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In many applications, metering ingredients in the pharmaceutical or meals trade for example, pumps are required that not only can be precisely managed in phrases of circulate fee and dosing time, but additionally convey the ingredients particularly gently. To enable the proven pump units of the ecodos collection from LEWA GmbH to satisfy this demanding activity with even more flexibility and power effectivity sooner or later, the producer is expanding the portfolio to include a model new type of wide-range pace management. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for short, are additionally used now. They are characterised by high vitality effectivity and a management range higher than 1:200. This considerably expands the range of functions. With PMSMs, it is now not essential to use a quantity of pumps for various flow charges or oversize asynchronous motors for low speeds. Since PMSMs could be designed with no fan, they proceed to be compact and simple to scrub. The latter characteristic predestines them for hygienic applications. High efficiency rating over the complete control vary in accordance with power effectivity class IE5+ additionally reduces energy costs, thus making certain a lower complete value of possession (TCO).
The diaphragm metering pumps in the LEWA ecodos collection are notably nicely fitted to purposes in the meals or pharmaceutical industries. All materials in touch with the fluids used within the pump models meet the FDA and USP Class VI requirements, and the EU directives for the food trade. In the hygienic model, for instance, the pump head is made of PP or electropolished stainless steel with a floor roughness < 0.5 µm. This facilitates cleaning of the surfaces in touch with the product.
The motor applied sciences used thus far have had to make sacrifices: “For traditional asynchronous motors whose rotor is a squirrel-cage rotor, the control vary stays limited to 1:10 (1:50 is possible in particular person cases). With encoder suggestions, significant expansion is possible,” said Maurice Wirkner, an application manager at LEWA. “In addition, the drive is comparatively inefficient outdoors the rated speed range – particularly at low speeds. This requires the drive to be oversized, which will increase working prices.” Servomotors are optimized for highly dynamic requirements and likewise cowl the complete management vary (1-210 pump strokes), nonetheless, they are more expensive to purchase and as properly as, require a servo inverter for management.
Wide-range pace control with everlasting magnet synchronous motor extends the range of functions

LEWA has now expanded its personal portfolio with a drive technology 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 things, it features an excessive management range, which frequently makes the use of multiple pumps for different circulate rates pointless.” Particularly in the case of a number of pumps, an additional handbook stroke adjustment or electric stroke adjustment could be distributed with and the required circulate fee may be realized by pace management only. pressure gauge has a relentless torque. The complete torque could be utilized from engine velocity 0 rpm (standstill) as a lot as the rated pace of the motor. This ensures notably clean and mild system start-up, since each course of can be began with a pump capability of 1 percent instead of the usual 10 %.
It additionally features a high short-term overload capacity, which allows a drive design without oversizing for the starting torque. As a outcome, smaller, more cost-efficient sizes can be realized than with basic drives. “Like the asynchronous motor, the PMSM may be managed by way of a standard frequency converter, so customers can rely on frequent parts,” Wirkner defined. “With the servomotor quite the opposite, it would be necessary to purchase expensive servo controllers.” The compact drive could be easily cleaned because of its fanless design and offers excessive IP protection. If required a further conversion course of – known as nsd tupH – could be utilized to the aluminum physique for FDA necessities. This makes the floor extraordinarily resistant and even simpler to scrub – perfect for purposes with stringent hygienic requirements, corresponding to aroma metering within the food industry or additive dosing within the pharmaceutical business.
IE5+ PMSM allows cost discount and decentralized options

The sole limitation of the presently used PMSM is that it is only obtainable for protected areas. “Thanks to wide-range velocity management with IE5+ PMSM, we will meet the rising buyer demands for a wider adjustment vary and lower power consumption, in addition to general costs,” said Wirkner to sum up the situation. “The topic of energy efficiency specifically is turning into more and more necessary for our customers. A decentralized resolution in which the frequency converter is put in instantly on the PMSM, can now be implemented with Getriebebau NORD GmbH & Co. KG, LEWA’s motor companion for PMSM, too.”

LEWA GmbH was founded in 1952 by Herbert Ott and Rudolf Schestag as a household enterprise and is today 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 only a few many years. Since 2022, the company has been part of the Atlas Copco Group, a globally leading Swedish manufacturer of compressors, vacuum options, generators, pumps, power tools and meeting systems. Together with the new proprietor, LEWA will further broaden the industrial pumps enterprise. As a research and manufacturing firm, LEWA develops technologies and supplies options for the huge array of functions amongst its prospects. Its products are used primarily in the chemical business, the cosmetics trade, prescribed drugs and biotechnology, food and beverage trade and power utilities as properly as 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 sales places of work in more than eighty international locations.
Image material:
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 vary of 1:200, enabling a wider vary of functions to be coated by the identical drive or pump.
Source: LEWA GmbH

Image ID: Baby meals.jpg

Caption: The PMSM additionally has a relentless torque, i.e. all of the torque could be referred to as up at speed zero rpm. This ensures notably clean and delicate system start-up, since each process may be began with a conveyance fee of 1 percent as an alternative of the identical old 10 p.c. (Example: Metering omega three fatty acids in the production of child food)

Source: Adobe Stock

Image ID: Torque.jpg

Caption: In contrast to the ASMs shown, the constant torque of the PMSM enables continuous operation at low speeds. Oversizing for the required pump starting torque has turn into pointless as a result of excessive 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 forth.) with special parameterization, in order that users can rely on widespread elements.
เพรสเชอร์เกจ : 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 in which the frequency converter is installed instantly on the PMSM are additionally already potential with the PMSMs selected by LEWA.
Source: 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 speed vary above all, the PMSM efficiently demonstrated the advantages of fixed torque: the ecodos take a look at pump might be driven in a spread of 1:480 up to 5 bar.
Source: LEWA GmbH

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