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

In many purposes, metering ingredients within the pharmaceutical or meals industry for instance, pumps are required that not solely could be exactly controlled in terms of move price and dosing time, but additionally convey the elements notably gently. To allow the proven pump models of the ecodos collection from LEWA GmbH to satisfy this demanding activity with even more flexibility and vitality efficiency sooner or later, the manufacturer is expanding the portfolio to incorporate a brand new type of wide-range speed control. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for brief, are additionally used now. They are characterised by high power effectivity and a management vary greater than 1:200. This considerably expands the range of purposes. With PMSMs, it’s not needed to make use of several pumps for various move charges or oversize asynchronous motors for low speeds. Since PMSMs can be designed without a fan, they continue to be compact and simple to wash. The latter feature predestines them for hygienic applications. High effectivity score over the complete control range in accordance with energy effectivity class IE5+ also reduces vitality costs, thus guaranteeing a decrease total value of possession (TCO).
The diaphragm metering pumps in the LEWA ecodos collection are particularly nicely fitted to functions within the food or pharmaceutical industries. All supplies in touch with the fluids used within the pump items meet the FDA and USP Class VI requirements, and the EU directives for the food industry. In the hygienic version, for instance, the pump head is manufactured from PP or electropolished stainless-steel with a floor roughness < 0.5 µm. This facilitates cleaning of the surfaces in contact with the product.
The motor applied sciences used so far have had 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 possible in particular person cases). With encoder feedback, important growth is possible,” said Maurice Wirkner, an software supervisor at LEWA. “In addition, the drive is relatively inefficient outdoors the rated pace vary – particularly at low speeds. This requires the drive to be outsized, which increases operating costs.” Servomotors are optimized for extremely dynamic necessities and likewise cowl the complete management vary (1-210 pump strokes), nonetheless, they are dearer to buy and as nicely as, require a servo inverter for control.
Wide-range velocity control with everlasting magnet synchronous motor extends the vary of purposes
LEWA has now expanded its own 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 explained. “Among other things, it options an extreme control vary, which regularly makes the use of multiple pumps for different flow rates unnecessary.” Particularly within the case of a number of pumps, an additional handbook stroke adjustment or electrical stroke adjustment may be dispensed with and the required move fee can be realized by pace management solely. The PMSM additionally has a continuing torque. The complete torque may be utilized from engine velocity 0 rpm (standstill) up to the rated velocity of the motor. This ensures notably clean and gentle system start-up, since each process could be started with a pump capacity of 1 percent instead of the standard 10 p.c.
It also contains a high short-term overload capacity, which enables a drive design without oversizing for the beginning torque. As a outcome, smaller, more cost-efficient sizes could be realized than with traditional drives. “Like the asynchronous motor, the PMSM could be managed by way of a regular frequency converter, so customers can rely on frequent parts,” Wirkner defined. “With the servomotor quite the opposite, it will be needed to buy expensive servo controllers.” The compact drive could be easily cleaned due to its fanless design and offers excessive IP protection. If required an extra conversion process – referred to as nsd tupH – could be applied to the aluminum body for FDA requirements. This makes the surface extremely resistant and even simpler to clean – ideal for functions with stringent hygienic requirements, similar to aroma metering within the meals business or additive dosing within the pharmaceutical industry.
IE5+ PMSM enables value discount and decentralized solutions
The sole limitation of the currently used PMSM is that it is only obtainable for protected areas. “Thanks to wide-range speed management with IE5+ PMSM, we can meet the growing buyer demands for a wider adjustment range and lower vitality consumption, in addition to total prices,” said Wirkner to sum up the scenario. “The subject of power effectivity particularly is changing into more and more essential for our customers. A decentralized answer during which the frequency converter is put in immediately on the PMSM, can now be applied with Getriebebau NORD GmbH & Co. KG, LEWA’s motor companion for PMSM, too.”
LEWA GmbH was founded in 1952 by Herbert Ott and Rudolf Schestag as a household business and is today the world’s main producer of metering pumps and process diaphragm pumps as properly as complete metering packages for process engineering. Headquartered in Leonberg, the corporate developed into a world group in just a few a long time. Since pressure gauge น้ำมัน , the corporate has been a half of the Atlas Copco Group, a globally main Swedish producer of compressors, vacuum solutions, generators, pumps, power tools and meeting methods. Together with the brand new owner, LEWA will additional increase the industrial pumps business. As a analysis and manufacturing firm, LEWA develops technologies and supplies options for the vast array of functions amongst its clients. Its products are used primarily within the chemical trade, the cosmetics industry, prescription drugs and biotechnology, food and beverage business and power utilities as properly as in the manufacturing of plastics, detergents and cleaners. Additional software areas include refineries and petrochemicals, the oil and gasoline industry, and gas odorization. LEWA at present employs around 1,200 individuals and owns 14 subsidiaries all over the world alongside having 80 representatives and gross sales offices in more than eighty nations.
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 control range of 1:200, enabling a wider range of purposes to be lined by the same drive or pump.
Source: LEWA GmbH
Image ID: Baby meals.jpg
Caption: The PMSM additionally has a constant torque, i.e. all the torque can be referred to as up at pace 0 rpm. This ensures notably easy and gentle system start-up, since every course of could be began with a conveyance price of 1 % as a substitute of the usual 10 p.c. (Example: Metering omega 3 fatty acids in the manufacturing of child food)
Source: Adobe Stock
Image ID: Torque.jpg
Caption: In contrast to the ASMs proven, the fixed torque of the PMSM allows steady operation at low speeds. Oversizing for the required pump beginning torque has turn into pointless as a outcome of high overload functionality of the PMSM.
Source: LEWA GmbH
Image ID: Baugrößen_530PWebJPG.jpg
Caption: Like the asynchronous motor, the PMSM could be managed by way of a regular frequency converter (NORD, Danfoss, and so on.) with special parameterization, in order that users can rely 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 solutions in which the frequency converter is installed immediately 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 useful testing with the NORD PMSM prototype and an ecodos pump on the pump take a look at bench. In the decrease velocity range above all, the PMSM efficiently demonstrated some nice benefits of constant torque: the ecodos check pump could presumably be driven in a range of 1:480 up to 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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