Smoothness and absence of ripple are essential for the printing of elaborate color pictures on reusable plastic cups available at fast-food chains. The color image comprises of an incredible number of tiny ink spots of many colours and shades. The complete glass is printed in a single move (unlike regular color separation where each color is imprinted separately). The gearheads must work efficiently enough to synchronize ink blankets, printing plates, and glass rollers without introducing any ripple or inaccuracies that may smudge the image. In cases like this, the hybrid gearhead decreases motor shaft runout error, which reduces roughness.
Sometimes a motor’s capability could be limited to the point where it needs gearing. As servo manufacturers develop better motors that can muscle tissue applications through more difficult moves and generate higher torques and speeds, these motors require gearheads equal to the task.
Interestingly, only about a third of the motion control systems operating use gearing at all. There are, of program, good reasons to do therefore. Utilizing a gearhead with a servo motor or using an integrated gearmotor can enable the usage of a smaller motor, therefore reducing the machine size and cost. There are three primary advantages of going with gears, each which can enable the use of smaller sized motors and drives and therefore lower total system price:
Torque multiplication. The gears and quantity of teeth on each gear generate a ratio. If a engine can generate 100 in-pounds of torque, and a 5:1 ratio equipment head is mounted on its result, 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 mounted on it, the velocity at the output will be 200 rpm. This speed reduction can improve system efficiency because many motors do not operate effectively at very low rpm. For example, consider a stone-grinding mechanism that will require the motor to perform at 15 rpm. This slow speed makes servo gear reducer 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 engine and gear mind provides smooth rotation as the gearhead output offers a more constant force with its output rotating at 15 rpm.
Inertia matching. Servo motors generate more torque relative to frame size thanks to lightweight materials, 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 utilization of a gearhead to raised match the inertia of the electric motor to the inertia of the load can enable the usage of a smaller motor and results in a far more responsive system that’s easier to tune.