In many purposes, metering ingredients in the pharmaceutical or meals industry for instance, pumps are required that not solely could be exactly controlled by way of circulate price and dosing time, but also convey the ingredients significantly gently. To allow the proven pump models of the ecodos series from LEWA GmbH to fulfill this demanding activity with even more flexibility and energy effectivity in the future, the producer is increasing the portfolio to include a brand new form of wide-range speed control. Alongside asynchronous motors and servomotors, everlasting magnet synchronous motors, or PMSMs for brief, are additionally used now. They are characterized by high vitality efficiency and a control range higher than 1:200. This considerably expands the vary of purposes. With PMSMs, it’s not needed to use a number of pumps for various circulate rates or oversize asynchronous motors for low speeds. Since PMSMs could be designed with no fan, they continue to be compact and easy to wash. The latter characteristic predestines them for hygienic functions. High efficiency ranking over the whole management range in accordance with power efficiency class IE5+ additionally reduces power prices, thus making certain a decrease whole price of ownership (TCO).
The diaphragm metering pumps within the LEWA ecodos collection are particularly properly suited to functions in the meals or pharmaceutical industries. All materials in contact with the fluids used within the pump units meet the FDA and USP Class VI requirements, and the EU directives for the food industry. In the hygienic model, for example, the pump head is manufactured from PP or electropolished chrome steel with a surface roughness < 0.5 µm. This facilitates cleansing of the surfaces involved with the product.
The motor technologies used to date have needed to make sacrifices: “For basic asynchronous motors whose rotor is a squirrel-cage rotor, the management vary stays limited to 1:10 (1:50 is feasible in individual cases). With encoder feedback, important enlargement is feasible,” mentioned Maurice Wirkner, an utility supervisor at LEWA. “In addition, the drive is comparatively inefficient exterior the rated velocity range – particularly at low speeds. This requires the drive to be oversized, which will increase working costs.” Servomotors are optimized for highly dynamic requirements and likewise cowl the complete control vary (1-210 pump strokes), nevertheless, they are more expensive to buy and in addition, require a servo inverter for control.
Wide-range speed control with everlasting magnet synchronous motor extends the vary of purposes

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. without load-dependent slip,” Wirkner explained. “Among different issues, it features an extreme control vary, which often makes the utilization of multiple pumps for different flow charges unnecessary.” Particularly within the case of multiple pumps, an additional guide stroke adjustment or electric stroke adjustment could be dispensed with and the required flow rate could be realized by speed management only. The PMSM additionally has a continuing torque. The complete torque may be utilized from engine velocity zero rpm (standstill) as much as the rated pace of the motor. This ensures particularly easy and mild system start-up, since each process can be began with a pump capacity of 1 percent as an alternative of the same old 10 %.
เกจวัดแรงดัน features a high short-term overload capacity, which allows a drive design with out oversizing for the starting torque. As a end result, smaller, more cost-efficient sizes can be realized than with basic drives. “Like the asynchronous motor, the PMSM can be controlled via a regular frequency converter, so customers can rely on frequent components,” Wirkner defined. “With the servomotor on the contrary, it might be necessary to purchase expensive servo controllers.” The compact drive can be easily cleaned due to its fanless design and provides high IP safety. If required a further conversion course of – called nsd tupH – can be applied to the aluminum physique for FDA necessities. This makes the surface extremely resistant and even simpler to wash – best for functions with stringent hygienic requirements, such as aroma metering within the food industry or additive dosing within the pharmaceutical business.
IE5+ PMSM allows price reduction and decentralized options

The sole limitation of the presently used PMSM is that it is just obtainable for safe areas. “Thanks to wide-range speed management with IE5+ PMSM, we are able to meet the rising buyer demands for a wider adjustment vary and lower power consumption, as nicely as general prices,” said Wirkner to sum up the state of affairs. “The matter of vitality efficiency in particular is changing into more and more necessary for our clients. A decentralized solution during which the frequency converter is put in instantly on the PMSM, can now be implemented 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 family enterprise and is today the world’s main producer of metering pumps and course of diaphragm pumps as properly as full metering packages for course of engineering. Headquartered in Leonberg, the corporate developed into a world group in just a few decades. 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 meeting methods. Together with the new proprietor, LEWA will further expand the commercial pumps enterprise. As a research and manufacturing firm, LEWA develops technologies and offers solutions for the vast array of functions among its customers. Its merchandise are used mainly within the chemical trade, the cosmetics business, pharmaceuticals and biotechnology, meals and beverage business and power utilities as properly as in the production of plastics, detergents and cleaners. Additional application areas embrace refineries and petrochemicals, the oil and gas business, and fuel odorization. LEWA presently employs around 1,200 people and owns 14 subsidiaries all over the world alongside having 80 representatives and sales workplaces in additional than 80 international locations.
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 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 meals.jpg

Caption: The PMSM also has a constant torque, i.e. the entire torque may be called up at velocity zero rpm. This ensures significantly clean and delicate system start-up, since each process may be began with a conveyance fee of 1 p.c as an alternative of the identical old 10 percent. (Example: Metering omega three fatty acids within the manufacturing 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 beginning torque has become pointless 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 managed through a standard frequency converter (NORD, Danfoss, and so on.) with particular parameterization, in order that users can rely on widespread 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 options by which the frequency converter is put in directly on the PMSM are also 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 preliminary practical testing with the NORD PMSM prototype and an ecodos pump on the pump test bench. In the decrease velocity vary above all, the PMSM efficiently demonstrated the advantages of fixed torque: the ecodos take a look at pump might be driven in a range of 1:480 up to 5 bar.
Source: LEWA GmbH

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