Smoothness and lack of ripple are essential for the printing of elaborate color images on reusable plastic-type cups available at fast-food chains. The color image comprises of an incredible number of tiny ink dots of many colours and shades. The entire glass is printed in one move (unlike regular color separation where each color is imprinted separately). The gearheads must operate efficiently enough to synchronize ink blankets, printing plates, and cup rollers without introducing any ripple or inaccuracies that may smudge the picture. In this instance, the hybrid gearhead reduces motor shaft runout error, which reduces roughness.
Sometimes a motor’s capability could be limited to the main point where it requires gearing. As servo producers develop more powerful motors that can muscles applications through more complicated moves and produce higher torques and speeds, these motors require gearheads add up to the task.

Interestingly, no more than a third of the motion control systems in service use gearing at all. There are, of training course, reasons to do so. Utilizing a gearhead with a servo electric motor or using an integrated 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 of which can enable the utilization of smaller 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 gear head is attached to its output, the resulting torque will end up being near to 500 in-lbs.
When a motor is operating 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 effectively 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 level of 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 head provides smooth rotation while the gearhead output offers a more constant pressure 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 higher inertial mismatches between servo motors and the loads they are trying to control. The use of a gearhead to raised 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’s easier to tune.

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