Nico Kratz, Test Field Manager, HCP Sense GmbH
Ansgar Thilmann, Managing Director, HCP Sense GmbH
HCP Sense is an innovative start-up from Darmstadt that develops intelligent bearing monitoring systems for industrial applications. With a focus on predictive maintenance and condition monitoring, HCP Sense offers solutions to maximize operational efficiency, minimize downtime and extend the lifespan of machines.
The LubeSecure technology utilizes the fact that a bearing under full lubrication can be viewed as a capacitor in the electrotechnical sense in which the lubricating film acts as a dielectric. By measuring the electrical impedance, it is possible to differentiate between different lubrication states. This innovative approach makes it possible to react to inadequate lubrication at an early stage, before permanent metallic contact and the associated increased wear and tear occur. With that, LubeSecure technology doesn’t detect damages when they occur, as comparable condition monitoring technologies, but detects the underlying reasons for damages before they can actually form.
The following graphic shows the Stribeck curve from an electrotechnical perspective, illustrating the relationship between the specific lubricant film thickness and the electrical behavior.
Specific applications of LubeSecure technology
LubeSecure technology offers the following applications for rolling and plain bearings, among others:
1. Lubricant film monitoring:
Over 80% of bearing damage is due to lubrication problems in the bearing. HCP Sense’s impedance-based lubricant film monitoring enables early detection of a lack of lubricant or the use of a lubricant that is unsuitable for the application in question. In addition, natural and temperature-related lubricant ageing can be reliably identified.
Furthermore, in the development of the drivetrain of electrically powered vehicles for passenger cars and commercial vehicles, energy consumption can be reduced without jeopardizing durability. This is achieved because the use of LubeScure allows the lubrication to be ideally matched to the mechanical components and the framework conditions prevailing in reality.
2. Determination of the viscosity ratio κ:
The viscosity ratio κ is the measure of the quality of lubricant film formation in bearings. This makes it possible to determine in real time when the operating condition changes from mixed to liquid friction, for example, and whether the lubricating film is sufficiently formed. The additives contained in many lubricants are also taken into account. By using machine learning, HCP Sense can determine the viscosity ratio of a wide range of lubricants in real time, thus laying the foundation for optimized and low-wear machine operation. Our machine learning algorithms are trained with customer data and test data from our in-house testbenches, making sure that we use high quality data to further improve the predictions made by LubeSecure.
3. Identification of contamination:
The technology’s high measuring frequency ensures that even the smallest particles in the bearing can be identified at an early stage. Be it metallic debris from wear in the system or non- metallic particles from your process, LubeSecure detects changes in the lubricant condition almost immediately. This allows machines to be stopped in good time and maintenance measures to be initiated before major damage occurs.
By implementing LubeSecure technology, companies can not only plan their maintenance intervals more efficiently, but also optimize the energy consumption of their machines and increase overall operational safety.
The HCP Sense technology is currently being used successfully in numerous Gearbox test benches, field tests and from 2025 as a sensor installed as standard in new machines. Customers are already benefiting from the fact that they can prevent lubrication-related bearing damage, recognize machine failures at an early stage and plan maintenance more effectively. The areas of application are diverse and range from tunnelling machines to drivetrains and household appliances.
For more information:
www.hcp-sense.com
thilmann@hcp-sense.com
„In addition to reducing the risk of failure, the optimum operating condition identified by LubeSecure also contributes to significant energy and CO2 savings.”
Ansgar Thilmann, Founder & Managing Director, Commercial Director, HCP Sense GmbH
