Smoothness and absence of ripple are crucial for the printing of elaborate color images on reusable plastic-type material cups available at fast-food chains. The colour image is made up of millions of tiny ink dots of many colours and shades. The entire glass is printed in one move (unlike regular color separation where each color can be imprinted separately). The gearheads must work smoothly enough to synchronize ink blankets, printing plates, and cup rollers without presenting any ripple or inaccuracies that may smudge the picture. In cases like this, the hybrid gearhead reduces motor shaft runout error, which reduces roughness.
Sometimes a motor’s capability could be limited to the stage where it needs gearing. As servo producers develop better motors that can muscles applications through more complicated moves and create higher torques and speeds, these motors need 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. Using a gearhead with a servo electric motor or using a gearmotor can enable the use of a smaller motor, therefore reducing the machine size and price. 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 number of tooth on each gear produce a ratio. If a motor can generate 100 in-pounds of torque, and a 5:1 ratio equipment head is mounted on its servo gear reducer result, the resulting torque will be close to 500 in-lbs.
When 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 decrease can improve system overall performance because many motors usually do not operate effectively at very low rpm. For example, look at a stone-grinding mechanism that requires the motor to perform at 15 rpm. This slow swiftness makes turning the grinding wheel difficult because the motor tends to cog. The variable level of resistance of the stone being surface also hinders its simple turning. By adding a 100:1 gearhead and letting the engine run at 1,500 rpm, the electric motor 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 because of lightweight components, 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 engine to the inertia of the load can enable the utilization of a smaller engine and outcomes in a far more responsive system that’s easier to tune.