Smoothness and lack of ripple are essential for the printing of elaborate color pictures on reusable plastic-type cups available at fast-food chains. The colour image is made up of millions of tiny ink dots of many colors and shades. The entire glass is printed in one pass (unlike regular color separation where each color is usually imprinted separately). The gearheads must run easily enough to synchronize ink blankets, printing plates, and cup rollers without presenting any ripple or inaccuracies that may smudge the picture. In this instance, the hybrid gearhead reduces motor shaft runout error, which reduces roughness.
Sometimes a motor’s capability could be limited to the main point where it needs gearing. As servo producers 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 movement control systems in service use gearing at all. There are, of course, good 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 machine size and price. There are three main advantages of going with gears, each which can enable the usage of smaller motors and drives and for that reason lower total system cost:
Torque multiplication. The gears and amount of tooth on each gear make a ratio. If a engine can generate 100 in-pounds of torque, and a 5:1 ratio gear head is mounted on its result, the resulting torque will become close to 500 in-lbs.
Whenever a motor is operating 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 servo gear reducer improve system overall performance because many motors usually do not operate effectively at suprisingly 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 rock being ground also hinders its simple 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 provides a more constant force using its output rotating at 15 rpm.
Inertia matching. Servo motors generate more torque in accordance with frame size because of lightweight materials, dense copper windings, and high-energy magnets. The effect is better 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 load can enable the use of a smaller engine and results in a far more responsive system that’s easier to tune.