Smoothness and absence of ripple are crucial for the printing of elaborate color images on reusable plastic cups offered by fast-food chains. The colour image comprises of millions of tiny ink dots of many colors and shades. The entire cup is printed in a single pass (unlike regular color separation where each color is imprinted separately). The gearheads must work easily 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 could be limited to the point where it needs gearing. As servo manufacturers develop more powerful servo gear reducer motors that can muscle applications through more complicated moves and create higher torques and speeds, these motors require gearheads equal 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 therefore. Utilizing a gearhead with a servo electric motor or using a gearmotor can enable the utilization of a smaller motor, therefore reducing the system size and cost. There are three main advantages of choosing gears, each which can enable the use of smaller sized motors and drives and therefore lower total system cost:

Torque multiplication. The gears and amount of the teeth on each gear create a ratio. If a motor can generate 100 in-lbs of torque, and a 5:1 ratio equipment head is mounted on its output, the resulting torque will be near to 500 in-lbs.
When a motor is operating at 1,000 rpm and a 5:1 ratio gearhead is mounted on it, the rate at the output will be 200 rpm. This speed decrease can improve system functionality because many motors usually do not operate effectively at suprisingly low rpm. For example, look at a stone-grinding mechanism that will require the motor to perform at 15 rpm. This slow velocity makes turning the grinding wheel challenging because the motor will cog. The variable resistance of the rock being surface also hinders its simple turning. By adding a 100:1 gearhead and letting the electric motor run at 1,500 rpm, the engine and gear head provides smooth rotation as the gearhead output offers a more constant force using its output rotating at 15 rpm.
Inertia matching. Servo motors generate more torque in accordance with frame size thanks to lightweight materials, dense copper windings, and high-energy magnets. The effect is better inertial mismatches between servo motors and the loads they want to control. The usage of a gearhead to better match the inertia of the engine to the inertia of the strain can enable the usage of a smaller engine and results in a far more responsive system that’s easier to tune.