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

In many functions, metering ingredients in the pharmaceutical or meals industry for instance, pumps are required that not solely can be exactly managed when it comes to move price and dosing time, but in addition convey the elements particularly gently. To enable the confirmed pump models of the ecodos series from LEWA GmbH to meet this demanding task with much more flexibility and power effectivity in the future, the producer is increasing the portfolio to incorporate a model new form of wide-range speed management. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for brief, are also used now. They are characterised by high vitality effectivity and a control vary higher than 1:200. This significantly expands the range of applications. With PMSMs, it’s now not necessary to use several pumps for various move charges or oversize asynchronous motors for low speeds. Since PMSMs may be designed and not utilizing a fan, they remain compact and straightforward to wash. The latter function predestines them for hygienic applications. High efficiency score over the entire management range in accordance with power efficiency class IE5+ additionally reduces power costs, thus guaranteeing a lower total cost of possession (TCO).
The diaphragm metering pumps in the LEWA ecodos series are notably nicely suited for purposes in the food or pharmaceutical industries. All materials involved with the fluids used within the pump models meet the FDA and USP Class VI necessities, and the EU directives for the meals business. In the hygienic model, for example, the pump head is made from PP or electropolished stainless-steel with a surface roughness < zero.5 µm. This facilitates cleansing of the surfaces in touch with the product.
The motor applied sciences used to date have needed to make sacrifices: “For basic asynchronous motors whose rotor is a squirrel-cage rotor, the control range remains restricted to 1:10 (1:50 is feasible in particular person cases). With encoder suggestions, important expansion is possible,” stated Maurice Wirkner, an application supervisor at LEWA. “In addition, the drive is comparatively inefficient outside the rated pace range – particularly at low speeds. This requires the drive to be outsized, which will increase working costs.” Servomotors are optimized for highly dynamic requirements and also cowl the entire management vary (1-210 pump strokes), however, they are more expensive to purchase and as nicely as, require a servo inverter for management.
Wide-range speed control with permanent magnet synchronous motor extends the range of purposes
LEWA has now expanded its own 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 defined. “Among other things, it options an extreme control range, which often makes the usage of multiple pumps for various move rates pointless.” Particularly in the case of multiple pumps, a further manual stroke adjustment or electrical stroke adjustment could be dispensed with and the required flow fee can be realized by speed control only. The PMSM additionally has a constant torque. The full torque may be applied from engine speed 0 rpm (standstill) as much as the rated speed of the motor. This ensures notably easy and delicate system start-up, since each process could be began with a pump capability of 1 % as a substitute of the usual 10 %.
It additionally features a excessive short-term overload capacity, which enables a drive design without oversizing for the starting torque. As a result, smaller, more cost-efficient sizes can be realized than with traditional drives. “Like the asynchronous motor, the PMSM could be controlled through a normal frequency converter, so users can depend on common elements,” Wirkner explained. “With the servomotor on the contrary, it would be essential to buy expensive servo controllers.” The compact drive can be easily cleaned due to its fanless design and offers high IP safety. If required a further conversion process – referred to 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 applications with stringent hygienic requirements, such as aroma metering in the meals industry or additive dosing in the pharmaceutical industry.
IE5+ PMSM allows price discount and decentralized solutions
The sole limitation of the presently used PMSM is that it’s only obtainable for protected areas. “Thanks to wide-range pace control with IE5+ PMSM, we can meet the increasing customer calls for for a wider adjustment range and decrease power consumption, in addition to total costs,” said Wirkner to sum up the scenario. “The matter of vitality effectivity particularly is turning into increasingly essential for our clients. 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 associate for PMSM, too.”
Explode was based in 1952 by Herbert Ott and Rudolf Schestag as a family enterprise and is right now the world’s leading manufacturer of metering pumps and process diaphragm pumps in addition to complete metering packages for process engineering. Headquartered in Leonberg, the company developed into a world group in just a few a long time. Since 2022, the company has been part of the Atlas Copco Group, a globally main Swedish producer of compressors, vacuum solutions, mills, pumps, power tools and meeting techniques. Together with the brand new proprietor, LEWA will additional increase the industrial pumps business. As a research and manufacturing firm, LEWA develops technologies and provides options for the vast array of functions among its clients. Its merchandise are used primarily within the chemical business, the cosmetics trade, prescription drugs and biotechnology, meals and beverage industry and vitality utilities as well as in the manufacturing of plastics, detergents and cleaners. Additional utility areas include refineries and petrochemicals, the oil and fuel trade, and fuel odorization. LEWA presently employs around 1,200 folks and owns 14 subsidiaries all over the world alongside having eighty representatives and sales workplaces 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 management range of 1:200, enabling a wider vary of purposes to be coated 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 can be referred to as up at pace zero rpm. This ensures particularly clean and delicate system start-up, since each process may be started with a conveyance rate of 1 p.c as a substitute of the standard 10 %. (Example: Metering omega 3 fatty acids in the production of baby food)
Source: Adobe Stock
Image ID: Torque.jpg
Caption: In distinction to the ASMs proven, the fixed torque of the PMSM permits continuous operation at low speeds. Oversizing for the required pump starting torque has turn out to be pointless due to the high overload capability of the PMSM.
Source: LEWA GmbH
Image ID: Baugrößen_530PWebJPG.jpg
Caption: Like the asynchronous motor, the PMSM can be controlled by way of a regular frequency converter (NORD, Danfoss, and so on.) with particular parameterization, in order that users can depend on common 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 installed directly on the PMSM are additionally already attainable with the PMSMs chosen 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 test bench. In the lower speed vary above all, the PMSM successfully demonstrated some great advantages of fixed torque: the ecodos check pump might be driven in a variety of 1:480 as a lot as 5 bar.
Source: LEWA GmbH
More information for readers/viewers/interested events:
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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