Energy efficient in accordance with class IE5+: Compact permanent magnet synchronous motor extends control range and reduces total cost of ownership

LEWA ecodos LED3 mit PMSM (Quelle: LEWA GmbH) / LEWA ecodos LED3 with PMSM (Source: LEWA GmbH)

Die neu ins Portfolio aufgenommenen PMSM zeichnen sich unter anderem durch einen Regelbereich von 1:200 aus, so dass sich mit dem gleichen Antrieb bzw. der gleichen Pumpe ein größeres Anwendungsspektrum abdecken lässt. (Quelle: LEWA GmbH) / The PMSMs newly added to the portfolio feature a control range of 1:200, enabling a wider range of applications to be covered by the same drive or pump. (Source: LEWA GmbH)

Der PMSM weist zudem ein konstantes Drehmoment auf, d.h. das komplette Moment kann bei Drehzahl 0 U/min abgerufen werden. So wird ein besonders sanftes und produktschonendes Anfahren des Systems sichergestellt, da jeder Prozess mit einer Förderleistung von 1 Prozent statt der sonst üblichen 10 Prozent gestartet werden kann. (Beispiel: Dosierung Omega 3 Fettsäuren bei der Herstellung von Babynahrung) (Quelle: Adobe Stock) / The PMSM also has a constant torque, i.e. all of the torque can be called up at speed 0 rpm. This ensures particularly smooth and gentle system start-up, since each process can be started with a conveyance rate of 1 percent instead of the usual 10 percent. (Example: Metering omega 3 fatty acids in the production of baby food) (Source: Adobe Stock)

Das konstante Moment des PMSM ermöglicht im Gegensatz zu den dargestellten ASM einen Dauerbetrieb bei geringen Drehzahlen. Eine Überdimensionierung für das benötigte Startmoment der Pumpe ist aufgrund der hohen Überlastfähigkeit des PSMS überflüssig geworden. (Quelle: LEWA GmbH)

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 become unnecessary due to the high overload capability of the PMSM. (Source: LEWA GmbH)

Wie der Asynchronmotor lässt sich der PMSM über einen Standard-Frequenzumrichter (NORD, Danfoss, …) mit spezieller Parametrierung ansteuern, so dass der Anwender auf Gleichteile zurückgreifen kann. (Quelle: Getriebebau NORD GmbH & Co. KG) / Like the asynchronous motor, the PMSM can be controlled via a standard frequency converter (NORD, Danfoss, etc.) with special parameterization, so that users can rely on common parts. (Source: Getriebebau NORD GmbH & Co. KG)

Auch dezeAuch dezentrale Lösungen, in denen der Frequenzumrichter direkt am PMSM verbaut ist, sind mit den von LEWA gewählten PMSM bereits möglich. (Quelle: Getriebebau NORD GmbH & Co. KG) / Decentralized solutions in which the frequency converter is installed directly on the PMSM are also already possible with the PMSMs selected by LEWA. (Source: Getriebebau NORD GmbH & Co. KG)

Auch dezeAuch dezentrale Lösungen, in denen der Frequenzumrichter direkt am PMSM verbaut ist, sind mit den von LEWA gewählten PMSM bereits möglich. (Quelle: Getriebebau NORD GmbH & Co. KG) / Decentralized solutions in which the frequency converter is installed directly on the PMSM are also already possible with the PMSMs selected by LEWA. (Source: Getriebebau NORD GmbH & Co. KG)

Bereits im Jahr 2020 führte LEWA erste Funktionstests mit dem NORD PMSM Prototypen und einer Pumpe des Typs ecodos auf dem Pumpenprüfstand durch. Vor allem im unteren Drehzahlbereich konnte der PMSM seine Vorteile des konstanten Drehmoments erfolgreich unter Beweis stellen: Die ecodos konnte in einem Bereich von 1:480 bei bis zu 5 bar betrieben werden. (Quelle: LEWA GmbH) / As early as 2020, LEWA carried out initial functional testing with the NORD PMSM prototype and an ecodos pump on the pump test bench. In the lower speed range above all, the PMSM successfully demonstrated the advantages of constant torque: the ecodos test pump could be driven in a range of 1:480 up to 5 bar. (Source: LEWA GmbH)

In many applications, metering ingredients in the pharmaceutical or food industry for example, pumps are required that not only can be precisely controlled in terms of flow rate and dosing time, but also convey the ingredients particularly gently. To enable the proven pump units of the ecodos series from LEWA GmbH to fulfill this demanding task with even more flexibility and energy efficiency in the future, the manufacturer is expanding the portfolio to include a new form of wide-range speed control. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for short, are also used now. They are characterized by high energy efficiency and a control range greater than 1:200. This significantly expands the range of applications. With PMSMs, it is no longer necessary to use several pumps for different flow rates or oversize asynchronous motors for low speeds. Since PMSMs can be designed without a fan, they remain compact and easy to clean. The latter feature predestines them for hygienic applications. High efficiency rating over the complete control range in accordance with energy efficiency class IE5+ also reduces energy costs, thus ensuring a lower total cost of ownership (TCO).

The diaphragm metering pumps in the LEWA ecodos series are particularly well suited for applications in the food or pharmaceutical industries. All materials in contact with the fluids used in the pump units meet the FDA and USP Class VI requirements, 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 surface roughness < 0.5 µm. This facilitates cleaning of the surfaces in contact with the product.

The motor technologies 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 possible in individual cases). With encoder feedback, significant expansion is possible," said Maurice Wirkner, an application manager at LEWA. "In addition, the drive is relatively inefficient outside the rated speed range – especially at low speeds. This requires the drive to be oversized, which increases operating costs." Servomotors are optimized for highly dynamic requirements and also cover the complete control range (1-210 pump strokes), however, they are more expensive to purchase and in addition, require a servo inverter for control.

Wide-range speed control with permanent magnet synchronous motor extends the range of applications

LEWA has now expanded its own portfolio with a drive technology that does not have these weaknesses. "Unlike the asynchronous motor, the rotor of this drive consists of permanent magnets and rotates synchronously, i.e. without load-dependent slip," Wirkner explained. "Among other things, it features an extreme control range, which often makes the use of multiple pumps for different flow rates unnecessary." Particularly in the case of multiple pumps, an additional manual stroke adjustment or electric stroke adjustment can be dispensed with and the required flow rate can be realized by speed control only. The PMSM also has a constant torque. The complete torque can be applied from engine speed 0 rpm (standstill) up to the rated speed of the motor. This ensures particularly smooth and gentle system start-up, since each process can be started with a pump capacity of 1 percent instead of the usual 10 percent.

It also features a high short-term overload capacity, which enables 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 can be controlled via a standard frequency converter, so users can rely on common parts," Wirkner explained. "With the servomotor on the contrary, it would be necessary to purchase expensive servo controllers." The compact drive can be easily cleaned due to its fanless design and offers high IP protection. If required an additional conversion process – called nsd tupH – can be applied to the aluminum body for FDA requirements. This makes the surface extremely resistant and even easier to clean – ideal for applications with stringent hygienic requirements, such as aroma metering in the food industry or additive dosing in the pharmaceutical industry.

IE5+ PMSM enables cost reduction and decentralized solutions

The sole limitation of the currently used PMSM is that it is only available for safe areas. "Thanks to wide-range speed control with IE5+ PMSM, we can meet the increasing customer demands for a wider adjustment range and lower energy consumption, as well as overall costs," said Wirkner to sum up the situation. "The topic of energy efficiency in particular is becoming increasingly important for our customers. A decentralized solution in which the frequency converter is installed directly on the PMSM, can now be implemented with Getriebebau NORD GmbH & Co. KG, LEWA's motor partner for PMSM, too."