Smoothness and absence of ripple are crucial for the printing of elaborate color pictures on reusable plastic cups offered by fast-food chains. The color image comprises of millions of tiny ink dots of many shades and shades. The entire cup is printed in one complete (unlike regular color separation where each color is definitely printed separately). The gearheads must function easily enough to synchronize ink blankets, printing plates, and cup rollers without presenting any ripple or inaccuracies that may smudge the image. In this instance, the hybrid gearhead decreases motor shaft runout mistake, which reduces roughness.
Sometimes a motor’s capability may be limited to the stage where it requires gearing. As servo producers develop more powerful motors that can muscle tissue applications through more difficult moves and produce higher torques and speeds, these motors require gearheads equal to the task.
Interestingly, only about a third of the motion control systems in service use gearing at all. There are, of program, reasons to do so. Using a gearhead with a servo electric motor or using an integrated gearmotor can enable the use of a smaller motor, thereby reducing the system size and cost. There are three main advantages of choosing gears, each of which can enable the use of smaller sized motors and drives and therefore lower total system cost:
Torque multiplication. The gears and quantity of teeth on each gear generate 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.
When a motor is operating at 1,000 rpm and a 5:1 ratio gearhead is attached to it, the rate at the output will be 200 rpm. This speed reduction can improve system performance because many motors usually do not operate efficiently at very low rpm. For example, consider a stone-grinding mechanism that will require the motor to perform at 15 rpm. This slow speed makes turning the grinding wheel hard because the motor will cog. The variable resistance of the rock being ground also hinders its ease of turning. With the addition of a 100:1 gearhead and letting the electric motor run at 1,500 rpm, the electric motor and gear head provides smooth servo motor gearbox rotation while the gearhead output provides a more constant power with its output rotating at 15 rpm.
Inertia matching. Servo motors generate more torque relative to frame size because of lightweight materials, dense copper windings, and high-energy magnets. The result is better inertial mismatches between servo motors and the loads they want to control. The usage of a gearhead to raised match the inertia of the engine to the inertia of the strain can enable the use of a smaller motor and results in a more responsive system that is easier to tune.