In many purposes, metering elements within the pharmaceutical or meals trade for example, pumps are required that not only can be exactly managed when it comes to move price and dosing time, but also convey the components significantly gently. To allow the confirmed pump models of the ecodos sequence from LEWA GmbH to fulfill this demanding task with even more flexibility and energy efficiency in the future, the producer is increasing the portfolio to incorporate a new type of wide-range speed control. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for short, are also used now. They are characterised by excessive power effectivity and a management vary larger than 1:200. This considerably expands the vary of functions. With PMSMs, it’s not essential to use a number of pumps for different circulate rates or oversize asynchronous motors for low speeds. Since PMSMs could be designed with no fan, they remain compact and easy to clean. The latter characteristic predestines them for hygienic applications. High efficiency ranking over the complete control range in accordance with power efficiency class IE5+ additionally reduces energy prices, thus guaranteeing a lower total price of possession (TCO).
The diaphragm metering pumps in the LEWA ecodos sequence are notably nicely suited for functions in the meals or pharmaceutical industries. All materials in touch with the fluids used in the pump units meet the FDA and USP Class VI requirements, and the EU directives for the food business. 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 technologies used so far have needed to make sacrifices: “For basic asynchronous motors whose rotor is a squirrel-cage rotor, the control range remains limited to 1:10 (1:50 is feasible in individual cases). With encoder feedback, important growth is feasible,” said Maurice Wirkner, an software supervisor at LEWA. “In addition, the drive is comparatively inefficient outside the rated pace vary – especially at low speeds. This requires the drive to be outsized, which increases working costs.” Servomotors are optimized for highly dynamic requirements and also cover the whole management range (1-210 pump strokes), nonetheless, they are dearer to purchase and in addition, require a servo inverter for control.
Wide-range pace management with permanent magnet synchronous motor extends the vary of purposes
LEWA has now expanded its personal portfolio with a drive expertise 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 defined. “Among other issues, it features an extreme management vary, which often makes the use of a quantity of pumps for different flow charges pointless.” Particularly within the case of a quantity of pumps, a further manual stroke adjustment or electric stroke adjustment may be distributed with and the required flow price can be realized by velocity control only. The PMSM additionally has a relentless torque. The complete torque could be applied from engine velocity 0 rpm (standstill) up to the rated speed of the motor. This ensures particularly smooth and gentle system start-up, since each process can be began with a pump capability of 1 percent instead of the usual 10 p.c.
It additionally contains a high short-term overload capability, which enables a drive design with out oversizing for the beginning torque. As a outcome, smaller, more cost-efficient sizes could be realized than with basic drives. “Like the asynchronous motor, the PMSM may be managed through a normal frequency converter, so users can depend on common parts,” Wirkner explained. “With the servomotor on the contrary, it will be essential to purchase costly servo controllers.” The compact drive could be simply cleaned as a result of its fanless design and offers excessive IP safety. If required a further conversion course of – called nsd tupH – can be utilized to the aluminum physique for FDA necessities. This makes the floor extraordinarily resistant and even simpler to wash – ideal for applications with stringent hygienic requirements, similar to aroma metering in the meals business or additive dosing within the pharmaceutical trade.
IE5+ PMSM enables cost reduction and decentralized solutions
The sole limitation of the at present used PMSM is that it is only available for safe areas. “Thanks to wide-range speed management with IE5+ PMSM, we can meet the increasing customer calls for for a wider adjustment range and decrease vitality consumption, in addition to overall prices,” said Wirkner to sum up the state of affairs. “The subject of energy effectivity particularly is becoming more and more necessary for our customers. A decentralized answer during which the frequency converter is installed directly on the PMSM, can now be implemented with Getriebebau NORD GmbH & Co. KG, LEWA’ weksler pressure gauge ราคา for PMSM, too.”
LEWA GmbH was founded in 1952 by Herbert Ott and Rudolf Schestag as a household enterprise and is at present the world’s leading manufacturer of metering pumps and course of diaphragm pumps in addition to full metering packages for process engineering. Headquartered in Leonberg, the corporate developed into a world group in just some many years. Since 2022, the corporate has been a half of the Atlas Copco Group, a globally main Swedish manufacturer of compressors, vacuum options, generators, pumps, energy tools and assembly techniques. Together with the brand new owner, LEWA will further broaden the industrial pumps business. As a analysis and manufacturing firm, LEWA develops applied sciences and supplies options for the vast array of functions amongst its prospects. Its merchandise are used mainly within the chemical business, the cosmetics industry, prescribed drugs and biotechnology, food and beverage trade and power utilities in addition to within the production of plastics, detergents and cleaners. Additional application areas embrace refineries and petrochemicals, the oil and fuel industry, and fuel odorization. LEWA currently employs around 1,200 people and owns 14 subsidiaries all over the world alongside having eighty representatives and sales offices in additional than eighty 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 range of purposes to be coated by the same drive or pump.
Source: LEWA GmbH
Image ID: Baby meals.jpg
Caption: The PMSM additionally has a constant torque, i.e. the entire torque can be referred to as up at velocity zero rpm. This ensures significantly easy and mild system start-up, since every course of could be started with a conveyance price of 1 percent as an alternative of the standard 10 p.c. (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 shown, the fixed torque of the PMSM allows steady operation at low speeds. Oversizing for the required pump starting torque has turn into pointless due to 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 regular frequency converter (NORD, Danfoss, and so forth.) with particular parameterization, in order that users 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 in which the frequency converter is installed 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 initial useful testing with the NORD PMSM prototype and an ecodos pump on the pump take a look at bench. In the decrease pace range above all, the PMSM successfully demonstrated the advantages of constant torque: the ecodos take a look at pump might be pushed in a range of 1:480 as much as 5 bar.
Source: LEWA GmbH
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