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 is made up of an incredible number of tiny ink dots of many colours and shades. The entire cup is printed in a single pass (unlike regular color separation where each color is certainly imprinted separately). The gearheads must run smoothly 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 decreases motor shaft runout error, which reduces roughness.
At times a motor’s capability may be limited to the main point where it requires gearing. As servo producers develop more powerful motors that can muscle mass applications through more complicated moves and create higher torques and speeds, these motors require gearheads equal 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 so. Utilizing a gearhead with a servo motor or using an integrated gearmotor can enable the use of a smaller motor, thereby reducing the machine size and price. There are three primary advantages of going with gears, each of which can enable the use of smaller sized motors and drives and therefore lower total system cost:
Torque multiplication. The gears and quantity of the teeth on each gear develop a ratio. If a engine can generate 100 in-lbs of torque, and a 5:1 ratio gear head is attached to its output, the resulting torque will become 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 speed at the output will be 200 rpm. This speed decrease can improve system overall performance because many motors 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 acceleration makes turning the grinding wheel difficult because the motor tends to cog. The variable level of resistance of the stone being ground also hinders its simple 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 as the gearhead output provides a more constant drive using its output rotating at 15 rpm.
Inertia matching. Servo motors generate more torque relative to frame size thanks to lightweight materials, dense copper windings, and high-energy magnets. The result is greater inertial mismatches between servo motors and the loads they want to control. The use of a gearhead to better match the inertia of the motor 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.
Increase your understanding of servo motor gearbox.