In many purposes, metering elements within the pharmaceutical or meals business for example, pumps are required that not only could be exactly managed by means of circulate price and dosing time, but additionally convey the components significantly gently. To enable the confirmed pump models of the ecodos collection from LEWA GmbH to satisfy this demanding process with even more flexibility and energy efficiency sooner or later, the producer is expanding the portfolio to include a new form of wide-range speed control. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for brief, are also used now. They are characterised by excessive power effectivity and a control range larger than 1:200. This considerably expands the range of functions. With PMSMs, it’s not necessary to use a number of pumps for different move charges or oversize asynchronous motors for low speeds. Since PMSMs can be designed with no fan, they remain compact and straightforward to scrub. The latter characteristic predestines them for hygienic applications. High efficiency ranking over the complete management range in accordance with power efficiency class IE5+ additionally reduces energy prices, thus making certain a decrease complete cost of possession (TCO).
The diaphragm metering pumps in the LEWA ecodos collection are significantly nicely suited for applications in the meals or pharmaceutical industries. All supplies in touch with the fluids used in the pump models meet the FDA and USP Class VI necessities, and the EU directives for the meals industry. In the hygienic model, for example, the pump head is manufactured from PP or electropolished stainless steel with a floor roughness < 0.5 µm. This facilitates cleansing of the surfaces in contact with the product.
The motor technologies used so far have had to make sacrifices: “For basic asynchronous motors whose rotor is a squirrel-cage rotor, the management range remains limited to 1:10 (1:50 is possible in particular person cases). With encoder feedback, vital expansion is feasible,” mentioned Maurice Wirkner, an utility manager at LEWA. “In addition, the drive is comparatively inefficient outside the rated velocity range – particularly at low speeds. This requires the drive to be outsized, which increases operating prices.” Servomotors are optimized for extremely dynamic necessities and also cover the entire control vary (1-210 pump strokes), nevertheless, they’re costlier to buy and in addition, require a servo inverter for control.
Wide-range speed control with permanent magnet synchronous motor extends the vary of functions
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 permanent magnets and rotates synchronously, i.e. without load-dependent slip,” Wirkner defined. “Among other issues, it options an extreme management range, which often makes using a number of pumps for different move charges pointless.” Particularly in the case of a quantity of pumps, a further handbook stroke adjustment or electric stroke adjustment can be dispensed with and the required flow fee may be realized by velocity control only. The PMSM also has a relentless torque. The full torque can be applied from engine speed 0 rpm (standstill) up to the rated pace of the motor. This ensures significantly smooth and delicate system start-up, since each course of can be began with a pump capacity of 1 percent as a substitute of the same old 10 p.c.
It additionally contains a high short-term overload capacity, which allows a drive design without oversizing for the starting torque. As a outcome, smaller, extra cost-efficient sizes may be realized than with basic drives. “Like the asynchronous motor, the PMSM may be managed via a regular frequency converter, so customers can rely on widespread elements,” Wirkner defined. “With the servomotor quite the opposite, it will be essential to purchase costly servo controllers.” The compact drive could be easily cleaned as a outcome of its fanless design and provides high IP protection. If required an extra conversion process – called nsd tupH – could be utilized to the aluminum body for FDA necessities. This makes the surface extraordinarily resistant and even easier to scrub – best for purposes with stringent hygienic requirements, corresponding to aroma metering in the food trade or additive dosing in the pharmaceutical trade.
IE5+ PMSM permits value discount and decentralized solutions
The sole limitation of the presently used PMSM is that it is just obtainable for safe areas. “Thanks to wide-range speed control with IE5+ PMSM, we can meet the rising customer calls for for a wider adjustment vary and lower power consumption, in addition to general costs,” mentioned Wirkner to sum up the situation. “The topic of power effectivity particularly is changing into increasingly important for our prospects. A decentralized resolution by which the frequency converter is put in instantly on the PMSM, can now be applied with Getriebebau NORD GmbH & Co. KG, LEWA’s motor partner for PMSM, too.”
LEWA GmbH was founded in 1952 by Herbert Ott and Rudolf Schestag as a household enterprise and is today the world’s leading manufacturer of metering pumps and process diaphragm pumps as nicely as full metering packages for course of engineering. Headquartered in Leonberg, the corporate developed into an international group in just some a long time. Since 2022, the company has been part of the Atlas Copco Group, a globally leading Swedish producer of compressors, vacuum options, generators, pumps, power tools and meeting methods. Together with the model new owner, LEWA will additional increase the economic pumps enterprise. As a analysis and manufacturing company, LEWA develops applied sciences and offers options for the vast array of purposes among its customers. Its merchandise are used mainly within the chemical trade, the cosmetics trade, pharmaceuticals and biotechnology, food and beverage trade and energy utilities as nicely as in the manufacturing of plastics, detergents and cleaners. Additional application areas embody refineries and petrochemicals, the oil and gas industry, and fuel odorization. LEWA currently employs around 1,200 people and owns 14 subsidiaries around the globe alongside having eighty representatives and sales places of work 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 characteristic a control vary of 1:200, enabling a wider range of applications to be lined by the same drive or pump.
Source: LEWA GmbH
Image ID: Baby food.jpg
Caption: The PMSM also has a relentless torque, i.e. all the torque can be known as up at velocity zero rpm. This ensures particularly clean and gentle system start-up, since each process may be started with a conveyance fee of 1 p.c instead of the similar old 10 p.c. (Example: Metering omega three fatty acids within the manufacturing of child 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 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 by way of a regular frequency converter (NORD, Danfoss, and so forth.) with special parameterization, in order that users can depend on common 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 in which the frequency converter is installed directly 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 preliminary functional testing with the NORD PMSM prototype and an ecodos pump on the pump test bench. In the lower velocity vary above all, the PMSM successfully demonstrated the benefits of fixed torque: the ecodos test pump could be pushed in a variety of 1:480 up to 5 bar.
Source: LEWA GmbH
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