Smoothness and absence of ripple are essential for the printing of elaborate color pictures on reusable plastic material cups offered by fast-food chains. The colour image is made up of an incredible number of tiny ink dots of many shades and shades. The entire glass is printed in one pass (unlike regular color separation where each color is imprinted separately). The gearheads must run easily enough to synchronize ink blankets, printing plates, and cup rollers without presenting any ripple or inaccuracies that may smudge the picture. In this instance, the hybrid servo motor gearbox 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 more powerful motors that can muscle tissue applications through more difficult moves and produce higher torques and speeds, these motors need gearheads add up to the task.
Interestingly, only about a third of the motion control systems operating use gearing at all. There are, of training course, reasons to do so. Utilizing a gearhead with a servo engine or using a built-in gearmotor can enable the use of a smaller motor, therefore reducing the machine size and price. There are three principal advantages of going with gears, each which can enable the use of smaller sized motors and drives and therefore lower total system cost:
Torque multiplication. The gears and amount of tooth on each gear develop a ratio. If a motor can generate 100 in-lbs of torque, and a 5:1 ratio gear head is mounted on its output, the resulting torque will become near to 500 in-lbs.
When a motor is operating at 1,000 rpm and a 5:1 ratio gearhead is mounted on it, the speed at the output will be 200 rpm. This speed reduction can improve system performance because many motors usually do not operate effectively at very low rpm. For example, look at a stone-grinding mechanism that requires the motor to run at 15 rpm. This slow rate makes turning the grinding wheel difficult because the motor tends to cog. The variable resistance of the stone being floor also hinders its ease of turning. With the addition of a 100:1 gearhead and letting the electric motor run at 1,500 rpm, the motor and gear head provides smooth rotation while the gearhead output offers a more constant force using its output rotating at 15 rpm.
Inertia matching. Servo motors generate more torque in accordance with frame size because of lightweight materials, dense copper windings, and high-energy magnets. The result is better inertial mismatches between servo motors and the loads they want to control. The utilization of a gearhead to better match the inertia of the motor to the inertia of the load can enable the usage of a smaller motor and outcomes in a more responsive system that is easier to tune.