Smoothness and absence of ripple are essential for the printing of elaborate color images on reusable plastic material cups offered by fast-food chains. The color image comprises of an incredible number of tiny ink spots of many colors and shades. The complete cup is printed in one pass (unlike regular color separation where each color is usually printed separately). The gearheads must function easily enough to synchronize ink blankets, printing plates, and glass rollers without introducing any ripple or inaccuracies that may smudge the image. In this instance, the hybrid gearhead decreases motor shaft runout servo gear reducer mistake, which reduces roughness.
At times a motor’s capability may be limited to the point where it requires gearing. As servo producers develop better motors that can muscle tissue applications through more complicated moves and produce higher torques and speeds, these motors require gearheads equal to the task.
Interestingly, no more than a third of the motion control systems operating use gearing at all. There are, of course, good 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, therefore reducing the system size and price. There are three principal advantages of going with gears, each which can enable the use of smaller sized motors and drives and therefore lower total system price:
Torque multiplication. The gears and quantity of tooth on each gear produce 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 be near to 500 in-lbs.
When a motor is operating at 1,000 rpm and a 5:1 ratio gearhead is mounted on it, the rate at the output will be 200 rpm. This speed reduction can improve system overall performance because many motors usually do not operate effectively at very low rpm. For example, look at a stone-grinding mechanism that will require the motor to run at 15 rpm. This slow quickness makes turning the grinding wheel difficult because the motor will cog. The variable level of resistance of the rock being surface also hinders its ease of turning. With the addition of a 100:1 gearhead and letting the motor run at 1,500 rpm, the electric motor and gear head provides smooth rotation as the gearhead output offers a more constant pressure 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 effect is better inertial mismatches between servo motors and the loads they want to control. The utilization of a gearhead to better match the inertia of the engine to the inertia of the load can enable the utilization of a smaller motor and outcomes in a far more responsive system that’s easier to tune.