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 spots of many colors and shades. The complete cup is printed in one pass (unlike regular color servo gear reducer separation where each color is imprinted separately). The gearheads must operate easily enough to synchronize ink blankets, printing plates, and cup rollers without introducing any ripple or inaccuracies that may smudge the image. In this instance, the hybrid gearhead reduces motor shaft runout error, which reduces roughness.
At times a motor’s capability could be limited to the stage where it requires gearing. As servo manufacturers develop better motors that can muscle mass applications through more difficult 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 program, good reasons to do so. Using a gearhead with a servo electric motor or using a built-in gearmotor can enable the use of a smaller motor, therefore reducing the system size and cost. There are three main advantages of choosing gears, each which can enable the use of smaller motors and drives and for that reason lower total system price:
Torque multiplication. The gears and amount of teeth on each gear make a ratio. If a electric motor can generate 100 in-lbs of torque, and a 5:1 ratio gear head is attached to its result, the resulting torque will become near to 500 in-lbs.
Whenever a motor is working at 1,000 rpm and a 5:1 ratio gearhead is attached to it, the velocity at the output will be 200 rpm. This speed reduction can improve system performance because many motors usually do not operate efficiently at suprisingly low rpm. For example, look at a stone-grinding mechanism that will require the motor to perform at 15 rpm. This slow quickness makes turning the grinding wheel challenging because the motor tends to cog. The variable level of resistance of the rock being floor also hinders its simple turning. With the addition of a 100:1 gearhead and letting the engine run at 1,500 rpm, the electric motor and gear head provides smooth rotation as the gearhead output offers a more constant push with its output rotating at 15 rpm.
Inertia matching. Servo motors generate more torque in accordance with frame size thanks to lightweight materials, dense copper windings, and high-energy magnets. The effect is greater inertial mismatches between servo motors and the loads they want to control. The utilization of a gearhead to better match the inertia of the electric motor to the inertia of the strain can enable the use of a smaller engine and outcomes in a far more responsive system that is easier to tune.