In many functions, metering components within the pharmaceutical or food industry for instance, pumps are required that not only can be exactly managed in phrases of move fee and dosing time, but in addition convey the elements significantly gently. To allow the confirmed pump models of the ecodos sequence from LEWA GmbH to fulfill this demanding activity with even more flexibility and energy effectivity sooner or later, the producer is expanding the portfolio to incorporate a new form of wide-range pace control. Alongside asynchronous motors and servomotors, everlasting magnet synchronous motors, or PMSMs for brief, are also used now. They are characterized by excessive power effectivity and a management range larger than 1:200. This considerably expands the vary of applications. With PMSMs, it is no longer necessary to make use of several pumps for different circulate rates or oversize asynchronous motors for low speeds. Since PMSMs can be designed with no fan, they proceed to be compact and easy to wash. The latter function predestines them for hygienic applications. High effectivity rating over the entire control vary in accordance with energy effectivity class IE5+ also reduces power costs, thus making certain a decrease total price of ownership (TCO).
The diaphragm metering pumps within the LEWA ecodos series are particularly nicely suited to functions within the food or pharmaceutical industries. All supplies 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 version, for instance, the pump head is manufactured from PP or electropolished stainless-steel with a surface roughness < 0.5 µm. This facilitates cleansing of the surfaces involved with the product.
The motor technologies used thus far have needed to make sacrifices: “For traditional asynchronous motors whose rotor is a squirrel-cage rotor, the management range stays restricted to 1:10 (1:50 is feasible in individual cases). With encoder feedback, significant expansion is feasible,” said Maurice Wirkner, an utility manager at LEWA. “In addition, the drive is relatively inefficient exterior the rated speed range – especially at low speeds. This requires the drive to be outsized, which will increase working prices.” Servomotors are optimized for extremely dynamic necessities and in addition cover the whole management vary (1-210 pump strokes), however, they’re costlier to buy and in addition, require a servo inverter for control.
Wide-range velocity management with everlasting magnet synchronous motor extends the vary of applications

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 permanent magnets and rotates synchronously, i.e. with out load-dependent slip,” Wirkner explained. “Among other issues, it features an excessive control range, which regularly makes the use of a number of pumps for different move charges unnecessary.” Particularly in the case of multiple pumps, an additional manual stroke adjustment or electrical stroke adjustment can be allotted with and the required circulate rate can be realized by speed management only. The PMSM also has a constant torque. The complete 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 may be began with a pump capacity of 1 p.c as an alternative of the standard 10 %.
It additionally contains a high short-term overload capability, which enables a drive design without oversizing for the beginning torque. As a end result, smaller, more cost-efficient sizes could be realized than with classic drives. “Like the asynchronous motor, the PMSM can be controlled through a normal frequency converter, so customers can depend on frequent elements,” Wirkner explained. “With the servomotor on the contrary, it might be necessary to buy costly servo controllers.” The compact drive may be simply cleaned because of its fanless design and offers high IP protection. If required an extra conversion course of – known as nsd tupH – may be utilized to the aluminum physique for FDA necessities. This makes the surface extremely resistant and even easier to scrub – perfect for applications with stringent hygienic requirements, such as aroma metering within the food trade or additive dosing in the pharmaceutical trade.
IE5+ PMSM permits price reduction and decentralized solutions

The sole limitation of the presently used PMSM is that it is only available for secure areas. “Thanks to wide-range speed control with IE5+ PMSM, we can meet the growing buyer calls for for a wider adjustment range and lower power consumption, in addition to total prices,” mentioned Wirkner to sum up the state of affairs. “The matter of power efficiency specifically is becoming increasingly essential for our customers. A decentralized answer by which the frequency converter is installed immediately on the PMSM, can now be carried out 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 right now the world’s main producer of metering pumps and course of diaphragm pumps as properly as complete metering packages for course of engineering. Headquartered in Leonberg, the company developed into a world group in only a few decades. Since 2022, the corporate has been part of the Atlas Copco Group, a globally main Swedish manufacturer of compressors, vacuum solutions, turbines, pumps, power instruments and assembly methods. Together with the model new proprietor, LEWA will further expand the industrial pumps enterprise. As a analysis and manufacturing company, LEWA develops technologies and provides options for the vast array of applications amongst its customers. Its products are used mainly within the chemical trade, the cosmetics trade, prescribed drugs and biotechnology, meals and beverage trade and energy utilities in addition to in the manufacturing of plastics, detergents and cleaners. Additional utility areas embody refineries and petrochemicals, the oil and gas trade, and gas odorization. LEWA presently employs around 1,200 individuals and owns 14 subsidiaries around the world alongside having 80 representatives and gross sales offices in more than eighty nations.
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 control 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 additionally has a relentless torque, i.e. all of the torque may be called up at velocity zero rpm. This ensures significantly easy and mild system start-up, since every course of may be started with a conveyance rate of 1 % instead of the usual 10 %. (Example: Metering omega three fatty acids within the manufacturing of baby food)

Source: Adobe Stock

Image ID: Torque.jpg

Caption: In contrast to the ASMs shown, the constant torque of the PMSM allows continuous operation at low speeds. Oversizing for the required pump starting torque has turn out to be pointless as a result of high overload capability of the PMSM.
ไดอะแฟรม : LEWA GmbH

Image ID: Baugrößen_530PWebJPG.jpg

Caption: Like the asynchronous motor, the PMSM could be controlled through a regular frequency converter (NORD, Danfoss, etc.) with particular parameterization, so that users can rely on widespread 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 options during which the frequency converter is put in immediately on the PMSM are also already possible 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 initial practical testing with the NORD PMSM prototype and an ecodos pump on the pump check bench. In the lower pace vary above all, the PMSM efficiently demonstrated the benefits of constant torque: the ecodos test pump could be pushed in a spread of 1:480 as much as 5 bar.
Source: LEWA GmbH

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