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

In many applications, metering ingredients in the pharmaceutical or food industry for example, pumps are required that not solely may be exactly managed by means of flow rate and dosing time, but also convey the components notably gently. To allow the proven pump items of the ecodos series from LEWA GmbH to fulfill this demanding process with much more flexibility and energy effectivity sooner or later, the producer is expanding the portfolio to incorporate a brand new type of wide-range velocity management. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for short, are also used now. They are characterised by high vitality effectivity and a management vary larger than 1:200. This significantly expands the range of purposes. With PMSMs, it’s not essential to make use of several pumps for different flow charges or oversize asynchronous motors for low speeds. Since PMSMs can be designed without a fan, they proceed to be compact and easy to clean. The latter feature predestines them for hygienic functions. High efficiency ranking over the complete control vary in accordance with energy effectivity class IE5+ additionally reduces power prices, thus making certain a lower whole value of ownership (TCO).
The diaphragm metering pumps in the LEWA ecodos sequence are notably well suited for purposes in the food or pharmaceutical industries. All supplies in contact with the fluids used within the pump units meet the FDA and USP Class VI necessities, and the EU directives for the food industry. In the hygienic model, for example, the pump head is made of PP or electropolished chrome steel with a surface roughness < 0.5 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 vary remains limited to 1:10 (1:50 is possible in individual cases). With encoder suggestions, vital growth is possible,” said Maurice Wirkner, an software supervisor at LEWA. “In addition, the drive is comparatively inefficient outside the rated velocity vary – especially at low speeds. This requires the drive to be outsized, which will increase working costs.” Servomotors are optimized for extremely dynamic necessities and also cover the entire management range (1-210 pump strokes), however, they’re costlier to purchase and as properly as, require a servo inverter for control.
Wide-range velocity control with everlasting magnet synchronous motor extends the range of functions
LEWA has now expanded its own portfolio with a drive expertise that does not 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 control range, which regularly makes using multiple pumps for various flow rates unnecessary.” Particularly in the case of a number of pumps, an extra handbook stroke adjustment or electric stroke adjustment may be allotted with and the required move fee can be realized by speed management solely. The PMSM also has a constant torque. The complete torque could be utilized from engine speed 0 rpm (standstill) up to the rated velocity of the motor. This ensures particularly smooth and mild system start-up, since each process can be started with a pump capability of 1 % instead of the same old 10 %.
It also contains a excessive short-term overload capability, which allows a drive design without oversizing for the beginning torque. As a end result, smaller, more cost-efficient sizes could be realized than with classic drives. “Like the asynchronous motor, the PMSM can be controlled through a normal frequency converter, so users can depend on frequent elements,” Wirkner explained. “With the servomotor quite the opposite, it would be needed to purchase costly servo controllers.” The compact drive can be easily cleaned due to its fanless design and provides high IP protection. If required an extra conversion process – called nsd tupH – could be applied to the aluminum body for FDA requirements. This makes the floor extremely resistant and even easier to wash – ideal for functions with stringent hygienic necessities, such as aroma metering in the food business or additive dosing within the pharmaceutical industry.
IE5+ PMSM enables cost discount and decentralized options
The sole limitation of the currently used PMSM is that it is just out there for safe areas. “Thanks to wide-range velocity control with IE5+ PMSM, we can meet the increasing buyer demands for a wider adjustment range and decrease power consumption, in addition to total costs,” mentioned Wirkner to sum up the situation. “The subject of vitality effectivity specifically is turning into increasingly essential for our clients. A decentralized resolution in which the frequency converter is put in instantly on the PMSM, can now be implemented with Getriebebau NORD GmbH & Co. KG, LEWA’s motor associate for PMSM, too.”
LEWA GmbH was founded in 1952 by Herbert Ott and Rudolf Schestag as a family enterprise and is right now the world’s main producer of metering pumps and process diaphragm pumps in addition to full metering packages for process engineering. Headquartered in Leonberg, the company developed into a world group in only a few decades. Since 2022, the corporate has been a part of the Atlas Copco Group, a globally main Swedish manufacturer of compressors, vacuum solutions, mills, pumps, energy instruments and meeting techniques. Together with the new proprietor, LEWA will further expand the commercial pumps enterprise. As a research and manufacturing firm, LEWA develops applied sciences and supplies options for the vast array of functions amongst its clients. Its merchandise are used primarily within the chemical industry, the cosmetics business, prescription drugs and biotechnology, meals and beverage business and power utilities as properly as in the manufacturing of plastics, detergents and cleaners. ราคาเกจวัดแรงดันลม include refineries and petrochemicals, the oil and gas trade, and gasoline odorization. LEWA currently 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.
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 functions to be covered by the identical drive or pump.
Source: LEWA GmbH
Image ID: Baby meals.jpg
Caption: The PMSM additionally has a continuing torque, i.e. the entire torque may be called up at pace 0 rpm. This ensures notably smooth and mild system start-up, since each process could be started with a conveyance rate of 1 % instead of the standard 10 %. (Example: Metering omega 3 fatty acids in the manufacturing of baby food)
Source: Adobe Stock
Image ID: Torque.jpg
Caption: In distinction to the ASMs proven, the fixed torque of the PMSM permits steady operation at low speeds. Oversizing for the required pump starting torque has become unnecessary because of the high overload capability of the PMSM.
Source: LEWA GmbH
Image ID: Baugrößen_530PWebJPG.jpg
Caption: Like the asynchronous motor, the PMSM could be controlled through a standard frequency converter (NORD, Danfoss, etc.) with particular parameterization, in order that customers can rely 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 additionally already potential 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 useful testing with the NORD PMSM prototype and an ecodos pump on the pump test bench. In the decrease velocity vary above all, the PMSM efficiently demonstrated the benefits of constant torque: the ecodos test pump might be pushed in a spread of 1:480 as much as 5 bar.
Source: LEWA GmbH
More info 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 info 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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