Smoothness and absence of ripple are crucial for the printing of elaborate color images on reusable plastic-type material cups available at fast-food chains. The colour image is made up of millions of tiny ink dots of many colours and shades. The entire glass is printed in one complete (unlike regular color separation where each color can be 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 cases like this, the hybrid gearhead reduces motor shaft runout error, which reduces roughness.
Sometimes a motor’s capability could be limited to the stage where it needs gearing. As servo producers develop more powerful motors that can muscles applications through more difficult moves and create higher torques and speeds, these motors require gearheads equal to the task.
Interestingly, no more than a third of the motion control systems operating use gearing at all. There are, of course, good reasons to do so. Utilizing a gearhead with a servo electric motor or using a built-in gearmotor can enable the use of a servo motor gearbox smaller motor, thereby reducing the system size and cost. There are three primary advantages of choosing gears, each which can enable the use of smaller sized motors and drives and for that reason lower total system cost:
Torque multiplication. The gears and number of teeth on each gear develop a ratio. If a electric motor can generate 100 in-lbs of torque, and a 5:1 ratio equipment head is mounted on its output, the resulting torque will end up being close to 500 in-lbs.
Whenever a motor is running at 1,000 rpm and a 5:1 ratio gearhead is attached to it, the speed at the output will be 200 rpm. This speed reduction can improve system functionality because many motors do not operate efficiently at suprisingly low rpm. For example, consider a stone-grinding mechanism that will require the motor to perform 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 simple turning. By adding a 100:1 gearhead and letting the electric motor run at 1,500 rpm, the engine and gear mind provides smooth rotation while the gearhead output offers a more constant drive with its output rotating at 15 rpm.
Inertia matching. Servo motors generate more torque in accordance with frame size thanks to lightweight materials, dense copper windings, and high-energy magnets. The result is higher inertial mismatches between servo motors and the loads they are trying to control. The use of a gearhead to better match the inertia of the motor to the inertia of the strain can enable the use of a smaller electric motor and results in a more responsive system that is easier to tune.