Smoothness and lack of ripple are essential for the printing of elaborate color pictures on reusable plastic material cups offered by fast-food chains. The color image is made up of millions of tiny ink dots of many colors and shades. The entire cup is printed in a single complete (unlike regular color separation where each color can be published separately). The gearheads must function easily enough to synchronize ink blankets, printing plates, and cup rollers without introducing any ripple or inaccuracies that may smudge the picture. 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 main point where it requires gearing. As servo producers develop better motors that can muscle applications through more difficult moves and create higher torques and speeds, these motors require gearheads equal to the task.
Interestingly, no more than a third of the motion control systems in service use gearing at all. There are, of program, good 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, therefore reducing the system size and cost. There are three main advantages of going with gears, each which can enable the use of smaller motors and drives and for that reason lower total system price:
Torque multiplication. The gears and number of the teeth on each gear make a ratio. If a engine can generate 100 in-lbs of torque, and a 5:1 ratio equipment head is attached to its output, the resulting torque will become close to 500 in-lbs.
Whenever a motor is running at 1,000 rpm and a 5:1 ratio gearhead is attached to it, the quickness at the output will be 200 rpm. This speed decrease can improve system efficiency because many motors usually do not 
operate effectively at suprisingly low rpm. For example, consider a stone-grinding mechanism that will require the motor to run at 15 rpm. This slow velocity makes turning the grinding wheel difficult because the motor tends to cog. The variable resistance of the rock being ground 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 head 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 effect is better inertial mismatches between servo motors and the loads they want to control. The usage of a gearhead to raised match the inertia of the engine to the inertia of the strain can enable the usage of a smaller engine and outcomes in a far more responsive system that’s easier to tune.
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