Digital measuring system for ball and roller rail systems

Bosch Rexroth has expanded its integrated measuring system for profiled rail systems with additional sensors and communication standards. The technology is aimed at mechanical and plant engineering, particularly dynamic applications such as linear robots and machine tools, to provide continuous process data for plant monitoring.

Challenges of process monitoring in linear technology
Dynamic applications in industrial plant engineering, including gantry systems as well as laser and cutting systems, require the highest level of accuracy and mechanical process stability. To ensure effective condition and process monitoring, the linear axes used must be digitally evaluable. Previous linear systems primarily provided pure position data to control systems. Modern predictive maintenance concepts, however, require additional physical parameters directly from the axis of motion, without increasing the structural installation space through additional external sensors.

MEMS sensors and BiSS-C communication
To acquire these extended measured variables, the IMS-A absolute measuring system integrates a MEMS sensor directly into the runner block of the precision ball and roller rail systems (available for the BSHP and RSHP series) in a space-optimized manner. In addition to position measurement, the sensor unit records parameters such as acceleration, spatial position, temperature, as well as mileage and operating hours. Data transmission to the machine control system takes place synchronously and interference-free via the BiSS-C (Bidirectional Serial Synchronous Interface) sensor interface. As a certified further development of the SSI standard, this open-source protocol enables fully digital, bidirectional communication with higher clock rates, integrated diagnostics, and CRC protection.

Data basis for machine health and fault analysis
The provision of additional sensor data directly from the runner block creates a reliable information basis for complex monitoring architectures. Through the continuous recording of vibrations in three spatial axes or temperature profiles, machine health evaluations, condition-based maintenance, or AI-supported process analyses can be realized. In the event of mechanical malfunctions or unexpected deviations, the extended data transparency accelerates diagnostics. Machine crashes, for example, can be reconstructed in detail using the recorded acceleration values to precisely clarify service or liability questions.

Integration and interface configuration
The new BiSS-C version complements the existing interface portfolio of the IMS-A, which already covers protocols such as SSI, HIPERFACE, DRIVE-CLiQ, and FANUC αi. The design and configuration of the systems, including the provision of CAD data and technical documentation, are carried out via digital online configurators for runner blocks and guide rails.

Additional Context
This section details technical specifications and competitive benchmarking not included in the original product announcement

In the market for integrated measuring systems in linear guides, the Bosch Rexroth IMS-A competes with systems such as the SCHNEEBERGER MONORAIL AMS or the integrated measuring systems from HEIDENHAIN. While high-resolution optical or magnetic linear encoders are primarily designed for the precise recording of position, the IMS-A differentiates itself through the direct integration of a MEMS (Micro-Electro-Mechanical Systems) sensor for the simultaneous recording of 3D acceleration and temperature data. This merging of position encoder and condition monitoring sensor in a single housing significantly reduces the wiring effort in highly dynamic machine tools. The implementation of the open-source protocol maintained by the BiSS-C Association also offers a hardware-independent alternative to proprietary drive interfaces, which significantly facilitates signal integration into heterogeneous control landscapes.

Edited by Maria Brueva, Induportals editor – adapted by AI.

www.boschrexroth.com