The competitive nature of the modern manufacturing industry coupled with increasing consumer demand and a dynamic economy, lead manufacturers to operate their production computer numerical control (CNC) machines beyond their capable operational limits. This unsustainable behaviour leads to the rapid deterioration and breakdown of the CNC’s critical subsystems and components. Consequently, increasing the amount of unplanned downtime and cost of maintenance. To put it into perspective, downtime in the automotive manufacturing sector can reach upwards of USD 2 million per hour. The linear axis is one of the CNC’s critical subsystems, its robust and accurate positioning capabilities drive the operational and geometric performance of CNC machines. Failure to promptly address developed faults in the linear axis, may lead to poor geometric performance and system sluggishness, overall affecting the production quality of manufactured products. Therefore, it is crucial to monitor the health condition of this subsystem and its components. The principal aim of the presented research was to develop a condition-based monitoring (CBM) system to monitor the health condition of the linear axis and its various components. To achieve this aim, the research work was divided into four objectives. Firstly, objective one consisted of designing an industrial level linear axis testbed that resembles a CNCs linear axis to conduct all experiments. Furthermore, the testbed’s main contribution is to serve as a data generation platform for the research community. Objective two focused in the design of a framework to establish a reference baseline dataset for CBM systems. The framework’s contribution consisted of building an understanding of the healthy condition of the linear axis and its components using vibration monitoring and time domain statistical feature analysis. It was found that under a known healthy condition the time domain features exhibit low variability, there is a negligible difference between a forward and reverse stroke, and a robust baseline can be established by collecting data for approximately an hour of operation rather than a 6-hour operational shift. The third objective of the research consisted in conducting a comprehensive health assessment of the linear axis and its components through a multi-sensor approach, when a root-cause failure fault (FF) is present. Additionally, the health assessment’s contribution was further enhanced by analyzing the repair condition of these faults and comparing the results to the original baseline. The assessment demonstrated that the most frequently occurring root-cause FF, carrier block raceway blockage, can easily be detected through the system’s internal data. Moreover, the repair state condition exhibited less than 10% error when compared to the baseline state. Finally, the fourth objective was centered in the development and application of a novel signal segmentation technique to detect and localize the leading root-cause of failure in the linear axis, misalignment. The technique’s main contribution rests in its functionality as a localization and verification tool in linear axis maintenance. The findings from the conducted studies revealed that the technique increased the usability of time domain features such as RMS, by approximately double. Lastly, the evaluation of both stroke directions aided in localizing the misalignment in the linear axis. / Thesis / Doctor of Philosophy (PhD) / Computer numerical control (CNC) machines are pivotal assets for the manufacturing sector, yet the demand from the modern industry often drives the operation of these machines to exceed their capable operational limits. Consequently, causing the breakdowns of their critical subsystems, resulting in high maintenance costs and machine downtime. The linear axis is one of these critical subsystems, primarily tasked with the positioning function in the CNC machine. In the presented research, a condition-based monitoring (CBM) system was developed, to monitor the health state of this critical subsystem and its components. The development of the system first focused on understanding the healthy condition of a linear axis and its components by implementing a statistics-based baseline dataset framework. Then, a comprehensive health assessment was conducted to evaluate multiple data streams and detect signal variation when root cause failure faults (FFs) are present in the system. Unlike previous health assessments, the repair condition of the evaluated components was also included in the analysis. Finally, a novel signal segmentation algorithm was developed to complement the CBM system, specifically serving as a localization tool to pinpoint an artificially induced misalignment on the guide rail component of the linear axis.

This thesis deals with construction, connection and control axis with linear motor. The beginning of thesis is focused on principle of functioning and characteristics of linear motors. The following part describes used components of axis, their mechanical configuration and electrical wiring. Further thesis deals with creating PLC program and user interface for control axis in TwinCAT system. In last part is dealing correct software settings of axis.

This thesis is dealing with determining of technical and economical limits of axis X of portal milling machine driven by gear rack and pinion. And designing drive of axis like this. In chapter overview of the current state of knowledge are researched options of drive systems of linear axis, primarily of using ball screw and couple of pinion and gear rack. Basic parameters of axis X portal milling machines, options of measuring, guiding of axis and electric motors. Then the limit suitability of using pinion and gear rack is determined. In next chapters is designed few variations of arrangements of drives and selected the best one. This arrangement is then designed.

Master´s thesis is focused on portal milling machine driven by ball screw and nut. There is a limit where it is suitable to use a driven screw or driven nut. Both variants are solved based on specified X-axis travel distance. In last part is solved the design of support long shaft ball screw driven by nut. The work also includes 3D CAD model of both variants and drawing documentation.

The aim of this master thesis is the construction of a single-purpose machine used for reeling of composite insulator. In the first part is described the technology of reeling completed by the analysis of used components. Based on the findings, the final constructional version with necessary calculations is stated. The result of this thesis is a 3D model of the chosen design together with drawings and calculations of given parts.

The thesis deals with the design of a robotic workplace for the operation of injection moulding machines. It is concerned with the design of the workplace component deployment and the evaluation of the best variant using a multi-criteria assessment. In detail, attention is paid to the end effectors of industrial robots and the assembly workplace, where finishing operations take place. Finally, the risk analysis and technical and economic evaluation of the proposed workplace are carried out.

The aim of the thesis was to study the Energy Models of Linear Axes with Ball Screws and Servo Drives, to analyze the individual parts of the axis with respect to losses, the methodology of calculating the losses on the electrical part and the mechanical part of the drive and creating a complex algorithm that calculates the energy consumed for the specified motion. The thesis is divided into a theoretical and practical part, where the theoretical part is divided into the treatise on the electrical part of the axis and its losses and the part that deals with the mechanical part and its losses. The calculation is divided into the basic verification algorithm and the calculation on the given example. Each calculation is calculated for both linear acceleration and S-curve acceleration. For both types of acceleration, the result of energy and its course over time is also the waveforms of position, velocity, acceleration, angular acceleration, moments, powers, power, speed and currents over time.

This diploma thesis deals with the design the drive of the feed coordinate portal machining center using a gear rack and pinion. The thesis contains researches from the area of CNC machining centers for non-rotating parts and sliding linear systems. Market analysis of portal machining centers of type of lower gantry with a gear rack and pinion was done. Furthermore, several design variants are proposed in terms of positioning the drive on the machine. These variants were further compared and the best option was selected for the specified machine. Subsequently, the technical calculation of the drive is performed and individual parameters and structural elements are proposed. The thesis also includes a 3D model of the proposed variant and the required drawing documentation.

This thesis contains a structural design of linear axis with a stroke up to 800mm and a maximum load of 800N. The thesis also deals with a modular assembly system of the linear axis based on the structural design. Linear axes can be fitted with rolled, whirled and grinded ball screws with thread pitch 5, 10, 16mm and rolled trapezoidal screws on pitch 4 and 8mm. The stroke of the linear axes can be selected in the range from 200 up to 800 mm, with a maximum load of 800N in all linear dimensions. The feed of linear axis is provided by shaped rolling guide way and four trucks. The modular system offers two servo motors with direct and indirect measuring four stepper engines with indirect measuring. The thesis also includes strength and functional calculations of principal components, graphs of the possible load on linear axis in different positions , durability of the ball screws, maximum speed and feed rate of the chosen screws, data sheet, 3D model, drawings and assembly drawings of the nodes.

This diploma thesis is concerned with providing a construction proposal of a linear axis X for multifunctional machining center. Moreover, this work presents characterisations of machining centers, overview of manufacturers, list of main construction components used in the linear axis, their evaluation, assessment of various options for construction, which are then explained further. These detailed construction methods include calculations with the subsequent choice of feed system component. Ultimately, final evaluation of chosen option is provided as well. Another section of this thesis is also an economical assessment and 3D model alongside with mechanical drawing.