Smoothness and absence of ripple are essential for the printing of elaborate color images on reusable plastic-type cups offered by fast-food chains. The colour image comprises of millions of tiny ink dots of many colors and shades. The complete glass is printed in a single pass (unlike regular color separation where each color is definitely published separately). The gearheads must work smoothly enough to synchronize ink blankets, printing plates, and glass rollers without presenting any ripple or inaccuracies that may smudge the picture. In this case, the hybrid gearhead decreases motor shaft runout error, which reduces roughness.
At times a motor’s capability could be limited to the stage where it needs gearing. As servo manufacturers develop better motors that can muscle applications through more difficult moves and generate higher torques and speeds, these motors need gearheads equal to the task.
Interestingly, no more than a third of the movement control systems operating use gearing at all. There are, of course, reasons to do so. Using a gearhead with a servo electric motor or using a built-in gearmotor can enable the usage of a smaller motor, therefore reducing the machine size and cost. There are three main advantages of choosing gears, each which can enable the use of smaller sized motors and drives and therefore lower total system cost:
Torque multiplication. The gears and quantity of tooth on each gear make a ratio. If a electric motor can generate 100 in-lbs of torque, and a 5:1 ratio gear head is attached to its output, the resulting torque will be close to 500 in-lbs.
Whenever a motor is operating at 1,000 rpm and a 5:1 ratio gearhead is mounted on it, the acceleration at the output will be 200 rpm. This speed reduction can improve system overall performance because many motors do not operate effectively at suprisingly low rpm. For example, look at a stone-grinding mechanism that will require the motor to run at 15 rpm. This slow acceleration makes turning the grinding wheel tough because the motor tends to cog. The variable resistance of the rock being floor also hinders its ease of turning. With the addition of a 100:1 gearhead and letting the motor run at 1,500 rpm, the motor and gear mind provides smooth rotation while the gearhead output offers a more servo gear reducer constant pressure with its output rotating at 15 rpm.
Inertia matching. Servo motors generate more torque in accordance with frame size thanks to lightweight components, dense copper windings, and high-energy magnets. The effect is better inertial mismatches between servo motors and the loads they want to control. The use of a gearhead to raised match the inertia of the motor to the inertia of the load can enable the use of a smaller motor and outcomes in a far more responsive system that is easier to tune.