Smoothness and absence of ripple are crucial for the printing of elaborate color images on reusable plastic material cups offered by fast-food chains. The colour image is made up of an incredible number of tiny ink spots of many shades and shades. The entire glass is printed in a single complete (unlike regular color separation where each color can be printed separately). The gearheads must run efficiently enough to synchronize ink blankets, printing plates, and cup rollers without introducing any ripple or inaccuracies that may smudge the image. In this instance, the hybrid gearhead decreases motor shaft runout error, which reduces roughness.
Sometimes a motor’s capability could be limited to the main point where it requires gearing. As servo manufacturers develop more powerful motors that can muscle applications through more complicated moves and create higher torques and speeds, these motors require gearheads add up to the task.
Interestingly, only about a third of the motion control systems in service use gearing at all. There are, of course, good reasons to do so. Utilizing a gearhead with a servo electric motor or using an integrated gearmotor can enable the use of a smaller motor, therefore servo gear reducer reducing the system size and price. There are three major advantages of going with gears, each which can enable the usage of smaller sized motors and drives and for that reason lower total system cost:
Torque multiplication. The gears and quantity of the teeth 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 end up being near to 500 in-lbs.
Whenever a motor is running at 1,000 rpm and a 5:1 ratio gearhead is mounted on it, the velocity at the output will be 200 rpm. This speed reduction can improve system functionality because many motors do not operate efficiently at very low rpm. For example, consider a stone-grinding mechanism that will require the motor to perform at 15 rpm. This slow rate makes turning the grinding wheel challenging because the motor will cog. The variable resistance of the rock being ground also hinders its simple turning. By adding a 100:1 gearhead and letting the engine run at 1,500 rpm, the motor and gear head provides smooth rotation as the gearhead output provides a more constant pressure using its output rotating at 15 rpm.
Inertia matching. Servo motors generate more torque relative to frame size because of lightweight components, dense copper windings, and high-energy magnets. The effect is better 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 usage of a smaller electric motor and results in a far more responsive system that is easier to tune.