Maximizing Machine Availability: A Closer Look at Our Axis Monitoring Solutions

Improve maintenance and operational practices to reduce costs and increase returns for both users and builders of machines. The feed drive systems are an important part of machine tools, and by monitoring them properly, you can extend the lifespan of their components, plan repairs or replacements more efficiently, and minimize unexpected downtime. Learn more about how our Axis Monitoring solution and techniques can help you monitor the feed drive systems, maximize machine performance, achieve greater efficiency, and save on maintenance and repair costs.

The importance of effective axis monitoring

Without proper monitoring of the feed drive systems and their corresponding components, machine tool operators and manufacturers may encounter a variety of issues that can have a significant impact on machine efficiency. These problems include unexpected downtime, premature component wear, rising repair costs, impact on product quality, tool wear, and an increase in component inventory.

On the other hand, insufficient or ineffective monitoring of these critical components can lead to data overload, confusion, and misinterpretation, along with increased maintenance and inventory costs. Achieving optimal machine tool performance requires a delicate balance of precise monitoring, data analysis, skilled maintenance, and repair, along with a commitment to continuous improvement.

IPercept’s solution for axis monitoring

This is where we come in! Years of dedicated research have fueled our advanced automated data analysis, tailored for the manufacturing industry. We apply our domain knowledge and extensive experience to pinpoint failure criticalities within components like Ball Screws, Shields, Bearings, and Guide Rails. Then, we fine-tune our smart machine learning algorithms to not only detect these failures but also provide recommendations on how to solve those machine-specific problems.

We perform discrete testing, which can either be carried out manually by an operator during maintenance windows or automatically triggered based on certain predefined parameters, saving time and allowing more focus on other things. As part of these discrete tests, we apply our patented test cycle, which we have adapted over years of research, allowing us to perform root cause analysis on a component level, identify degradation trends, and set up thresholds, alarms, and alerts. We have been able to extend the life of the critical components that comprise the feed drive systems, better plan for their repair or replacement, and ensure that they do not fail unexpectedly.

IPercept's Axis Monitoring - Data Visualization
Visualizing Data Insights: These plot examples showcase the captured and analyzed data that enables us to improve machine maintenance and operations for our customers.

This is achieved by retrofitting the machine with our machine-configured Smart IIoT Device, which is equipped with micrometer-accurate vibration and motion sensors and data acquisition system. Production data is not recorded, and this means that cybersecurity is an important benefit of the service. The device also does not require any connection to the IT infrastructure, Wi-Fi, or the machine controller.

IPercept - Machine Operation Improvement
Here’s a look at IPercept’s system architecture and a brief overview of how the system works.

It is truly plug-and-play, with installation and set-up times as short as an hour. Our advanced and patented algorithms then analyze and monitor the test cycles. This allows for more meaningful insights into maintenance and operations. These insights, along with other notifications, alerts, or alarms, can be viewed directly on our dashboard and additional discussions and deeper insights are shared through presentations and meetings.


“Our business relies on machines, and we need your technology!”

– Maintenance Engineering Manager, Automotive Manufacturing Company