Smoothness and absence of ripple are essential for the printing of elaborate color images on reusable plastic cups available at fast-food chains. The colour image comprises of an incredible servo motor gearbox number of tiny ink dots of many shades and shades. The complete cup is printed in a single pass (unlike regular color separation where each color is printed separately). The gearheads must run efficiently enough to synchronize ink blankets, printing plates, and glass rollers without introducing any ripple or inaccuracies that may smudge the image. In this case, the hybrid gearhead reduces motor shaft runout error, which reduces roughness.
Sometimes a motor’s capability may be limited to the stage where it needs gearing. As servo manufacturers develop more powerful 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, no more than a third of the movement control systems operating use gearing at all. There are, of course, reasons to do therefore. Using 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 main advantages of going with gears, each which can enable the use of smaller motors and drives and for that reason lower total system cost:
Torque multiplication. The gears and number of tooth on each gear produce 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 be close to 500 in-lbs.
When a motor is running at 1,000 rpm and a 5:1 ratio gearhead is mounted on it, the velocity 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, consider a stone-grinding mechanism that will require the motor to perform at 15 rpm. This slow swiftness makes turning the grinding wheel tough because the motor tends to cog. The variable level of resistance of the rock being surface also hinders its simple turning. By adding 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 offers a more constant drive with its output rotating at 15 rpm.
Inertia matching. Servo motors generate more torque in accordance with 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 use 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.