Smoothness and lack of ripple are essential for the printing of elaborate color images on reusable plastic cups offered by fast-food chains. The color image comprises of an incredible number of tiny ink dots of many colors and shades. The complete cup is printed in one pass (unlike regular color separation where each color is definitely published servo gear reducer separately). The gearheads must run easily enough to synchronize ink blankets, printing plates, and cup rollers without presenting any ripple or inaccuracies that may smudge the image. In this case, the hybrid gearhead reduces motor shaft runout error, which reduces roughness.
At times a motor’s capability may be limited to the stage where it needs gearing. As servo producers develop more powerful motors that can muscle mass applications through more complicated moves and create higher torques and speeds, these motors require gearheads add up to the task.
Interestingly, only about a third of the motion control systems in service use gearing at all. There are, of training course, good reasons to do therefore. Utilizing a gearhead with a servo motor or using a built-in gearmotor can enable the usage of a smaller motor, therefore reducing the system size and price. There are three main advantages of going with gears, each of which can enable the use of smaller motors and drives and for that reason lower total system cost:
Torque multiplication. The gears and quantity of tooth on each gear generate a ratio. If a motor can generate 100 in-pounds of torque, and a 5:1 ratio equipment head is attached to its result, the resulting torque will end up being 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 acceleration at the output will be 200 rpm. This speed decrease can improve system performance because many motors do not operate efficiently at suprisingly low rpm. For example, consider a stone-grinding mechanism that will require the motor to run at 15 rpm. This slow swiftness makes turning the grinding wheel hard because the motor will cog. The variable resistance of the rock being ground also hinders its simple 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 offers a more constant drive 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 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 strain can enable the use of a smaller engine and results in a more responsive system that is easier to tune.