Process force determination in machine tools is an important topic for both optimization of manufacturing processes as well as predictive maintenance purposes. This work aims at providing a short overview of existing methods, motivating the integration of sensors into a linear guide, and then showing the results of an implemented new method for capturing the load on a rolling element linear guide by measuring the stresses resulting from the rolling element contact at the side of the runner block. The implementation of the approach is based on the piezoresistive diamond like carbon (DLC) coating DiaForce® provided by the Fraunhofer Institute for Surface Engineering and Thin Films (IST), Braunschweig, Germany. Good agreement of measurements with analytical and finite element method simulation results promises a stable modeling and load estimation process. Nevertheless, non-idealities due to high temperature dependency and cross-sensitivity to non rolling element contact related stresses could be shown, but also an efficient approach to diminish these effects is included.
Keywords: linear guide; load measurement; piezoresistive.