Smoothness and absence of ripple are essential for the printing of elaborate color images on reusable plastic-type cups offered by fast-food chains. The colour image servo motor gearbox comprises of millions of tiny ink dots of many colors and shades. The complete glass is printed in a single move (unlike regular color separation where each color is definitely imprinted separately). The gearheads must work smoothly enough to synchronize ink blankets, printing plates, and glass rollers without presenting any ripple or inaccuracies that may smudge the picture. In this case, the hybrid gearhead decreases motor shaft runout error, which reduces roughness.
At times a motor’s capability could be limited to the stage where it needs gearing. As servo manufacturers develop better motors that can muscle applications through more difficult moves and generate higher torques and speeds, these motors need gearheads add up to the task.
Interestingly, only about a third of the movement control systems in service use gearing at all. There are, of course, good reasons to do so. Utilizing a gearhead with a servo engine or using an integrated gearmotor can enable the usage of a smaller motor, thereby reducing the machine size and cost. There are three principal advantages of going with gears, each which can enable the use of smaller motors and drives and therefore lower total system cost:
Torque multiplication. The gears and quantity of tooth on each gear produce a ratio. If a engine can generate 100 in-pounds of torque, and a 5:1 ratio gear head is attached to its result, the resulting torque will end up being 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 velocity at the output will be 200 rpm. This speed decrease can improve system performance because many motors usually do not operate effectively at very low rpm. For example, consider a stone-grinding mechanism that will require the motor to run at 15 rpm. This slow velocity makes turning the grinding wheel challenging because the motor will cog. The variable resistance of the stone being surface also hinders its simple turning. By adding 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 provides a more constant drive 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 result is higher inertial mismatches between servo motors and the loads they are trying to control. The usage of a gearhead to better match the inertia of the engine to the inertia of the strain can enable the use of a smaller electric motor and results in a far more responsive system that’s easier to tune.