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Area of Science:

  • Mechanical Engineering
  • Materials Science
  • Manufacturing Technology

Background:

  • Process force determination is crucial for optimizing manufacturing and enabling predictive maintenance in machine tools.
  • Existing methods for force sensing have limitations, necessitating novel approaches.
  • Integrating sensors directly into machine tool components like linear guides offers potential for in-situ measurements.

Purpose of the Study:

  • To present an overview of current process force determination methods.
  • To motivate the integration of sensors within linear guides.
  • To introduce and evaluate a new method for capturing load on rolling element linear guides.

Main Methods:

  • Developed a novel method measuring stresses from rolling element contact on the side of a runner block.
  • Utilized piezoresistive diamond-like carbon (DLC) coating (DiaForce®) for sensor implementation.
  • Validated measurements against analytical and finite element method (FEM) simulations.

Main Results:

  • Demonstrated good agreement between experimental measurements and simulation results.
  • Confirmed the potential for stable modeling and load estimation.
  • Identified non-idealities such as high temperature dependency and cross-sensitivity to other stresses.

Conclusions:

  • The developed method shows promise for accurate load estimation in linear guides.
  • An efficient approach to mitigate identified non-idealities (temperature dependency, cross-sensitivity) was successfully implemented.
  • This sensor integration offers a viable path for enhanced machine tool monitoring and control.