Smoothness and absence of ripple are essential for the printing of elaborate color images on reusable plastic material cups available at fast-food chains. The color image comprises of millions of tiny ink dots of many colors and shades. The entire glass is printed in a single complete (unlike regular color separation where each color is usually printed separately). The gearheads must servo gear reducer operate efficiently enough to synchronize ink blankets, printing plates, and glass rollers without introducing any ripple or inaccuracies that may smudge the image. In cases like this, the hybrid gearhead decreases motor shaft runout mistake, which reduces roughness.
At times a motor’s capability could be limited to the main point where it requires gearing. As servo manufacturers develop better motors that can muscles applications through more complicated moves and generate higher torques and speeds, these motors require gearheads add up to the task.
Interestingly, no more than a third of the movement control systems operating use gearing at all. There are, of course, reasons to do therefore. Utilizing a gearhead with a servo motor or using a built-in gearmotor can enable the utilization of a smaller motor, therefore reducing the system size and price. There are three principal advantages of choosing gears, each which can enable the use of smaller motors and drives and therefore lower total system cost:
Torque multiplication. The gears and amount of tooth on each gear develop a ratio. If a motor can generate 100 in-lbs of torque, and a 5:1 ratio gear head is attached to its result, the resulting torque will be close to 500 in-lbs.
Whenever 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 overall performance because many motors do not operate effectively at very low rpm. For example, consider a stone-grinding mechanism that will require the motor to perform at 15 rpm. This slow velocity makes turning the grinding wheel hard 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 motor run at 1,500 rpm, the motor and gear head 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 materials, dense copper windings, and high-energy magnets. The result is greater 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 load can enable the use of a smaller engine and results in a more responsive system that is easier to tune.