In many applications, metering elements in the pharmaceutical or meals business for example, pumps are required that not only can be exactly managed in terms of circulate price and dosing time, but also convey the ingredients particularly gently. To allow the proven pump units of the ecodos sequence from LEWA GmbH to fulfill this demanding activity with even more flexibility and vitality efficiency sooner or later, the producer is increasing the portfolio to incorporate a brand new type of wide-range velocity control. Alongside asynchronous motors and servomotors, everlasting magnet synchronous motors, or PMSMs for brief, are additionally used now. They are characterized by excessive vitality effectivity and a management range higher than 1:200. This significantly expands the vary of applications. With PMSMs, it’s no longer needed to make use of several pumps for different move rates or oversize asynchronous motors for low speeds. Since PMSMs can be designed without a fan, they remain compact and straightforward to clean. The latter feature predestines them for hygienic purposes. High efficiency score over the whole control range in accordance with vitality effectivity class IE5+ also reduces energy costs, thus ensuring a decrease total price of ownership (TCO).
The diaphragm metering pumps in the LEWA ecodos series are significantly nicely fitted to applications in the meals or pharmaceutical industries. All materials in touch with the fluids used within the pump units meet the FDA and USP Class VI requirements, and the EU directives for the meals industry. 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 contact with the product.
The motor technologies used thus far have needed to make sacrifices: “For traditional asynchronous motors whose rotor is a squirrel-cage rotor, the management range remains limited to 1:10 (1:50 is feasible in individual cases). With encoder feedback, important enlargement is possible,” stated Maurice Wirkner, an application manager at LEWA. “In addition, the drive is relatively inefficient outdoors the rated velocity range – especially at low speeds. This requires the drive to be oversized, which increases working prices.” Servomotors are optimized for extremely dynamic necessities and also cowl the entire management range (1-210 pump strokes), however, they are dearer to purchase and in addition, require a servo inverter for control.
Wide-range pace control with permanent magnet synchronous motor extends the vary of applications
LEWA has now expanded its personal portfolio with a drive know-how that does not have these weaknesses. “Unlike the asynchronous motor, the rotor of this drive consists of permanent magnets and rotates synchronously, i.e. with out load-dependent slip,” Wirkner defined. “Among other things, it features an excessive management range, which often makes using multiple pumps for different move rates pointless.” Particularly within the case of multiple pumps, a further guide stroke adjustment or electric stroke adjustment could be allotted with and the required flow fee could be realized by speed control solely. The PMSM additionally has a continuing torque. The complete torque may be utilized from engine pace 0 rpm (standstill) as a lot as the rated pace of the motor. This ensures significantly smooth and gentle system start-up, since each course of could be began with a pump capacity of 1 percent as an alternative of the same old 10 p.c.
It additionally includes a high short-term overload capacity, which enables a drive design with out oversizing for the beginning torque. As a outcome, smaller, extra cost-efficient sizes could be realized than with classic drives. “Like the asynchronous motor, the PMSM could be controlled via a normal frequency converter, so users can depend on widespread elements,” Wirkner defined. “With the servomotor quite the opposite, it might be needed to purchase costly servo controllers.” The compact drive may be simply cleaned because of its fanless design and offers high IP protection. If required a further conversion course of – referred to as nsd tupH – may be utilized to the aluminum body for FDA requirements. This makes the floor extremely resistant and even simpler to wash – perfect for purposes with stringent hygienic necessities, corresponding to aroma metering in the food trade or additive dosing in the pharmaceutical industry.
IE5+ PMSM enables cost reduction and decentralized solutions
The sole limitation of the presently used PMSM is that it’s only obtainable for protected areas. “Thanks to wide-range velocity control with IE5+ PMSM, we can meet the growing customer calls for for a wider adjustment vary and lower vitality consumption, in addition to overall prices,” mentioned Wirkner to sum up the situation. “The matter of vitality effectivity specifically is changing into more and more necessary for our prospects. A decentralized resolution in which the frequency converter is put in immediately on the PMSM, can now be implemented with Getriebebau NORD GmbH & Co. KG, LEWA’s motor associate for PMSM, too.”
LEWA GmbH was based in 1952 by Herbert Ott and Rudolf Schestag as a family business and is at present the world’s main producer of metering pumps and process diaphragm pumps in addition to full metering packages for course of engineering. Headquartered in Leonberg, the corporate developed into a global group in only a few decades. Since 2022, the company has been part of the Atlas Copco Group, a globally main Swedish producer of compressors, vacuum options, turbines, pumps, energy tools and assembly techniques. Together with the brand new proprietor, LEWA will additional expand the economic pumps business. As a research and manufacturing firm, LEWA develops applied sciences and offers options for the huge array of functions among its prospects. Its merchandise are used mainly in the chemical trade, the cosmetics trade, prescription drugs and biotechnology, meals and beverage business and power utilities as well as in the manufacturing of plastics, detergents and cleaners. Additional application areas embrace refineries and petrochemicals, the oil and gasoline trade, and gasoline odorization. LEWA presently employs around 1,200 folks and owns 14 subsidiaries around the globe alongside having 80 representatives and gross sales places of work in additional than eighty international locations.
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 function a management vary of 1:200, enabling a wider range of applications to be coated by the identical drive or pump.
Source: LEWA GmbH
Image ID: Baby food.jpg
Caption: The PMSM also has a constant torque, i.e. the entire torque may be referred to as up at speed 0 rpm. This ensures significantly easy and gentle system start-up, since each course of may be started with a conveyance fee of 1 percent as an alternative of the standard 10 percent. (Example: Metering omega three fatty acids within the production of baby food)
Source: Adobe Stock
Image ID: Torque.jpg
Caption: In distinction to the ASMs shown, the constant torque of the PMSM allows continuous operation at low speeds. Oversizing for the required pump beginning torque has turn out to be unnecessary due to the excessive overload functionality of the PMSM.
Source: LEWA GmbH
Image ID: Baugrößen_530PWebJPG.jpg
Caption: Like the asynchronous motor, the PMSM could be controlled via a normal frequency converter (NORD, Danfoss, etc.) with particular parameterization, so that customers can depend on widespread 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 options during which the frequency converter is put in directly on the PMSM are also already attainable with the PMSMs selected by LEWA.
เพรสเชอร์เกจ4นิ้ว : Getriebebau NORD GmbH & Co. KG
Image ID: Functional testing.jpg
Caption: As early as 2020, LEWA carried out preliminary useful testing with the NORD PMSM prototype and an ecodos pump on the pump take a look at bench. In the decrease speed vary above all, the PMSM efficiently demonstrated some great advantages of fixed torque: the ecodos take a look at pump might be driven in a variety of 1:480 up to 5 bar.
Source: LEWA GmbH
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