Comprehensive health assessment of faulty and repaired linear axis components through multi-sensor monitoring

Modern manufacturing machinery is often pushed beyond its operational limits, leading to the degradation and failure of critical subsystems, including the linear axis. This paper presents a comprehensive health assessment study that evaluates the root cause failure faults (FFs) of linear axis components against an established system baseline. The study further enhances the health assessment by comparing the system’s repaired state to the baseline data. Each FF was artificially introduced into its respective component in the linear axis. After evaluation, the FFs were carefully repaired by following industrial practices related to the maintenance of the affected component. Our findings reveal that the most frequently occurring FF can be readily detected via the system’s internal data, and the repaired state of the evaluated FFs exhibited a percentage error of less than 10% when compared to the healthy state. This study highlights the importance of understanding how root cause FFs impact the system operation and provides valuable insights for maintaining nominal machine performance after repair.