Smoothness and lack of ripple are crucial for the printing of elaborate color images on reusable plastic-type cups available at fast-food chains. The color image comprises of millions of tiny ink dots of many colours and shades. The entire glass is printed in one complete (unlike regular color separation where each color is certainly imprinted separately). The gearheads must function efficiently enough to synchronize ink blankets, printing plates, and glass rollers without presenting any ripple or inaccuracies that may smudge the image. In this instance, the hybrid gearhead reduces motor shaft runout mistake, which reduces roughness.
Sometimes a motor’s capability may be limited to the stage where it needs gearing. As servo manufacturers develop better motors that can muscle applications through more difficult moves and create higher torques and speeds, these motors require gearheads equal to the task.
Interestingly, no more than a third of the motion control systems in service use gearing at all. There are, of course, reasons to do therefore. Utilizing a gearhead with a servo electric motor or using a built-in gearmotor can enable the use of a smaller motor, thereby reducing the machine size and cost. There are three major advantages of going with gears, each which can enable the use of smaller sized motors and drives and for that reason lower total system cost:
Torque multiplication. The gears and quantity of teeth on each gear make a ratio. If a electric motor can generate 100 in-lbs of torque, and a 5:1 ratio equipment head is mounted on its output, the resulting torque will end up being near to 500 in-lbs.
Whenever a motor is operating at 1,000 rpm and a 5:1 ratio gearhead is attached to it, the quickness at the output will be 200 rpm. This speed reduction can improve system overall performance because many motors usually 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 acceleration makes turning the grinding wheel tough 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 servo motor gearbox letting the motor run at 1,500 rpm, the motor and gear head provides smooth rotation as the gearhead output offers a more constant force with its output rotating at 15 rpm.
Inertia matching. Servo motors generate more torque relative to frame size because of lightweight components, 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 better match the inertia of the engine to the inertia of the load can enable the use of a smaller electric motor and outcomes in a far more responsive system that’s easier to tune.