Smoothness and absence of ripple are essential for the printing of elaborate color images on reusable plastic cups offered by fast-food chains. The colour image comprises of an incredible number of tiny ink dots of many colours and shades. The complete glass is printed in one complete (unlike regular color separation where each color is definitely published separately). The gearheads must work smoothly enough to synchronize ink blankets, printing plates, and glass rollers without introducing any ripple or inaccuracies that may smudge the picture. In this instance, the hybrid gearhead reduces motor shaft runout mistake, which reduces roughness.
Sometimes a motor’s capability may be limited to the main point where it needs gearing. As servo manufacturers develop more powerful motors that can muscles applications through more complicated moves and create higher torques and 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 therefore. Using a gearhead with a servo motor or using an integrated gearmotor can enable the use of a smaller motor, thereby reducing the system size and price. There are three primary advantages of choosing 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 quantity of the teeth on each gear produce a ratio. If a motor can generate 100 in-pounds of torque, and a 5:1 ratio equipment head is attached to its output, the resulting torque will end up being close to 500 in-lbs.
Whenever a motor is operating at 1,000 rpm and a 5:1 ratio gearhead is attached to it, the rate 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, look at a stone-grinding mechanism that requires the motor to run at 15 rpm. This slow acceleration makes turning the grinding wheel hard because the motor tends to 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 engine run at 1,500 rpm, the motor and gear mind provides smooth rotation while the gearhead output provides a more constant push 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 result is better inertial mismatches between servo motors and the loads they want to control. The use of a gearhead to raised match the inertia of the electric motor to the inertia of the strain can enable the use of a smaller engine and servo motor gearbox outcomes in a more responsive system that is easier to tune.