Smoothness and absence of ripple are crucial for the printing of elaborate color images on reusable plastic-type material cups available at fast-food chains. The colour image comprises of an incredible number of tiny ink spots of many shades and shades. The entire cup is printed in one complete (unlike regular color separation where each color is usually imprinted separately). The gearheads must work 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 may be limited to the point where it needs gearing. As servo producers develop better motors that can muscle applications through more complicated moves and produce higher torques and speeds, these motors require gearheads equal to the task.
Interestingly, only about a third of the motion control systems in service use gearing at all. There are, of course, good reasons to do therefore. Utilizing a gearhead with a servo electric motor or using a gearmotor can enable the use of a smaller motor, thereby reducing the system size and price. There are three major advantages of choosing gears, each which can enable the use of smaller sized motors and drives and for that reason lower total system price:
Torque multiplication. The gears and quantity of teeth on each gear develop a ratio. If a engine can generate 100 in-pounds of torque, and a 5:1 ratio gear head is attached to its output, the resulting torque will become close to 500 in-lbs.
When a motor is working 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 efficiency because many motors usually do not operate efficiently at very low rpm. For example, look at a stone-grinding servo motor gearbox mechanism that requires the motor to perform at 15 rpm. This slow velocity makes turning the grinding wheel difficult because the motor will cog. The variable level of resistance of the rock being ground also hinders its ease of turning. By adding a 100:1 gearhead and letting the electric motor run at 1,500 rpm, the motor and gear head provides smooth rotation as the gearhead output provides a more constant force using its output rotating at 15 rpm.
Inertia matching. Servo motors generate more torque in accordance with frame size because of lightweight components, 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 motor to the inertia of the load can enable the use of a smaller engine and outcomes in a far more responsive system that’s easier to tune.