Smoothness and lack of ripple are crucial for the printing of elaborate color images on reusable plastic-type 
material cups offered by fast-food chains. The color image is made up of millions 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 is imprinted separately). The gearheads must run efficiently enough to synchronize ink blankets, printing plates, and cup rollers without presenting any ripple or inaccuracies that may smudge the image. In cases like this, the hybrid gearhead decreases motor shaft runout mistake, which reduces roughness.
At times a motor’s capability could be limited to the stage where it requires gearing. As servo producers develop better motors that can muscle tissue applications through more difficult moves and produce higher torques and speeds, these motors require 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 training course, reasons to do so. Using a gearhead with a servo engine or using an integrated gearmotor can enable the utilization of a smaller motor, thereby reducing the machine size and price. There are three principal advantages of choosing gears, each of which can enable the use of smaller motors and drives and therefore lower total system price:
Torque multiplication. The gears and quantity of the teeth on each gear create a ratio. If a electric motor can servo gear reducer generate 100 in-lbs of torque, and a 5:1 ratio equipment head is attached to its output, the resulting torque will end up being near to 500 in-lbs.
Whenever a motor is running 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 reduction can improve system overall performance because many motors do not operate effectively at very low rpm. For example, look at a stone-grinding mechanism that requires the motor to perform at 15 rpm. This slow speed makes turning the grinding wheel difficult because the motor tends to cog. The variable resistance of the rock being ground also hinders its simple turning. By adding a 100:1 gearhead and letting the engine run at 1,500 rpm, the motor and gear mind provides smooth rotation while the gearhead output provides 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 materials, dense copper windings, and high-energy magnets. The effect is greater inertial mismatches between servo motors and the loads they want 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 motor and outcomes in a more responsive system that is easier to tune.