Real-Time Load Monitoring in Linear Guideways Using Integrated Inductive Proximity Sensors

Linear guideways are essential components of manufacturing technology, providing precise motion and supporting significant loads in machine tools and automated systems. Real-time load measurement in these guideways is critical for effective condition monitoring and predictive maintenance. However, the compact and integrated nature of linear guideway systems makes such measurements inherently challenging. This study presents a novel approach to measuring load using relatively inexpensive inductive proximity sensors integrated in the linear guideway. The proposed method estimates the load by analyzing the relative position between the rolling element and the carriage, which is determined using switching signals. The concept of the measurement method was validated in a preliminary study on a 3-axis machine tool and subsequently tested on a fatigue life test rig under various load conditions. The results are promising and demonstrate the potential of this method for real-time load monitoring.