In many functions, metering ingredients within the pharmaceutical or meals trade for example, pumps are required that not only can be exactly managed when it comes to circulate rate and dosing time, but additionally convey the components notably gently. To allow the proven pump items of the ecodos collection from LEWA GmbH to meet this demanding process with even more flexibility and power effectivity in the future, the producer is increasing the portfolio to incorporate a model new type of wide-range velocity management. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for short, are additionally used now. They are characterised by excessive vitality efficiency and a management vary larger than 1:200. This significantly expands the range of applications. With PMSMs, it’s no longer essential to make use of a quantity of pumps for different move charges or oversize asynchronous motors for low speeds. Since PMSMs could be designed with no fan, they continue to be compact and simple to scrub. The latter characteristic predestines them for hygienic functions. High effectivity rating over the entire management range in accordance with power efficiency class IE5+ also reduces vitality costs, thus ensuring a decrease total price of possession (TCO).
The diaphragm metering pumps within the LEWA ecodos sequence are significantly nicely suited for applications 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 necessities, and the EU directives for the food industry. In the hygienic version, for example, the pump head is made of PP or electropolished stainless steel with a floor roughness < zero.5 µm. This facilitates cleaning of the surfaces in contact with the product.
The motor applied sciences used to date have had to make sacrifices: “For classic 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, vital growth is feasible,” stated Maurice Wirkner, an software supervisor at LEWA. “In addition, the drive is comparatively inefficient exterior the rated pace vary – especially at low speeds. This requires the drive to be outsized, which will increase working prices.” Servomotors are optimized for extremely dynamic requirements and also cowl the whole management vary (1-210 pump strokes), nonetheless, they’re dearer to purchase and in addition, require a servo inverter for management.
Wide-range velocity control with everlasting magnet synchronous motor extends the range of functions
LEWA has now expanded its personal portfolio with a drive know-how that doesn’t have these weaknesses. “Unlike the asynchronous motor, the rotor of this drive consists of everlasting magnets and rotates synchronously, i.e. without load-dependent slip,” Wirkner defined. “Among other things, it options an extreme control range, which frequently makes the use of multiple pumps for various circulate rates pointless.” Particularly within the case of a number of pumps, an additional handbook stroke adjustment or electrical stroke adjustment can be dispensed with and the required flow fee may be realized by pace control solely. เกจวัดแรงดันnuovafima has a continuing torque. The full torque could be utilized from engine speed 0 rpm (standstill) as much as the rated pace of the motor. This ensures significantly clean and delicate system start-up, since every course of could be started with a pump capacity of 1 percent instead of the standard 10 percent.
It also features a excessive short-term overload capacity, which permits a drive design without oversizing for the starting torque. As a result, smaller, more cost-efficient sizes can be realized than with classic drives. “Like the asynchronous motor, the PMSM could be managed by way of a normal frequency converter, so customers can depend on frequent parts,” Wirkner explained. “With the servomotor quite the opposite, it would be essential to buy expensive servo controllers.” The compact drive can be easily cleaned due to its fanless design and presents high IP safety. If required an extra conversion process – called nsd tupH – could be applied to the aluminum body for FDA requirements. This makes the floor extraordinarily resistant and even easier to clean – best for purposes with stringent hygienic necessities, such as aroma metering in the meals industry or additive dosing in the pharmaceutical industry.
IE5+ PMSM allows value reduction and decentralized options
The sole limitation of the currently used PMSM is that it is only available for protected areas. “Thanks to wide-range velocity control with IE5+ PMSM, we are able to meet the growing buyer calls for for a wider adjustment range and lower vitality consumption, as nicely as total costs,” mentioned Wirkner to sum up the scenario. “The topic of power efficiency particularly is becoming increasingly necessary for our customers. A decentralized solution during which the frequency converter is put in instantly on the PMSM, can now be applied with Getriebebau NORD GmbH & Co. KG, LEWA’s motor partner for PMSM, too.”
LEWA GmbH was based in 1952 by Herbert Ott and Rudolf Schestag as a family enterprise and is right now the world’s leading manufacturer of metering pumps and process diaphragm pumps as properly as full metering packages for process engineering. Headquartered in Leonberg, the corporate developed into a world group in only a few many years. Since 2022, the company has been a part of the Atlas Copco Group, a globally leading Swedish manufacturer of compressors, vacuum solutions, turbines, pumps, power instruments and assembly systems. Together with the new proprietor, LEWA will further increase the commercial pumps business. As a analysis and manufacturing company, LEWA develops applied sciences and supplies solutions for the vast array of functions amongst its customers. Its merchandise are used mainly within the chemical business, the cosmetics industry, prescription drugs and biotechnology, meals and beverage business and vitality utilities as properly as in the production of plastics, detergents and cleaners. Additional application areas embrace refineries and petrochemicals, the oil and gas trade, and gasoline odorization. LEWA at present employs around 1,200 people and owns 14 subsidiaries around the world alongside having 80 representatives and sales workplaces in additional than eighty 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 functions to be lined by the identical drive or pump.
Source: LEWA GmbH
Image ID: Baby meals.jpg
Caption: The PMSM additionally has a constant torque, i.e. the entire torque could be known as up at velocity 0 rpm. This ensures particularly easy and gentle system start-up, since each process can be began with a conveyance price of 1 percent as an alternative of the standard 10 %. (Example: Metering omega 3 fatty acids in the manufacturing of child food)
Source: Adobe Stock
Image ID: Torque.jpg
Caption: In distinction to the ASMs shown, the fixed torque of the PMSM permits steady operation at low speeds. Oversizing for the required pump starting torque has turn out to be pointless as a end result of high overload capability of the PMSM.
Source: LEWA GmbH
Image ID: Baugrößen_530PWebJPG.jpg
Caption: Like the asynchronous motor, the PMSM can be managed by way of a normal frequency converter (NORD, Danfoss, and so forth.) with special parameterization, in order that users can depend on widespread parts.
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 by which the frequency converter is put in 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 useful testing with the NORD PMSM prototype and an ecodos pump on the pump check bench. In the lower speed range above all, the PMSM successfully demonstrated some great advantages of fixed torque: the ecodos check pump might be pushed in a spread of 1:480 up to 5 bar.
Source: LEWA GmbH
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