Smoothness and lack of ripple are crucial for the printing of elaborate color pictures on reusable plastic cups offered by fast-food chains. The colour image comprises of millions of tiny ink spots of many shades and shades. The complete cup is printed in a single pass (unlike regular color separation where each color is usually published separately). The gearheads must run easily enough to synchronize ink blankets, printing plates, and glass rollers without presenting any ripple or inaccuracies that may smudge the image. In this instance, the hybrid gearhead decreases motor shaft runout mistake, which reduces roughness.
At times a motor’s capability could be limited to the stage where it needs gearing. As servo manufacturers develop more powerful motors that can muscle applications through more complicated moves and create higher torques and servo motor gearbox speeds, these motors need gearheads equal to the task.
Interestingly, no more than a third of the motion control systems operating use gearing at all. There are, of course, reasons to do so. Using a gearhead with a servo electric motor 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 use of smaller sized motors and drives and for that reason lower total system cost:
Torque multiplication. The gears and amount of the teeth on each gear develop a ratio. If a electric motor can generate 100 in-lbs of torque, and a 5:1 ratio equipment head is attached to its output, the resulting torque will end up being near to 500 in-lbs.
When a motor is working at 1,000 rpm and a 5:1 ratio gearhead is mounted on it, the speed at the output will be 200 rpm. This speed reduction can improve system efficiency because many motors usually do not operate efficiently at very low rpm. For example, look at a stone-grinding mechanism that requires the motor to run at 15 rpm. This slow quickness makes turning the grinding wheel hard because the motor will cog. The variable resistance of the rock being ground also hinders its simple turning. With the addition of a 100:1 gearhead and letting the electric motor run at 1,500 rpm, the motor and gear mind provides smooth rotation while 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 components, dense copper windings, and high-energy magnets. The result is greater 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 utilization of a smaller electric motor and results in a more responsive system that’s easier to tune.