Smoothness and absence of ripple are essential for the printing of elaborate color images on reusable plastic cups available at fast-food chains. The color image comprises of millions of tiny ink spots of many shades and shades. The entire cup is printed in a single pass (unlike regular color separation where each color is definitely printed separately). The gearheads must function easily enough to synchronize ink blankets, printing plates, and cup 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 better motors that can muscle applications through more complicated moves and create 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 program, reasons to do so. Using a gearhead with a servo motor or using a gearmotor can enable the use of a smaller motor, therefore reducing the machine size and price. There are three major advantages of going with gears, each which can enable the use of smaller motors and drives and therefore lower total system price:
Torque multiplication. The gears and amount of the teeth on each gear produce a ratio. If a electric motor can generate 100 in-lbs of torque, and a 5:1 ratio gear head is attached to its result, the resulting torque will be close to 500 in-lbs.
Whenever a motor is running 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 reduction can improve system functionality because many motors usually do not operate efficiently at very low rpm. For example, look at a stone-grinding mechanism that requires the motor to perform at 15 rpm. This slow velocity makes turning the grinding wheel challenging because the motor tends to cog. The variable resistance of the stone being surface also hinders its simple turning. By adding a 100:1 gearhead and letting the motor run at 1,500 rpm, the engine and gear head provides smooth rotation while the gearhead output offers a more constant push using its output rotating at 15 rpm.
Inertia matching. Servo motors generate more torque relative to frame size thanks to lightweight components, dense copper windings, and high-energy magnets. The effect is better 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 electric 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 is easier to tune.
This is how servo motor gearbox can be utilised for your benefit.