Smoothness and lack of ripple are essential for the printing of elaborate color pictures on reusable plastic-type cups offered by fast-food chains. The color image is made up of an incredible number of tiny ink spots of many colours and shades. The entire cup is printed in one pass (unlike regular color separation where each color is usually published separately). The gearheads must operate smoothly enough to synchronize ink blankets, printing plates, and glass rollers without introducing any ripple or inaccuracies that may smudge the image. In this instance, the hybrid gearhead reduces motor shaft runout error, which reduces roughness.
At times a motor’s capability could be limited to the point where it needs gearing. As servo producers develop more powerful motors that can muscle applications through more complicated moves and produce higher torques and speeds, these motors require gearheads equal to the task.
Interestingly, only about a third of the movement control systems in service use gearing at all. There are, of course, reasons to do so. Using a gearhead with a servo electric motor or using a gearmotor can enable the use of a smaller motor, thereby reducing the system size and price. There are three main advantages of choosing 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 tooth on each gear make a ratio. If a electric motor can generate 100 in-pounds of torque, and a 5:1 ratio gear head is attached to its result, the resulting torque will be near to 500 in-lbs.
When a motor is operating at 1,000 rpm and a 5:1 ratio gearhead is attached to it, the velocity 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 run at 15 rpm. This slow quickness makes turning the grinding wheel tough because the motor will cog. The variable resistance of the stone being surface also hinders its ease of turning. By adding a 100:1 gearhead and letting the motor run at 1,500 rpm, the electric motor and gear head provides smooth rotation while the gearhead output offers a more constant pressure with its output rotating at 15 rpm.
Inertia matching. Servo motors generate more torque relative to frame size thanks to servo motor gearbox lightweight materials, dense copper windings, and high-energy magnets. The result is greater inertial mismatches between servo motors and the loads they want to control. The use of a gearhead to better match the inertia of the electric motor to the inertia of the strain can enable the usage of a smaller engine and outcomes in a more responsive system that’s easier to tune.