Smoothness and absence of ripple are crucial for the printing of elaborate color pictures on reusable plastic cups offered by fast-food chains. The color image comprises of millions of tiny ink spots of many colours and shades. The complete cup is printed in a single complete (unlike regular color separation where each color can be imprinted separately). The gearheads must operate efficiently enough to synchronize ink blankets, printing plates, and cup rollers without introducing any ripple or inaccuracies that may smudge the image. In cases like this, the hybrid gearhead reduces motor shaft runout error, which reduces roughness.
Sometimes a motor’s capability may be limited to the main point where it requires gearing. As servo manufacturers develop more powerful motors that can muscle mass applications through more difficult moves and produce higher torques and speeds, these motors need 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 program, good reasons to do therefore. Utilizing a gearhead with a servo engine or using a gearmotor can enable the use of a smaller motor, thereby reducing the machine size and price. There are three main advantages of choosing gears, each of which can enable the use of smaller motors and drives and therefore lower total system cost:

Torque multiplication. The gears and amount of teeth on each gear create a ratio. If a engine can generate 100 in-pounds 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 rate at the output will be 200 rpm. This speed decrease can improve system efficiency because many motors do not operate efficiently at suprisingly low rpm. For example, consider a stone-grinding mechanism that requires the motor to perform at 15 rpm. This slow rate makes turning the grinding wheel tough because the motor tends to cog. The variable resistance of the stone being ground also hinders its simple turning. With the addition of a 100:1 gearhead and letting the electric motor run at 1,500 rpm, the engine and gear mind provides smooth rotation as the gearhead output provides a more constant force with its output rotating at 15 rpm.
Inertia matching. Servo motors generate more torque relative to frame size because of lightweight servo gear reducer components, dense copper windings, and high-energy magnets. The effect is higher inertial mismatches between servo motors and the loads they are trying to control. The use 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’s easier to tune.