Smoothness and lack of ripple are essential for the printing of elaborate color pictures on reusable plastic-type cups offered by fast-food chains. The color image comprises of an incredible number 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 definitely imprinted separately). The gearheads must function easily 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 mistake, which reduces roughness.
At times a motor’s capability could be limited to the main point where it requires gearing. As servo producers develop better motors that can muscle mass applications through more difficult moves and produce higher torques and speeds, these motors require gearheads equal to the task.
Interestingly, only about a third of the motion control systems in service use gearing at all. There are, of program, good reasons to do so. Using a gearhead with a servo motor or using an integrated gearmotor can enable the use of a smaller motor, therefore reducing the system size and price. There are three major advantages of going with gears, each of which can enable the utilization of smaller motors and drives and therefore lower total system cost:
Torque multiplication. The gears and number of teeth on each gear create 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 end up being close to 500 in-lbs.
Whenever 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 reduction can improve system performance because many motors do not 
operate efficiently at suprisingly low rpm. For example, consider a stone-grinding mechanism that will require the motor to perform at 15 rpm. This slow acceleration makes turning the grinding wheel challenging because the motor tends to cog. The variable resistance of the rock being floor also hinders its simple turning. By adding a 100:1 gearhead and letting the motor run at 1,500 rpm, the engine and gear mind provides smooth rotation while the gearhead output offers a more constant power using 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 motor to the inertia of the strain can enable the usage of a smaller motor and results in a far more responsive system that’s easier to tune.
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