In many purposes, metering elements in the pharmaceutical or food trade for instance, pumps are required that not solely can be precisely managed in terms of circulate price and dosing time, but also convey the elements particularly gently. To enable the confirmed pump units of the ecodos sequence from LEWA GmbH to satisfy this demanding activity with much more flexibility and energy effectivity sooner or later, the manufacturer is increasing the portfolio to incorporate a 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 high vitality efficiency and a management vary greater than 1:200. This significantly expands the range of applications. With PMSMs, it is now not needed to use several pumps for various move rates or oversize asynchronous motors for low speeds. Since PMSMs may be designed and not using a fan, they proceed to be compact and straightforward to scrub. The latter function predestines them for hygienic purposes. High efficiency score over the whole control range in accordance with power efficiency class IE5+ also reduces vitality prices, thus guaranteeing a lower total value of possession (TCO).
The diaphragm metering pumps within the LEWA ecodos collection are particularly well fitted to purposes within the food or pharmaceutical industries. All materials 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 trade. In the hygienic model, for instance, the pump head is manufactured from PP or electropolished stainless-steel with a surface roughness < zero.5 µm. เครื่องมือที่ใช้วัดความดัน facilitates cleaning of the surfaces in contact with the product.
The motor applied sciences used to date have needed to make sacrifices: “For traditional asynchronous motors whose rotor is a squirrel-cage rotor, the control vary remains restricted to 1:10 (1:50 is possible in individual cases). With encoder feedback, important expansion is possible,” said Maurice Wirkner, an software manager at LEWA. “In addition, the drive is comparatively inefficient outside the rated speed range – particularly at low speeds. This requires the drive to be outsized, which increases working prices.” Servomotors are optimized for extremely dynamic necessities and also cover the entire control vary (1-210 pump strokes), nevertheless, they’re dearer to buy and in addition, require a servo inverter for management.
Wide-range velocity management with permanent magnet synchronous motor extends the range of purposes
LEWA has now expanded its personal 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 defined. “Among different issues, it options an extreme control vary, which regularly makes the use of a quantity of pumps for different circulate charges pointless.” Particularly in the case of multiple pumps, a further guide stroke adjustment or electric stroke adjustment may be allotted with and the required circulate rate could be realized by pace management solely. The PMSM additionally has a constant torque. The full torque can be applied from engine pace 0 rpm (standstill) as a lot as the rated pace of the motor. This ensures notably smooth and delicate system start-up, since every process could be started with a pump capacity of 1 percent instead of the usual 10 p.c.
It additionally includes a excessive short-term overload capability, which enables a drive design without oversizing for the starting torque. As a end result, smaller, extra cost-efficient sizes could be realized than with classic drives. “Like the asynchronous motor, the PMSM could be controlled via a regular frequency converter, so users can rely on common components,” Wirkner explained. “With the servomotor quite the opposite, it would be needed to buy costly servo controllers.” The compact drive could be easily cleaned because of its fanless design and presents high IP protection. If required an extra conversion course of – known as nsd tupH – may be utilized to the aluminum physique for FDA requirements. This makes the floor extraordinarily resistant and even simpler to wash – perfect for applications with stringent hygienic necessities, corresponding to aroma metering within the meals industry or additive dosing in the pharmaceutical industry.
IE5+ PMSM enables value reduction and decentralized solutions
The sole limitation of the currently used PMSM is that it is just available for safe areas. “Thanks to wide-range pace management with IE5+ PMSM, we will meet the increasing buyer demands for a wider adjustment range and decrease energy consumption, as well as overall costs,” said Wirkner to sum up the situation. “The matter of power efficiency in particular is changing into more and more important for our customers. A decentralized resolution during which the frequency converter is installed instantly on the PMSM, can now be carried out 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 household enterprise and is today the world’s main producer of metering pumps and course of 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 decades. Since 2022, the corporate has been part of the Atlas Copco Group, a globally leading Swedish producer of compressors, vacuum options, mills, pumps, power instruments and assembly techniques. Together with the brand new proprietor, LEWA will further expand the economic pumps enterprise. As a research and manufacturing firm, LEWA develops technologies and offers solutions for the vast array of applications amongst its clients. Its products are used mainly in the chemical industry, the cosmetics industry, prescribed drugs and biotechnology, food and beverage business and power utilities as well as in the manufacturing of plastics, detergents and cleaners. Additional software areas embody refineries and petrochemicals, the oil and gasoline industry, and gasoline odorization. LEWA presently employs round 1,200 folks and owns 14 subsidiaries all over the world alongside having eighty representatives and sales places of work in additional than 80 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 control range of 1:200, enabling a wider vary of purposes to be coated by the identical drive or pump.
Source: LEWA GmbH
Image ID: Baby meals.jpg
Caption: The PMSM also has a relentless torque, i.e. all the torque could be called up at speed zero rpm. This ensures notably smooth and mild system start-up, since every process may be started with a conveyance price of 1 % as a substitute of the same old 10 %. (Example: Metering omega 3 fatty acids within the manufacturing of child food)
Source: Adobe Stock
Image ID: Torque.jpg
Caption: In distinction to the ASMs shown, the fixed torque of the PMSM permits steady operation at low speeds. Oversizing for the required pump beginning torque has turn out to be unnecessary because of the excessive overload capability of the PMSM.
Source: LEWA GmbH
Image ID: Baugrößen_530PWebJPG.jpg
Caption: Like the asynchronous motor, the PMSM may be controlled via a normal frequency converter (NORD, Danfoss, and so on.) with particular parameterization, in order that customers 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 during which the frequency converter is installed 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 initial useful testing with the NORD PMSM prototype and an ecodos pump on the pump take a look at bench. In the decrease velocity vary above all, the PMSM efficiently demonstrated some nice advantages of fixed torque: the ecodos check pump might be pushed in a variety of 1:480 as a lot as 5 bar.
Source: LEWA GmbH
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