Smoothness and lack 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 is made up of an incredible number of tiny ink spots of many colours and shades. The entire glass is printed in one pass (unlike regular color separation where each color is certainly printed separately). The gearheads must run smoothly enough to synchronize ink blankets, printing plates, and cup rollers without presenting any ripple or inaccuracies that may smudge the picture. In this instance, the hybrid gearhead decreases motor shaft runout mistake, which reduces roughness.
At times a motor’s capability could be limited to the point where it needs gearing. As servo manufacturers develop more powerful motors that can muscle applications through more complicated moves and generate higher torques and speeds, these motors require gearheads equal to the task.
Interestingly, only about 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 a built-in gearmotor can enable the use of a smaller motor, thereby reducing the machine size and price. There are three primary advantages of going with gears, each of 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 teeth on each gear produce a ratio. If a motor can generate 100 in-lbs of torque, and a 5:1 ratio gear head is mounted on its output, the resulting torque will be close to 500 in-lbs.
When a motor is running at 1,000 rpm and a 5:1 ratio gearhead is attached to it, the acceleration at the output will be 200 rpm. This speed reduction can improve system functionality because many motors usually 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 rate makes turning the grinding wheel challenging because the motor tends to cog. The variable resistance of the stone 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 engine and gear mind provides smooth rotation as the gearhead output offers a more constant pressure using its output rotating at 15 rpm.
Inertia servo gear reducer matching. Servo motors generate more torque relative to frame size thanks to lightweight materials, dense copper windings, and high-energy magnets. The effect is higher inertial mismatches between servo motors and the loads they want to control. The utilization 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 results in a far more responsive system that’s easier to tune.