Smoothness and lack of ripple are essential for the printing of elaborate color images on reusable plastic-type cups available at fast-food chains. The color image is made up of millions of tiny ink dots of many colors and shades. The complete cup is printed in a single complete (unlike regular color separation where each color is usually printed separately). The gearheads must run smoothly enough to synchronize ink blankets, printing plates, and cup rollers without introducing any ripple or inaccuracies that may smudge the picture. In this case, the hybrid gearhead reduces motor shaft runout mistake, which reduces roughness.
Sometimes a motor’s capability could be limited to the main point where it needs gearing. As servo manufacturers develop better motors that can muscle mass applications through more difficult moves and produce higher torques and speeds, these motors require gearheads equal to the task.
Interestingly, only about a third of the motion control systems in service use gearing at all. There are, of program, reasons to do so. Utilizing a gearhead with a servo motor or using an integrated gearmotor can enable the use of a smaller motor, thereby reducing the system size and price. There are three main advantages of going with gears, each which can enable the use of smaller motors and drives and for that reason lower total system cost:
Torque multiplication. The gears and amount of the teeth on each gear produce a ratio. If a 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 servo gear reducer running at 1,000 rpm and a 5:1 ratio gearhead is attached to it, the rate at the output will be 200 rpm. This speed reduction can improve system overall performance because many motors do not operate effectively at very low rpm. For example, look at a stone-grinding mechanism that will require the motor to run at 15 rpm. This slow velocity makes turning the grinding wheel challenging because the motor tends to cog. The variable resistance of the rock being surface also hinders its ease of turning. By adding a 100:1 gearhead and letting the motor run at 1,500 rpm, the motor and gear mind provides smooth rotation as the gearhead output provides a more constant push using 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 effect is higher inertial mismatches between servo motors and the loads they are trying to control. The use of a gearhead to raised match the inertia of the engine to the inertia of the strain can enable the use of a smaller electric motor and outcomes in a far more responsive system that is easier to tune.