Smoothness and lack of ripple are essential for the printing of elaborate color images on reusable plastic-type material cups available at fast-food chains. The colour image comprises of millions of tiny ink dots of many colours and shades. The complete glass is printed in a single move (unlike regular color separation where each color can be printed separately). The gearheads must work 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 reduces motor shaft runout error, which reduces roughness.
At times a motor’s capability may be limited to the stage where it needs gearing. As servo manufacturers develop better motors that can muscle mass applications through more complicated moves and generate higher torques and speeds, these motors need 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 therefore. Using a gearhead with a servo electric motor or using a gearmotor can enable the use of a smaller motor, thereby reducing the machine size and cost. There are three primary advantages of going with gears, each of which can enable the use of smaller sized motors and drives and for that reason lower total system price:
Torque multiplication. The gears and number of teeth on each gear make a ratio. If a engine can generate 100 in-lbs of torque, and a 5:1 ratio equipment head is attached to its result, the servo gear reducer 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 speed at the output will be 200 rpm. This speed decrease can improve system performance because many motors do not operate effectively at very low rpm. For example, look at a stone-grinding mechanism that requires the motor to run at 15 rpm. This slow quickness makes turning the grinding wheel hard 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 mind provides smooth rotation while the gearhead output provides a more constant power with its output rotating at 15 rpm.
Inertia matching. Servo motors generate more torque in accordance with frame size thanks to lightweight components, dense copper windings, and high-energy magnets. The result is greater 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 motor 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.