In many applications, metering components within the pharmaceutical or food business for instance, pumps are required that not only may be exactly controlled when it comes to move fee and dosing time, but additionally convey the components notably gently. To enable the proven pump items of the ecodos sequence from LEWA GmbH to fulfill this demanding activity with even more flexibility and power efficiency in the future, the manufacturer is expanding the portfolio to incorporate a new type of wide-range speed management. Alongside asynchronous motors and servomotors, everlasting magnet synchronous motors, or PMSMs for short, are also used now. They are characterized by excessive energy efficiency and a management range greater than 1:200. This considerably expands the range of applications. With PMSMs, it is not essential to make use of a number of pumps for various flow rates or oversize asynchronous motors for low speeds. Since PMSMs can be designed and not utilizing a fan, they remain compact and straightforward to wash. The latter characteristic predestines them for hygienic purposes. High effectivity score over the whole control vary in accordance with energy efficiency class IE5+ additionally reduces power costs, thus making certain a lower whole cost of possession (TCO).
The diaphragm metering pumps in the LEWA ecodos series are particularly nicely suited to applications in the meals 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 business. In the hygienic model, for instance, the pump head is made from PP or electropolished stainless steel with a floor roughness < zero.5 µm. This facilitates cleaning of the surfaces involved with the product.
The motor applied sciences used to date have had to make sacrifices: “For basic asynchronous motors whose rotor is a squirrel-cage rotor, the control vary remains limited to 1:10 (1:50 is possible in individual cases). With encoder feedback, vital expansion is feasible,” said Maurice Wirkner, an utility supervisor at LEWA. “In addition, the drive is relatively inefficient outdoors the rated speed range – especially at low speeds. This requires the drive to be oversized, which increases working prices.” Servomotors are optimized for highly dynamic necessities and in addition cowl the whole control vary (1-210 pump strokes), nevertheless, they’re costlier to purchase and as well as, 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 technology that doesn’t have these weaknesses. “Unlike the asynchronous motor, the rotor of this drive consists of permanent magnets and rotates synchronously, i.e. with out load-dependent slip,” Wirkner defined. “Among different issues, it options an extreme control vary, which often makes the use of multiple pumps for different flow rates pointless.” Particularly in the case of multiple pumps, a further guide stroke adjustment or electrical stroke adjustment can be allotted with and the required flow price may be realized by pace control solely. The PMSM also has a continuing torque. The full torque could be applied from engine speed 0 rpm (standstill) as a lot as the rated pace of the motor. This ensures significantly clean and delicate system start-up, since each process may be began with a pump capacity of 1 percent as an alternative of the usual 10 %.
It also includes a excessive short-term overload capability, which permits a drive design with out 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 can be managed by way of a normal frequency converter, so customers can depend on common elements,” Wirkner explained. “With the servomotor on the contrary, it will be necessary to buy expensive servo controllers.” The compact drive could be simply cleaned due to its fanless design and offers high IP safety. If required an additional conversion process – referred to as nsd tupH – could be applied to the aluminum physique for FDA requirements. This makes the floor extraordinarily resistant and even easier to wash – best for functions with stringent hygienic requirements, similar to aroma metering within the meals industry or additive dosing in the pharmaceutical trade.
IE5+ PMSM permits value discount and decentralized solutions

The sole limitation of the presently used PMSM is that it is just available for protected areas. “Thanks to wide-range pace control with IE5+ PMSM, we can meet the increasing customer demands for a wider adjustment range and decrease vitality consumption, as properly as overall costs,” mentioned Wirkner to sum up the state of affairs. “The subject of vitality effectivity specifically is becoming more and more essential for our customers. A decentralized answer 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 household enterprise and is at present the world’s main manufacturer of metering pumps and process diaphragm pumps as nicely as full metering packages for process engineering. Headquartered in Leonberg, the corporate developed into a global group in only a few decades. Since 2022, the company has been part of the Atlas Copco Group, a globally main Swedish producer of compressors, vacuum options, generators, pumps, energy tools and assembly techniques. Together with the model new owner, LEWA will further increase the commercial pumps enterprise. As a analysis and manufacturing firm, LEWA develops technologies and supplies solutions for the huge array of applications among its customers. Its products are used mainly in the chemical trade, the cosmetics industry, prescribed drugs and biotechnology, food and beverage trade and power utilities as well as in the manufacturing of plastics, detergents and cleaners. Additional application areas embrace refineries and petrochemicals, the oil and fuel industry, and gas odorization. LEWA presently employs round 1,200 folks and owns 14 subsidiaries around the world alongside having eighty representatives and gross sales offices in additional than 80 countries.
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 range of 1:200, enabling a wider range of purposes to be lined by the identical drive or pump.
Source: LEWA GmbH

Image ID: Baby food.jpg

Caption: The PMSM additionally has a constant torque, i.e. all the torque can be called up at speed zero rpm. เพรสเชอร์เกจ ensures significantly smooth and delicate system start-up, since every process can be began with a conveyance fee of 1 percent as a substitute of the identical old 10 %. (Example: Metering omega 3 fatty acids within the production of child food)

Source: Adobe Stock

Image ID: Torque.jpg

Caption: In contrast to the ASMs proven, the constant torque of the PMSM permits steady operation at low speeds. Oversizing for the required pump starting torque has turn into unnecessary due to the high overload capability of the PMSM.
Source: LEWA GmbH

Image ID: Baugrößen_530PWebJPG.jpg

Caption: Like the asynchronous motor, the PMSM may be managed by way of a normal frequency converter (NORD, Danfoss, etc.) with special parameterization, so that customers can depend 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 in which the frequency converter is installed directly on the PMSM are additionally already attainable 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 useful testing with the NORD PMSM prototype and an ecodos pump on the pump check bench. In the lower pace vary above all, the PMSM successfully demonstrated the advantages of fixed torque: the ecodos take a look at pump could be pushed in a variety of 1:480 up to 5 bar.
Source: LEWA GmbH

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