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

In many functions, metering elements in the pharmaceutical or food business for example, pumps are required that not solely may be exactly controlled by means of circulate price and dosing time, but in addition convey the ingredients particularly gently. To allow เพรสเชอร์เกจไฮดรอลิค proven pump units of the ecodos series from LEWA GmbH to satisfy this demanding process with even more flexibility and vitality efficiency sooner or later, the manufacturer is expanding the portfolio to include a brand new type of wide-range speed management. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for short, are also used now. They are characterised by excessive power efficiency and a control vary greater than 1:200. This significantly expands the range of purposes. With PMSMs, it is now not needed to make use of a quantity of pumps for various move rates or oversize asynchronous motors for low speeds. Since PMSMs can be designed with no fan, they remain compact and easy to scrub. The latter function predestines them for hygienic purposes. High effectivity ranking over the whole management vary in accordance with energy efficiency class IE5+ additionally reduces vitality prices, thus ensuring a lower whole value of ownership (TCO).
The diaphragm metering pumps within the LEWA ecodos sequence are particularly nicely fitted to purposes within the meals or pharmaceutical industries. All supplies involved with the fluids used within the pump models meet the FDA and USP Class VI necessities, and the EU directives for the meals trade. In the hygienic version, for instance, the pump head is manufactured from PP or electropolished stainless steel with a floor roughness < 0.5 µm. This facilitates cleaning of the surfaces involved with the product.
The motor applied sciences used thus far have needed to make sacrifices: “For classic asynchronous motors whose rotor is a squirrel-cage rotor, the management range stays restricted to 1:10 (1:50 is possible in particular person cases). With encoder feedback, significant growth is possible,” mentioned Maurice Wirkner, an application supervisor at LEWA. “In addition, the drive is comparatively inefficient outdoors the rated pace range – especially at low speeds. This requires the drive to be oversized, which will increase operating costs.” Servomotors are optimized for extremely dynamic necessities and likewise cover the whole management range (1-210 pump strokes), however, they are more expensive to buy and in addition, require a servo inverter for management.
Wide-range speed control with everlasting magnet synchronous motor extends the range of purposes
LEWA has now expanded its own portfolio with a drive know-how that doesn’t 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 explained. “Among different issues, it options an excessive management vary, which regularly makes using multiple pumps for various move rates unnecessary.” Particularly within the case of multiple pumps, an extra guide stroke adjustment or electrical stroke adjustment could be distributed with and the required circulate price could be realized by pace control only. The PMSM additionally has a constant torque. The complete torque could be applied from engine velocity zero rpm (standstill) as much as the rated speed of the motor. This ensures particularly smooth and gentle system start-up, since each course of may be began with a pump capacity of 1 % instead of the identical old 10 %.
It additionally features 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 can be realized than with basic drives. “Like the asynchronous motor, the PMSM can be managed via a normal frequency converter, so users can rely on frequent elements,” Wirkner explained. “With the servomotor quite the opposite, it might be essential to purchase costly servo controllers.” The compact drive can be easily cleaned because of its fanless design and offers high IP protection. If required an extra conversion process – called nsd tupH – may be applied to the aluminum physique for FDA necessities. This makes the floor extraordinarily resistant and even easier to wash – perfect for purposes with stringent hygienic requirements, corresponding to aroma metering within the food industry or additive dosing within the pharmaceutical industry.
IE5+ PMSM permits cost discount and decentralized solutions
The sole limitation of the currently used PMSM is that it’s only out there for safe areas. “Thanks to wide-range speed management with IE5+ PMSM, we are in a position to meet the growing customer calls for for a wider adjustment vary and decrease energy consumption, as well as overall costs,” stated Wirkner to sum up the state of affairs. “The matter of power effectivity in particular is changing into increasingly essential for our clients. A decentralized resolution by which the frequency converter is put in directly on the PMSM, can now be carried out with Getriebebau NORD GmbH & Co. KG, LEWA’s motor companion for PMSM, too.”
LEWA GmbH was founded in 1952 by Herbert Ott and Rudolf Schestag as a family enterprise and is today the world’s main manufacturer of metering pumps and course of diaphragm pumps in addition to full metering packages for process engineering. Headquartered in Leonberg, the company developed into an international group in only a few many years. Since 2022, the corporate has been part of the Atlas Copco Group, a globally main Swedish producer of compressors, vacuum options, turbines, pumps, power instruments and meeting techniques. Together with the model new owner, LEWA will additional broaden the economic pumps business. As a analysis and manufacturing company, LEWA develops applied sciences and supplies solutions for the huge array of functions among its customers. Its merchandise are used primarily within the chemical business, the cosmetics business, pharmaceuticals and biotechnology, meals and beverage business and energy utilities as nicely as within the manufacturing of plastics, detergents and cleaners. Additional software areas embody refineries and petrochemicals, the oil and gas industry, and gas odorization. LEWA at present employs around 1,200 individuals and owns 14 subsidiaries around 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 feature a control vary of 1:200, enabling a wider range of purposes 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. all the torque could be referred to as up at velocity 0 rpm. This ensures particularly clean and delicate system start-up, since every course of may be started with a conveyance fee of 1 percent instead of the similar old 10 percent. (Example: Metering omega three fatty acids within 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 allows steady operation at low speeds. Oversizing for the required pump starting torque has turn out to be pointless 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 managed through a regular frequency converter (NORD, Danfoss, and so forth.) with particular parameterization, so that customers can depend on frequent 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 immediately 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 initial functional testing with the NORD PMSM prototype and an ecodos pump on the pump test bench. In the lower velocity range 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 up to 5 bar.
Source: LEWA GmbH
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Email: lewa@lewa.de
Internet: www.lewa.de
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Phone: +49 89 500315-20, Fax: +49 89 500315-15
Email: info@abopr.de
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