In many purposes, metering components within the pharmaceutical or meals business for instance, pumps are required that not only can be exactly managed by method of move price and dosing time, but in addition convey the components particularly gently. To enable the confirmed pump units of the ecodos series from LEWA GmbH to meet this demanding process with even more flexibility and power effectivity in the future, the producer is increasing the portfolio to include a brand new type of wide-range pace control. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for short, are additionally used now. They are characterised by excessive vitality effectivity and a control range higher than 1:200. This significantly expands the range of applications. With PMSMs, it’s not needed to make use of a quantity of pumps for various circulate charges or oversize asynchronous motors for low speeds. Since PMSMs could be designed with no fan, they remain compact and easy to scrub. The latter feature predestines them for hygienic purposes. High effectivity rating over the complete control vary in accordance with vitality effectivity class IE5+ additionally reduces vitality prices, thus ensuring a decrease total price of ownership (TCO).
The diaphragm metering pumps in the LEWA ecodos series are particularly nicely suited for functions within the food or pharmaceutical industries. All supplies in contact with the fluids used in the pump items 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 made from PP or electropolished stainless-steel with a surface roughness < 0.5 µm. This facilitates cleaning of the surfaces involved with the product.
The motor applied sciences used so far have needed to make sacrifices: “For basic asynchronous motors whose rotor is a squirrel-cage rotor, the control vary stays limited to 1:10 (1:50 is possible in individual cases). With encoder suggestions, important expansion is possible,” mentioned Maurice Wirkner, an application manager at LEWA. “In เกจวัดอาร์กอน , the drive is comparatively inefficient exterior the rated pace range – particularly at low speeds. This requires the drive to be oversized, which increases working prices.” Servomotors are optimized for extremely dynamic requirements and likewise cover the whole management vary (1-210 pump strokes), nevertheless, they are costlier to purchase and as well as, require a servo inverter for management.
Wide-range speed control with everlasting magnet synchronous motor extends the vary of functions
LEWA has now expanded its own portfolio with a drive know-how 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 options an excessive management range, which frequently makes the use of multiple pumps for different circulate charges pointless.” Particularly in the case of a number of pumps, an extra handbook stroke adjustment or electrical stroke adjustment can be allotted with and the required flow rate may be realized by pace control only. The PMSM also has a continuing torque. The full torque can be applied from engine pace zero rpm (standstill) as much as the rated pace of the motor. This ensures particularly easy and gentle system start-up, since every course of may be started with a pump capability of 1 % as an alternative of the same old 10 p.c.
It also contains a high short-term overload capability, which allows a drive design without oversizing for the starting torque. As a end result, smaller, more cost-efficient sizes could be realized than with traditional drives. “Like the asynchronous motor, the PMSM can be controlled through a normal frequency converter, so customers can depend on frequent parts,” Wirkner defined. “With the servomotor quite the opposite, it would be needed to buy expensive servo controllers.” The compact drive can be easily cleaned as a end result of its fanless design and presents high IP safety. If required an additional conversion process – referred to as nsd tupH – may be applied to the aluminum body for FDA requirements. This makes the surface extremely resistant and even easier to clean – ideal for functions with stringent hygienic necessities, corresponding to aroma metering within the meals trade or additive dosing within the pharmaceutical business.
IE5+ PMSM permits price discount and decentralized options
The sole limitation of the currently used PMSM is that it’s only obtainable for secure areas. “Thanks to wide-range speed control with IE5+ PMSM, we will meet the increasing customer calls for for a wider adjustment range and decrease power consumption, as well as overall costs,” said Wirkner to sum up the scenario. “The topic of vitality efficiency specifically is changing into more and more important for our clients. A decentralized answer by which the frequency converter is installed directly 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 enterprise and is today the world’s leading producer of metering pumps and course of diaphragm pumps in addition to complete metering packages for process engineering. Headquartered in Leonberg, the corporate developed into a global group in only a few many years. Since 2022, the company has been a half of the Atlas Copco Group, a globally main Swedish producer of compressors, vacuum solutions, mills, pumps, power tools and meeting systems. Together with the new owner, LEWA will additional expand the industrial pumps business. As a research and manufacturing company, LEWA develops applied sciences and provides solutions for the huge array of purposes among its customers. Its products are used primarily in the chemical industry, the cosmetics industry, prescribed drugs and biotechnology, food and beverage trade and vitality utilities in addition to within the manufacturing of plastics, detergents and cleaners. Additional software areas include refineries and petrochemicals, the oil and gas business, and fuel odorization. LEWA at present employs round 1,200 people and owns 14 subsidiaries around the globe alongside having eighty representatives and sales workplaces in more 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 characteristic a control 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 food.jpg
Caption: The PMSM also has a continuing torque, i.e. all the torque can be referred to as up at velocity zero rpm. This ensures notably clean and mild system start-up, since every course of could be started with a conveyance price of 1 percent instead of the standard 10 p.c. (Example: Metering omega three fatty acids in 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 enables continuous operation at low speeds. Oversizing for the required pump starting torque has become unnecessary as a result of high overload functionality of the PMSM.
Source: LEWA GmbH
Image ID: Baugrößen_530PWebJPG.jpg
Caption: Like the asynchronous motor, the PMSM may be managed through a standard frequency converter (NORD, Danfoss, etc.) with special parameterization, so that customers can depend on widespread 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 solutions in which the frequency converter is installed directly on the PMSM are also already potential 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 lower velocity range above all, the PMSM efficiently demonstrated the benefits of constant torque: the ecodos take a look at pump might be driven in a range of 1:480 up to 5 bar.
Source: LEWA GmbH
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