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 colour image is made up of an incredible number of tiny ink spots of many colors and shades. The entire cup is printed in a single complete (unlike regular color separation where each color can be imprinted separately). The gearheads must function efficiently enough to synchronize ink blankets, printing plates, and cup rollers without introducing 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 could be limited to the stage where it requires gearing. As servo producers develop more powerful motors that can muscles applications through more difficult moves and create higher torques and speeds, these motors need gearheads add up to the task.
Interestingly, no more than a third of the movement control systems in service use gearing at all. There are, of training course, good reasons to do so. Utilizing a gearhead with a servo electric motor or using an integrated gearmotor can enable the use of a smaller motor, thereby reducing the machine 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 for that reason lower total system price:
Torque multiplication. The gears and amount of teeth on each gear generate a ratio. If a engine can generate 100 in-pounds of torque, and a 5:1 ratio equipment head is mounted on its output, the resulting torque will become 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 acceleration at the output will be 200 rpm. This speed decrease 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 requires the motor to run at 15 rpm. This slow speed makes turning the grinding wheel difficult because the motor will cog. The variable level of resistance of the rock being floor also hinders its simple turning. With the addition of a 100:1 gearhead and letting the motor run at 1,500 rpm, the motor and gear head provides smooth rotation as the gearhead output provides a more constant power using 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 are trying to control. The use of a gearhead to raised match the inertia of the electric motor to the inertia of the load can enable the use of a smaller engine and results in a far more responsive system that’s easier to tune.
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