Smoothness and lack of ripple are crucial for the printing of elaborate color images on reusable plastic material cups offered by fast-food chains. The colour image comprises of millions of tiny ink dots of many colors and shades. The entire cup is printed in one pass (unlike regular color separation where each color is usually imprinted separately). The gearheads must operate smoothly enough to synchronize ink blankets, printing plates, and cup rollers without introducing any ripple or inaccuracies that may smudge the image. In this case, the hybrid gearhead decreases motor shaft runout error, which reduces roughness.
Sometimes a motor’s capability could be limited to the stage where it requires gearing. As servo producers develop more powerful motors that can muscle applications through more complicated moves and generate 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. Utilizing a gearhead with a servo engine or using a gearmotor can enable the use of a smaller motor, thereby reducing the machine size and price. There are three principal advantages of choosing gears, each of which can enable the use of smaller motors and drives and therefore lower total system price:
Torque multiplication. The gears and number of teeth on each gear generate a ratio. If a engine can generate 100 in-pounds of torque, and a 5:1 ratio gear head is mounted on its output, the resulting torque will end up being close to 500 in-lbs.
When a motor is working 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 very low rpm. For example, consider a stone-grinding mechanism that will require the motor to run at 15 rpm. This slow acceleration makes turning the grinding wheel difficult because the motor will cog. The variable resistance of the stone being ground also hinders its ease of turning. With the addition of a 100:1 gearhead and letting the motor run at 1,500 rpm, the electric motor and gear head servo motor gearbox provides smooth rotation while the gearhead output provides a more constant push 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 higher inertial mismatches between servo motors and the loads they are trying to control. The usage 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.