New low cost sensing head and taut wire method for automated straightness measurement of machine tool axes

► A novel system is proposed for measuring straightness error of machine toll's axes. ► The system uses taut wire, optical sensors and two-point method. ► The system combines low cost, quick and simple setup, versatility and high accuracy. ► Zero-difference, roll, pitch and yaw errors have a negligible effect on the system. ► Straightness tests carried out on a 0.48 m-long axis correlate with laser test results.