In many purposes, metering elements in the pharmaceutical or meals business for example, pumps are required that not solely can be exactly controlled when it comes to flow rate and dosing time, but in addition convey the components notably gently. To allow the confirmed pump units of the ecodos sequence from LEWA GmbH to satisfy this demanding task with much more flexibility and power effectivity in the future, the manufacturer is increasing the portfolio to include a brand new type of wide-range speed control. 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 management vary greater than 1:200. This significantly expands the vary of purposes. With PMSMs, it’s now not essential to use a quantity of pumps for various circulate charges or oversize asynchronous motors for low speeds. Since PMSMs may be designed with no fan, they remain compact and simple to scrub. The latter feature predestines them for hygienic purposes. เครื่องวัดแรงดันเกจที่นิยมใช้ over the entire management range in accordance with power efficiency class IE5+ additionally reduces vitality prices, thus making certain a decrease whole cost of ownership (TCO).
The diaphragm metering pumps in the LEWA ecodos sequence are significantly nicely suited to functions in the food or pharmaceutical industries. All supplies involved with the fluids used in the pump models meet the FDA and USP Class VI requirements, and the EU directives for the meals trade. In the hygienic model, for example, the pump head is made from PP or electropolished chrome steel with a floor 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 restricted to 1:10 (1:50 is feasible in particular person cases). With encoder feedback, vital growth is feasible,” stated Maurice Wirkner, an software supervisor at LEWA. “In addition, the drive is comparatively inefficient outside the rated pace range – especially at low speeds. This requires the drive to be outsized, which will increase working costs.” Servomotors are optimized for highly dynamic requirements and in addition cowl the complete management range (1-210 pump strokes), nonetheless, they are dearer to purchase and as properly as, require a servo inverter for control.
Wide-range speed control with permanent magnet synchronous motor extends the range of functions
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 explained. “Among other things, it options an excessive management vary, which often makes using a number of pumps for various move rates unnecessary.” Particularly within the case of multiple pumps, an extra guide stroke adjustment or electrical stroke adjustment can be allotted with and the required flow fee may be realized by pace management only. The PMSM also has a constant torque. The full torque could be utilized from engine pace zero rpm (standstill) up to the rated speed of the motor. This ensures particularly easy and gentle system start-up, since every course of can be began with a pump capability of 1 % as an alternative of the usual 10 percent.
It additionally includes a excessive short-term overload capacity, which enables a drive design with out oversizing for the beginning torque. As a end result, smaller, extra cost-efficient sizes could be realized than with classic drives. “Like the asynchronous motor, the PMSM can be controlled via a standard frequency converter, so customers can depend on widespread parts,” Wirkner defined. “With the servomotor on the contrary, it will be needed to purchase expensive servo controllers.” The compact drive may be simply cleaned due to its fanless design and presents high IP protection. If required a further conversion process – referred to as nsd tupH – may be utilized to the aluminum physique for FDA necessities. This makes the surface extraordinarily resistant and even simpler to scrub – ideal for purposes with stringent hygienic requirements, such as aroma metering within the food business or additive dosing within the pharmaceutical industry.
IE5+ PMSM enables cost reduction and decentralized solutions
The sole limitation of the currently used PMSM is that it’s only obtainable for secure areas. “Thanks to wide-range velocity control with IE5+ PMSM, we are able to meet the increasing customer demands for a wider adjustment range and lower energy consumption, in addition to general costs,” said Wirkner to sum up the state of affairs. “The topic of power effectivity in particular is changing into increasingly important for our customers. 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 associate for PMSM, too.”
LEWA GmbH was based in 1952 by Herbert Ott and Rudolf Schestag as a household enterprise and is right now the world’s main manufacturer of metering pumps and process diaphragm pumps in addition to full metering packages for course of engineering. Headquartered in Leonberg, the company developed into an international group in just a few decades. Since 2022, the company has been a half of the Atlas Copco Group, a globally leading Swedish producer of compressors, vacuum solutions, turbines, pumps, power instruments and assembly methods. Together with the brand new owner, LEWA will additional broaden the commercial pumps business. As a research and manufacturing firm, LEWA develops technologies and provides solutions for the vast array of functions amongst its clients. Its merchandise are used mainly in the chemical business, the cosmetics business, prescription drugs and biotechnology, food and beverage business and energy utilities as properly as in the production of plastics, detergents and cleaners. Additional software areas include refineries and petrochemicals, the oil and fuel business, and fuel odorization. LEWA presently employs round 1,200 individuals and owns 14 subsidiaries around the world alongside having 80 representatives and sales places of work in additional 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 characteristic a management range of 1:200, enabling a wider vary of purposes to be lined by the same drive or pump.
Source: LEWA GmbH
Image ID: Baby meals.jpg
Caption: The PMSM also has a constant torque, i.e. all the torque may be known as up at pace zero rpm. This ensures notably easy and gentle system start-up, since every process may be began with a conveyance price of 1 percent as an alternative of the usual 10 %. (Example: Metering omega three fatty acids in the production of child food)
Source: Adobe Stock
Image ID: Torque.jpg
Caption: In distinction to the ASMs proven, the constant torque of the PMSM permits continuous operation at low speeds. Oversizing for the required pump starting torque has become unnecessary due to the high overload functionality of the PMSM.
Source: LEWA GmbH
Image ID: Baugrößen_530PWebJPG.jpg
Caption: Like the asynchronous motor, the PMSM may be controlled through a regular frequency converter (NORD, Danfoss, and so on.) with particular parameterization, so that users can rely 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 solutions during which the frequency converter is installed immediately on the PMSM are additionally already possible 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 preliminary functional testing with the NORD PMSM prototype and an ecodos pump on the pump take a look at bench. In the decrease velocity range above all, the PMSM efficiently demonstrated the advantages of fixed torque: the ecodos test pump could possibly be pushed in a spread of 1:480 up to 5 bar.
Source: LEWA GmbH
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