In many applications, metering components in the pharmaceutical or meals industry for example, pumps are required that not solely can be precisely controlled in phrases of move price and dosing time, but additionally convey the ingredients significantly gently. To enable the confirmed pump models of the ecodos series from LEWA GmbH to fulfill this demanding task with even more flexibility and power effectivity in the future, the producer is expanding the portfolio to include a brand new form of wide-range pace control. Alongside asynchronous motors and servomotors, everlasting magnet synchronous motors, or PMSMs for brief, are also used now. They are characterized by excessive power efficiency and a control vary greater than 1:200. This significantly expands the range of functions. With PMSMs, it is not needed to make use of several pumps for various move charges or oversize asynchronous motors for low speeds. Since PMSMs may be designed without a fan, they remain compact and simple to scrub. The latter feature predestines them for hygienic purposes. High effectivity ranking over the whole management vary in accordance with vitality effectivity class IE5+ additionally reduces vitality prices, thus making certain a decrease total cost of ownership (TCO).
The diaphragm metering pumps in the LEWA ecodos collection are significantly nicely suited for functions in the meals or pharmaceutical industries. All materials in touch with the fluids used in the pump models meet the FDA and USP Class VI requirements, and the EU directives for the meals business. In the hygienic model, for example, the pump head is manufactured from PP or electropolished stainless-steel with a surface roughness < 0.5 µm. This facilitates cleaning of the surfaces in touch 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 control range stays limited to 1:10 (1:50 is possible in individual cases). With encoder feedback, vital growth is possible,” mentioned Maurice Wirkner, an software manager 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 prices.” Servomotors are optimized for highly dynamic requirements and likewise cowl the entire control vary (1-210 pump strokes), however, they’re dearer to buy and in addition, require a servo inverter for management.
Wide-range speed control with permanent magnet synchronous motor extends the vary of applications
LEWA has now expanded its personal 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. with out load-dependent slip,” Wirkner explained. “Among different issues, it options an extreme control vary, which regularly makes the utilization of multiple pumps for various flow rates pointless.” Particularly within the case of a number of pumps, an extra guide stroke adjustment or electrical stroke adjustment can be dispensed with and the required move rate can be realized by speed control solely. The PMSM also has a constant torque. The complete torque can be applied from engine speed 0 rpm (standstill) up to the rated pace of the motor. This ensures particularly easy and mild system start-up, since each process may be started with a pump capability of 1 p.c as an alternative of the similar old 10 p.c.
It also contains a excessive short-term overload capability, which enables a drive design without oversizing for the beginning torque. As a result, smaller, extra cost-efficient sizes may be realized than with basic drives. “Like the asynchronous motor, the PMSM may be managed by way of a regular frequency converter, so customers can depend on common parts,” Wirkner defined. “With the servomotor on the contrary, it might be necessary to purchase costly servo controllers.” The compact drive may be simply cleaned due to its fanless design and presents high IP protection. If required a further conversion course of – referred to as nsd tupH – can be applied to the aluminum body for FDA necessities. This makes the surface extremely resistant and even easier to wash – perfect for purposes with stringent hygienic necessities, similar to aroma metering in the meals trade or additive dosing within the pharmaceutical business.
IE5+ PMSM allows cost reduction and decentralized solutions
The sole limitation of the presently used PMSM is that it’s only out there for protected areas. “Thanks to wide-range pace management with IE5+ PMSM, we will meet the growing buyer calls for for a wider adjustment range and lower power consumption, as well as general costs,” mentioned Wirkner to sum up the state of affairs. “The matter of power effectivity in particular is changing into more and more essential for our clients. เกจวัดแรงดันsumo 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 right now the world’s leading manufacturer of metering pumps and course of diaphragm pumps as well as full metering packages for process engineering. Headquartered in Leonberg, the corporate developed into a global group in just a few a long time. Since 2022, the company has been part of the Atlas Copco Group, a globally main Swedish producer of compressors, vacuum options, mills, pumps, power instruments and assembly methods. Together with the model new owner, LEWA will additional broaden the economic pumps enterprise. As a analysis and manufacturing firm, LEWA develops technologies and offers options for the huge array of applications amongst its customers. Its merchandise are used primarily in the chemical business, the cosmetics trade, prescribed drugs and biotechnology, food and beverage industry and vitality utilities in addition to within the production of plastics, detergents and cleaners. Additional software areas include refineries and petrochemicals, the oil and fuel industry, and gas odorization. LEWA presently employs round 1,200 individuals and owns 14 subsidiaries all over the world alongside having 80 representatives and sales workplaces in more than 80 countries.
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 range of 1:200, enabling a wider vary of applications to be lined by the identical drive or pump.
Source: LEWA GmbH
Image ID: Baby food.jpg
Caption: The PMSM additionally has a relentless torque, i.e. all the torque can be known as up at speed zero rpm. This ensures particularly easy and delicate system start-up, since each course of could be started with a conveyance fee of 1 % as a substitute of the standard 10 percent. (Example: Metering omega 3 fatty acids within the manufacturing of baby food)
Source: Adobe Stock
Image ID: Torque.jpg
Caption: In distinction to the ASMs proven, the constant torque of the PMSM enables steady operation at low speeds. Oversizing for the required pump starting torque has turn into 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 can be controlled via a regular frequency converter (NORD, Danfoss, and so forth.) with special parameterization, so that users can rely on frequent 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 solutions during which the frequency converter is installed immediately on the PMSM are also 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 preliminary practical testing with the NORD PMSM prototype and an ecodos pump on the pump check bench. In the lower pace range above all, the PMSM efficiently demonstrated the benefits of fixed torque: the ecodos check pump could be pushed in a spread of 1:480 as much as 5 bar.
Source: LEWA GmbH
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