Smoothness and absence of ripple are crucial for the printing of elaborate color pictures on reusable plastic-type material cups available at fast-food chains. The color image is made up of an incredible number of tiny ink dots of many colors and shades. The entire glass is printed in one pass (unlike regular color separation where each color is published separately). The gearheads must run easily enough to synchronize ink blankets, printing plates, and glass rollers without introducing any ripple or inaccuracies that may smudge the picture. In this case, the hybrid gearhead decreases motor shaft runout error, which reduces roughness.
Sometimes a motor’s capability may be limited to the point where it requires gearing. As servo producers develop more powerful motors that can muscles applications through more complicated moves and generate higher torques and speeds, these motors need gearheads add up to the task.

Interestingly, only about a third of the motion control systems operating use gearing at all. There are, of program, reasons to do so. Utilizing a gearhead with a servo engine or using a built-in gearmotor can enable the utilization of a smaller motor, thereby reducing the machine size and cost. There are three principal advantages of going with gears, each of which can enable the usage of smaller motors and drives and therefore lower total system cost:

Torque multiplication. The gears and number of tooth on each gear develop a ratio. If a electric motor can generate 100 in-lbs of torque, and a 5:1 ratio gear head is attached to 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 velocity at the output will be 200 rpm. This speed decrease can improve system performance because many motors do not operate efficiently at very low rpm. For example, consider a stone-grinding mechanism that requires the motor to perform at 15 rpm. This slow quickness makes turning the grinding wheel hard because the motor will cog. The variable level of resistance of the stone 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 engine and gear head provides smooth rotation while the gearhead output provides a more constant push 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 effect is higher 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 strain can enable the use of a smaller motor and results in a far more responsive system that’s easier to tune.

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