In many functions, metering ingredients within the pharmaceutical or meals trade for instance, pumps are required that not only could be exactly managed in terms of move fee and dosing time, but in addition convey the components particularly gently. To allow เพรสเชอร์เกจ confirmed pump items of the ecodos collection from LEWA GmbH to fulfill this demanding task with even more flexibility and vitality effectivity sooner or later, the producer is expanding the portfolio to include a new form of wide-range pace management. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for brief, are also used now. They are characterised by excessive power effectivity and a control vary higher than 1:200. This significantly expands the vary of functions. With PMSMs, it is now not essential to use several pumps for different circulate charges or oversize asynchronous motors for low speeds. Since PMSMs can be designed and not utilizing a fan, they proceed to be compact and straightforward to clean. The latter function predestines them for hygienic purposes. High effectivity ranking over the whole control range in accordance with energy effectivity class IE5+ additionally reduces energy prices, thus making certain a decrease total value of ownership (TCO).
The diaphragm metering pumps within the LEWA ecodos series are notably well fitted to applications within the food 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 industry. In the hygienic version, for example, the pump head is manufactured from PP or electropolished stainless-steel with a floor roughness < 0.5 µm. This facilitates cleansing of the surfaces in contact with the product.
The motor technologies used so far have had to make sacrifices: “For basic asynchronous motors whose rotor is a squirrel-cage rotor, the management range remains limited to 1:10 (1:50 is feasible in individual cases). With encoder feedback, vital enlargement is possible,” stated Maurice Wirkner, an utility supervisor at LEWA. “In addition, the drive is comparatively inefficient outside the rated speed range – especially at low speeds. This requires the drive to be oversized, which increases working prices.” Servomotors are optimized for extremely dynamic requirements and in addition cover the complete control vary (1-210 pump strokes), nevertheless, they are costlier to purchase and in addition, require a servo inverter for management.
Wide-range pace management with everlasting magnet synchronous motor extends the range of applications
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. with out load-dependent slip,” Wirkner defined. “Among different things, it features an excessive management vary, which often makes the use of multiple pumps for various flow rates unnecessary.” Particularly in the case of a quantity of pumps, a further guide stroke adjustment or electrical stroke adjustment could be allotted with and the required flow rate can be realized by velocity control only. The PMSM also has a relentless torque. The full torque can be utilized from engine velocity 0 rpm (standstill) as much as the rated velocity of the motor. This ensures notably easy and mild system start-up, since each course of can be started with a pump capacity of 1 p.c as an alternative of the standard 10 %.
It additionally features a high short-term overload capacity, which allows a drive design with out oversizing for the beginning torque. As a result, smaller, more cost-efficient sizes could be realized than with traditional drives. “Like the asynchronous motor, the PMSM can be controlled by way of a standard frequency converter, so users can rely on widespread parts,” Wirkner defined. “With the servomotor on the contrary, it would be necessary to buy expensive servo controllers.” The compact drive can be simply cleaned due to its fanless design and presents excessive IP protection. If required an extra conversion process – referred to as nsd tupH – could be utilized to the aluminum body for FDA requirements. This makes the surface extremely resistant and even easier to wash – perfect for purposes with stringent hygienic requirements, corresponding to aroma metering within the meals industry or additive dosing within the pharmaceutical trade.
IE5+ PMSM permits price reduction and decentralized options
The sole limitation of the presently used PMSM is that it is just out there for safe areas. “Thanks to wide-range speed management with IE5+ PMSM, we are in a position to meet the rising customer calls for for a wider adjustment vary and lower energy consumption, in addition to overall prices,” mentioned Wirkner to sum up the state of affairs. “The subject of vitality efficiency in particular is changing into more and more important for our prospects. A decentralized resolution in which the frequency converter is put in immediately on the PMSM, can now be applied 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 household enterprise and is at present the world’s leading manufacturer of metering pumps and course of diaphragm pumps in addition to complete metering packages for process engineering. Headquartered in Leonberg, the company developed into a world group in just a few decades. Since 2022, the corporate has been a part of the Atlas Copco Group, a globally main Swedish producer of compressors, vacuum solutions, mills, pumps, power instruments and assembly techniques. Together with the model new proprietor, LEWA will further increase the industrial pumps enterprise. As a research and manufacturing firm, LEWA develops applied sciences and provides options for the vast array of applications among its clients. Its merchandise are used mainly within the chemical trade, the cosmetics trade, prescription drugs and biotechnology, meals and beverage trade and power utilities in addition to in the manufacturing of plastics, detergents and cleaners. Additional software areas include refineries and petrochemicals, the oil and gasoline business, and gasoline odorization. LEWA at present employs round 1,200 individuals and owns 14 subsidiaries all over the world alongside having 80 representatives and gross sales places of work in more than eighty countries.
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 management range of 1:200, enabling a wider vary of applications to be coated by the identical drive or pump.
Source: LEWA GmbH
Image ID: Baby food.jpg
Caption: The PMSM additionally has a continuing torque, i.e. all of the torque could be known as up at pace 0 rpm. This ensures notably smooth and gentle system start-up, since each course of may be began with a conveyance price of 1 % instead of the same old 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 shown, the fixed torque of the PMSM allows steady operation at low speeds. Oversizing for the required pump beginning torque has turn out to be pointless as a end 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 via a regular frequency converter (NORD, Danfoss, etc.) with particular parameterization, in order that users can rely 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 by which the frequency converter is put in immediately on the PMSM are also already attainable with the PMSMs chosen by LEWA.
digital pressure gauge : Getriebebau NORD GmbH & Co. KG
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Caption: As early as 2020, LEWA carried out initial practical testing with the NORD PMSM prototype and an ecodos pump on the pump test bench. In the lower pace vary above all, the PMSM efficiently demonstrated the benefits of fixed torque: the ecodos check pump might be driven in a range of 1:480 as much as 5 bar.
Source: LEWA GmbH
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