Smoothness and absence of ripple are crucial for the printing of elaborate color images on reusable plastic cups offered by fast-food chains. The color image is made up of millions of tiny ink dots of many shades and shades. The complete cup is printed in one move (unlike regular color separation where each color is usually imprinted separately). The gearheads must operate easily enough to synchronize ink blankets, printing plates, and cup 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.
At times a motor’s capability could be limited to the point where it requires gearing. As servo producers develop better motors that can muscles applications through more complicated moves and produce higher torques and speeds, these motors need gearheads add up to the task.
Interestingly, only about a third of the movement control systems operating use gearing at all. There are, of course, good reasons to do so. Utilizing a gearhead with a servo engine or using a built-in gearmotor can enable the use of a smaller motor, thereby reducing the system size and cost. There are three primary 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 number of tooth on each gear create a ratio. If a electric motor can generate 100 in-lbs of torque, and a 5:1 ratio equipment head is servo gear reducer mounted on its output, the resulting torque will be near to 500 in-lbs.
When a motor is running at 1,000 rpm and a 5:1 ratio gearhead is mounted on it, the swiftness at the output will be 200 rpm. This speed reduction can improve system overall performance because many motors do not operate efficiently at suprisingly low rpm. For example, look at a stone-grinding mechanism that requires the motor to perform at 15 rpm. This slow quickness makes turning the grinding wheel challenging because the motor tends to cog. The variable resistance of the rock being floor also hinders its ease of turning. By adding a 100:1 gearhead and letting the engine run at 1,500 rpm, the engine and gear mind provides smooth rotation as the gearhead output offers a more constant drive using 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 better match the inertia of the electric motor to the inertia of the load can enable the use of a smaller electric motor and results in a more responsive system that is easier to tune.