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

In many applications, metering ingredients within the pharmaceutical or food industry for instance, pumps are required that not only may be exactly controlled in phrases of circulate fee and dosing time, but also convey the ingredients significantly gently. To enable the confirmed pump models of the ecodos series from LEWA GmbH to fulfill this demanding task with even more flexibility and energy efficiency sooner or later, the manufacturer is increasing the portfolio to incorporate a brand new type of wide-range velocity control. Alongside asynchronous motors and servomotors, everlasting magnet synchronous motors, or PMSMs for short, are additionally used now. They are characterised by high power efficiency and a management vary larger than 1:200. This significantly expands the range of applications. With PMSMs, it’s now not needed to use a quantity of pumps for different move rates or oversize asynchronous motors for low speeds. Since PMSMs can be designed with no fan, they remain compact and easy to clean. The latter feature predestines them for hygienic purposes. High effectivity rating over the complete management range in accordance with energy effectivity class IE5+ additionally reduces power costs, thus making certain a lower complete value of ownership (TCO).
The diaphragm metering pumps within the LEWA ecodos collection are particularly well suited for functions within the meals or pharmaceutical industries. All materials involved with the fluids used in the pump items meet the FDA and USP Class VI necessities, and the EU directives for the food industry. In the hygienic version, for example, the pump head is manufactured from PP or electropolished stainless-steel with a surface roughness < 0.5 µm. This facilitates cleansing of the surfaces involved with the product.
The motor applied sciences used to date have had to make sacrifices: “For basic asynchronous motors whose rotor is a squirrel-cage rotor, the control vary remains limited to 1:10 (1:50 is possible in individual cases). With encoder suggestions, significant expansion is possible,” said Maurice Wirkner, an utility supervisor at LEWA. “In addition, the drive is relatively inefficient outdoors the rated pace vary – especially at low speeds. This requires the drive to be oversized, which increases working prices.” Servomotors are optimized for extremely dynamic requirements and in addition cover the complete control vary (1-210 pump strokes), however, they’re dearer to buy and in addition, require a servo inverter for management.
Wide-range speed control with everlasting magnet synchronous motor extends the range of purposes
LEWA has now expanded its own portfolio with a drive know-how that does not have these weaknesses. “Unlike the asynchronous motor, the rotor of this drive consists of permanent magnets and rotates synchronously, i.e. without load-dependent slip,” Wirkner explained. “Among different issues, it features an excessive control range, which frequently makes the usage of multiple pumps for different circulate charges unnecessary.” Particularly within the case of a number of pumps, an extra guide stroke adjustment or electrical stroke adjustment could be dispensed with and the required move rate can be realized by pace control only. The PMSM also has a continuing torque. The complete torque may be utilized from engine speed zero rpm (standstill) as a lot as the rated pace of the motor. This ensures particularly smooth and gentle system start-up, since each course of can be began with a pump capability of 1 percent as a substitute of the identical old 10 p.c.
It also includes a excessive short-term overload capability, which allows a drive design without oversizing for the beginning torque. As a end result, smaller, extra cost-efficient sizes may be realized than with classic drives. “Like the asynchronous motor, the PMSM may be controlled by way of a standard frequency converter, so customers can rely on frequent parts,” Wirkner defined. “With the servomotor on the contrary, it would be necessary to purchase expensive servo controllers.” The compact drive may be simply cleaned as a end result of its fanless design and provides excessive IP safety. If required an additional conversion process – called nsd tupH – can be applied to the aluminum physique for FDA requirements. This makes the surface extremely resistant and even easier to clean – perfect for applications with stringent hygienic requirements, such as aroma metering in the meals trade or additive dosing within the pharmaceutical industry.
IE5+ PMSM allows cost reduction and decentralized solutions
The sole limitation of the presently used PMSM is that it is only available for protected areas. “Thanks to wide-range speed control with IE5+ PMSM, we can meet the growing customer calls for for a wider adjustment vary and decrease vitality consumption, as properly as overall costs,” stated Wirkner to sum up the situation. “The subject of energy efficiency in particular 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 implemented with Getriebebau NORD GmbH & Co. KG, LEWA’s motor companion for PMSM, too.”
LEWA GmbH was based in 1952 by Herbert Ott and Rudolf Schestag as a household business and is right now the world’s leading manufacturer of metering pumps and course of diaphragm pumps as nicely as full metering packages for process engineering. Headquartered in Leonberg, the company developed into an international group in just some decades. Since 2022, the corporate has been part of the Atlas Copco Group, a globally main Swedish producer of compressors, vacuum options, mills, pumps, energy instruments and assembly systems. Together with the model new proprietor, LEWA will further expand the commercial pumps business. As a research and manufacturing company, LEWA develops technologies and provides solutions for the vast array of applications among its clients. เกจวัดความดันแก๊ส are used primarily in the chemical trade, the cosmetics business, prescribed drugs and biotechnology, food and beverage business and power utilities as nicely as in the manufacturing of plastics, detergents and cleaners. Additional application areas embrace refineries and petrochemicals, the oil and fuel trade, and fuel odorization. LEWA at present employs around 1,200 individuals and owns 14 subsidiaries around the world alongside having eighty representatives and gross sales workplaces in more than eighty 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 function a control vary of 1:200, enabling a wider range of applications to be covered by the same drive or pump.
Source: LEWA GmbH
Image ID: Baby meals.jpg
Caption: The PMSM additionally has a relentless torque, i.e. the entire torque may be referred to as up at pace zero rpm. This ensures notably smooth and gentle system start-up, since each process can be began with a conveyance fee of 1 % as an alternative of the usual 10 %. (Example: Metering omega 3 fatty acids within the production of baby food)
Source: Adobe Stock
Image ID: Torque.jpg
Caption: In contrast to the ASMs shown, the constant torque of the PMSM allows steady operation at low speeds. Oversizing for the required pump starting torque has turn out to be pointless because of the high overload functionality of the PMSM.
Source: LEWA GmbH
Image ID: Baugrößen_530PWebJPG.jpg
Caption: Like the asynchronous motor, the PMSM can be managed via a normal frequency converter (NORD, Danfoss, etc.) with particular parameterization, so that users can depend on frequent 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 options by which the frequency converter is installed directly on the PMSM are additionally 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 functional testing with the NORD PMSM prototype and an ecodos pump on the pump take a look at bench. In the lower velocity vary above all, the PMSM successfully demonstrated the advantages of constant torque: the ecodos take a look at pump might be driven in a variety of 1:480 as much as 5 bar.
Source: LEWA GmbH
More info 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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