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

In many purposes, metering ingredients in the pharmaceutical or food trade for example, pumps are required that not only may be exactly controlled when it comes to circulate fee and dosing time, but additionally convey the elements notably gently. To allow the confirmed pump models of the ecodos collection from LEWA GmbH to fulfill this demanding task with much more flexibility and power effectivity sooner or later, the producer is expanding the portfolio to include a model new type of wide-range velocity management. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for brief, are additionally used now. They are characterised by excessive vitality efficiency and a control vary larger than 1:200. This considerably expands the vary of functions. With PMSMs, it’s no longer needed to make use of a quantity of pumps for various move charges or oversize asynchronous motors for low speeds. Since PMSMs could be designed and not using a fan, they remain compact and straightforward to wash. The latter function predestines them for hygienic purposes. High efficiency rating over the complete management vary in accordance with energy effectivity class IE5+ also reduces vitality costs, thus guaranteeing a lower whole price of ownership (TCO).
The diaphragm metering pumps within the LEWA ecodos sequence are notably properly suited for functions in the food or pharmaceutical industries. All supplies involved with the fluids used within the pump items meet the FDA and USP Class VI necessities, and the EU directives for the meals industry. In the hygienic version, for instance, 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 technologies used to date have needed to make sacrifices: “For basic asynchronous motors whose rotor is a squirrel-cage rotor, the management vary stays limited to 1:10 (1:50 is feasible in individual cases). With encoder feedback, significant growth is feasible,” said Maurice Wirkner, an utility supervisor at LEWA. “In addition, the drive is comparatively inefficient outdoors the rated pace vary – particularly at low speeds. This requires the drive to be oversized, which increases working prices.” Servomotors are optimized for highly dynamic requirements and in addition cowl the entire management vary (1-210 pump strokes), however, they’re dearer to buy and in addition, 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 personal portfolio with a drive expertise 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 defined. “Among other issues, it features an excessive management vary, which often makes the usage of multiple pumps for different flow charges unnecessary.” Particularly within the case of a number of pumps, a further guide stroke adjustment or electric stroke adjustment may be distributed with and the required flow price could be realized by velocity management only. The PMSM additionally has a continuing torque. The full torque can be utilized from engine speed 0 rpm (standstill) as much as the rated pace of the motor. This ensures particularly clean and delicate system start-up, since each process may be began with a pump capability of 1 p.c instead of the similar old 10 p.c.
It also contains a excessive short-term overload capacity, which allows a drive design with out oversizing for the starting torque. As a outcome, smaller, extra cost-efficient sizes could be realized than with basic drives. “Like the asynchronous motor, the PMSM can be managed via a normal frequency converter, so users can depend on widespread elements,” Wirkner explained. “With the servomotor quite the opposite, it would be needed to buy costly servo controllers.” The compact drive can be easily cleaned because of its fanless design and presents high IP safety. If required an additional conversion process – known as nsd tupH – may be utilized to the aluminum body for FDA necessities. This makes the surface extraordinarily resistant and even simpler to clean – perfect for applications with stringent hygienic necessities, corresponding to aroma metering in the meals business or additive dosing within the pharmaceutical industry.
IE5+ PMSM permits price reduction and decentralized solutions

The sole limitation of the at present used PMSM is that it is just obtainable for safe areas. “Thanks to wide-range speed management with IE5+ PMSM, we can meet the growing buyer calls for for a wider adjustment vary and lower power consumption, in addition to general costs,” said Wirkner to sum up the scenario. “The matter of energy efficiency specifically is turning into increasingly essential for our prospects. A decentralized resolution during which the frequency converter is put in instantly on the PMSM, can now be implemented 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 household business and is right now the world’s leading manufacturer of metering pumps and process diaphragm pumps as well as complete metering packages for process engineering. Headquartered in Leonberg, the corporate developed into an international group in only a few a long time. Since 2022, the corporate has been a part of the Atlas Copco Group, a globally leading Swedish manufacturer of compressors, vacuum options, mills, pumps, energy tools and assembly methods. Together with the brand new owner, LEWA will further broaden the industrial pumps enterprise. As a analysis and manufacturing company, LEWA develops technologies and provides options for the vast array of purposes among its clients. Its merchandise are used mainly in the chemical business, the cosmetics business, prescribed drugs and biotechnology, meals and beverage trade and vitality utilities in addition to within the production of plastics, detergents and cleaners. Additional application areas embody refineries and petrochemicals, the oil and gasoline trade, and gas odorization. LEWA presently employs around 1,200 people and owns 14 subsidiaries around the globe alongside having 80 representatives and gross sales offices in additional than 80 nations.
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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 vary of purposes to be covered 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 zero rpm. This ensures particularly smooth and gentle system start-up, since every process could be started with a conveyance rate of 1 p.c instead of the standard 10 p.c. (Example: Metering omega 3 fatty acids within 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 enables continuous operation at low speeds. Oversizing for the required pump beginning torque has turn into unnecessary because of the excessive overload functionality of the PMSM.
Source: LEWA GmbH

Image ID: Baugrößen_530PWebJPG.jpg

Caption: Like the asynchronous motor, the PMSM could be managed through a normal frequency converter (NORD, Danfoss, and so on.) with special parameterization, in order that users can rely 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 during which the frequency converter is installed immediately on the PMSM are additionally already possible 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 practical testing with the NORD PMSM prototype and an ecodos pump on the pump test bench. In the decrease velocity range above all, the PMSM efficiently demonstrated some nice benefits of constant torque: the ecodos check pump could be pushed in a range of 1:480 up to 5 bar.
Source: LEWA GmbH

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Internet: www.lewa.de

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Phone: +49 89 500315-20, Fax: +49 89 500315-15

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