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

In many applications, metering components within the pharmaceutical or meals business for instance, pumps are required that not only can be exactly controlled by method of circulate price and dosing time, but also convey the components significantly gently. To enable the proven pump models of the ecodos series from LEWA GmbH to meet this demanding process with even more flexibility and vitality effectivity in the future, the manufacturer is increasing the portfolio to include a brand new type of wide-range pace control. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for short, are also used now. They are characterized by high vitality efficiency and a control vary larger than 1:200. This significantly expands the vary of purposes. With PMSMs, it is not needed to use a number of pumps for various circulate rates or oversize asynchronous motors for low speeds. Since PMSMs could be designed with no fan, they remain compact and easy to wash. The latter feature predestines them for hygienic applications. High efficiency rating over the whole management range in accordance with vitality efficiency class IE5+ also reduces power costs, thus ensuring a decrease total cost of possession (TCO).
The diaphragm metering pumps within the LEWA ecodos collection are significantly well fitted to functions within the food or pharmaceutical industries. All supplies in contact with the fluids used in the pump items meet the FDA and USP Class VI requirements, and the EU directives for the meals industry. In the hygienic model, for instance, the pump head is manufactured from PP or electropolished chrome steel with a surface roughness < zero.5 µm. This facilitates cleaning of the surfaces involved 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 control vary remains limited to 1:10 (1:50 is possible in individual cases). With encoder suggestions, vital growth is feasible,” mentioned Maurice Wirkner, an application supervisor at LEWA. “In addition, the drive is relatively inefficient exterior the rated speed vary – particularly at low speeds. This requires the drive to be outsized, which increases operating costs.” Servomotors are optimized for extremely dynamic necessities and in addition cover the complete management range (1-210 pump strokes), nonetheless, they’re dearer to buy and as well as, require a servo inverter for control.
Wide-range pace management with everlasting magnet synchronous motor extends the range 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 features an extreme control range, which often makes the usage of a quantity of pumps for different flow rates unnecessary.” Particularly in the case of multiple pumps, an additional handbook stroke adjustment or electric stroke adjustment could be distributed with and the required circulate price could be realized by velocity management only. The PMSM additionally has a continuing torque. ที่วัดแรงดัน can be utilized from engine velocity 0 rpm (standstill) as much as the rated speed of the motor. This ensures notably easy and gentle system start-up, since each course of could be started with a pump capability of 1 p.c as an alternative of the standard 10 percent.
It additionally features a excessive short-term overload capacity, which enables a drive design without oversizing for the beginning torque. As a outcome, smaller, extra cost-efficient sizes can be realized than with basic drives. “Like the asynchronous motor, the PMSM may be controlled by way of a regular frequency converter, so users can rely on widespread elements,” Wirkner explained. “With the servomotor on the contrary, it will be necessary to buy costly servo controllers.” The compact drive can be easily cleaned because of its fanless design and presents high IP protection. If required an extra conversion process – referred to as nsd tupH – may be applied to the aluminum physique for FDA requirements. This makes the floor extraordinarily resistant and even easier to wash – perfect for functions with stringent hygienic necessities, similar to aroma metering in the meals industry or additive dosing within the pharmaceutical industry.
IE5+ PMSM enables cost reduction and decentralized options
The sole limitation of the at present used PMSM is that it’s only available for protected areas. “Thanks to wide-range speed control with IE5+ PMSM, we will meet the rising customer demands for a wider adjustment range and decrease vitality consumption, in addition to overall costs,” said Wirkner to sum up the scenario. “The matter of vitality efficiency in particular is turning into more and more important for our prospects. A decentralized solution during which the frequency converter is put in directly on the PMSM, can now be applied with Getriebebau NORD GmbH & Co. KG, LEWA’s motor partner for PMSM, too.”
LEWA GmbH was based in 1952 by Herbert Ott and Rudolf Schestag as a family enterprise and is today the world’s leading producer of metering pumps and course of diaphragm pumps as nicely as complete metering packages for course of engineering. Headquartered in Leonberg, the corporate developed into a world group in only a few decades. Since 2022, the corporate has been a part of the Atlas Copco Group, a globally main Swedish manufacturer of compressors, vacuum solutions, generators, pumps, power tools and meeting systems. Together with the new owner, LEWA will further increase the commercial pumps business. As a analysis and manufacturing company, LEWA develops technologies and provides options for the vast array of functions among its customers. Its merchandise are used primarily in the chemical industry, the cosmetics industry, prescribed drugs and biotechnology, meals and beverage trade and power utilities as nicely as in the manufacturing of plastics, detergents and cleaners. Additional software areas embrace refineries and petrochemicals, the oil and gasoline business, and gas odorization. LEWA at present employs round 1,200 people and owns 14 subsidiaries all over the world alongside having 80 representatives and sales places of work 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 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 also has a constant torque, i.e. all the torque could be referred to as up at velocity 0 rpm. This ensures particularly easy and delicate system start-up, since every process could be began with a conveyance rate of 1 percent as a substitute of the standard 10 %. (Example: Metering omega 3 fatty acids in 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 enables continuous operation at low speeds. Oversizing for the required pump starting torque has turn out to be pointless because of the excessive overload capability of the PMSM.
Source: LEWA GmbH
Image ID: Baugrößen_530PWebJPG.jpg
Caption: Like the asynchronous motor, the PMSM could be managed through a standard frequency converter (NORD, Danfoss, etc.) with special parameterization, in order that users can depend 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 directly 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 preliminary 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 could be driven in a spread of 1:480 up to 5 bar.
Source: LEWA GmbH
More information 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 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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