within the meals trade or additive dosing in the pharmaceutical business.
IE5+ PMSM allows value reduction and decentralized options
The sole limitation of the at present used PMSM is that it is only obtainable for secure areas. “Thanks to wide-range velocity control with IE5+ PMSM, we can meet the growing buyer calls for for a wider adjustment range and decrease power consumption, as well as general prices,” mentioned Wirkner to sum up the situation. “ เกจวัดความดันpressuregauge of vitality efficiency specifically is turning into increasingly necessary for our customers. A decentralized solution in which the frequency converter is installed immediately 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 right now the world’s main producer of metering pumps and course of diaphragm pumps as well as complete metering packages for course of engineering. Headquartered in Leonberg, the company developed into an international group in only a few decades. Since 2022, the corporate has been part of the Atlas Copco Group, a globally main Swedish producer of compressors, vacuum solutions, generators, pumps, power instruments and assembly systems. Together with the model new proprietor, LEWA will additional expand the commercial pumps enterprise. As a research and manufacturing firm, LEWA develops technologies and provides solutions for the huge array of functions among its customers. Its merchandise are used mainly within the chemical business, the cosmetics business, prescribed drugs and biotechnology, meals and beverage trade and vitality utilities as properly as within the production of plastics, detergents and cleaners. Additional application areas embody refineries and petrochemicals, the oil and fuel industry, and gasoline odorization. LEWA at present employs round 1,200 people and owns 14 subsidiaries around the world alongside having eighty representatives and sales workplaces in more than eighty international locations.
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 control vary of 1:200, enabling a wider vary of functions to be lined by the same drive or pump.
Source: LEWA GmbH
Image ID: Baby meals.jpg
Caption: The PMSM also has a constant torque, i.e. all the torque could be known as up at velocity zero rpm. This ensures notably smooth and delicate system start-up, since every process can be started with a conveyance price of 1 % as an alternative of the standard 10 p.c. (Example: Metering omega three fatty acids within the production 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 as a result of high overload capability of the PMSM.
Source: LEWA GmbH
Image ID: Baugrößen_530PWebJPG.jpg
Caption: Like the asynchronous motor, the PMSM may be controlled by way of a regular frequency converter (NORD, Danfoss, etc.) with particular parameterization, so 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 options in which the frequency converter is put in immediately 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 initial practical testing with the NORD PMSM prototype and an ecodos pump on the pump check bench. In the lower pace range above all, the PMSM efficiently demonstrated the advantages of fixed torque: the ecodos test pump could be driven in a range of 1:480 as much as 5 bar.
Source: LEWA GmbH
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