Smoothness and absence of ripple are essential for the printing of elaborate color pictures on reusable plastic-type material cups available at fast-food chains. The color image is made up of an incredible number of tiny ink dots of many shades and shades. The complete glass is printed in one pass (unlike regular color separation where each color can be published separately). The gearheads must function smoothly enough to synchronize ink blankets, printing plates, and cup rollers without introducing any ripple or inaccuracies that may smudge the image. 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 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 operating use gearing at all. There are, of course, good reasons to do so. Utilizing a gearhead with a servo motor or using a gearmotor can enable the usage of a smaller motor, therefore reducing the system size and price. There are three principal advantages of going with gears, each which can enable the usage of smaller motors and drives and therefore lower total system price:
Torque multiplication. The gears and amount of the teeth on each gear create 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 become near to 500 in-lbs.
Whenever a motor is working 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 decrease can improve system functionality because many motors usually do not operate efficiently at very low rpm. For example, consider a stone-grinding mechanism that requires the motor to perform at 15 rpm. This slow swiftness makes turning the grinding wheel challenging because the motor tends to cog. The variable resistance of the stone being ground 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 electric motor and gear head provides smooth rotation as the gearhead output offers a more constant drive with its output rotating at 15 rpm.
Inertia matching. Servo motors generate more torque relative to frame size because of 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 raised match the inertia of the servo motor gearbox engine to the inertia of the load can enable the usage of a smaller motor and results in a more responsive system that is easier to tune.