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 acts electrotechnically like a capacitor 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.
The following graphic shows the Stribeck curve from an electrotechnical perspective, illustrating the relationship between the specific lubricant film thickness and the electrical behaviour.
Specific applications of LubeSecure technology
LubeSecure technology offers the following applications for rolling and plain bearings, among others:
- 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.
- 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.
- identification of contamination:
The technology’s high measuring frequency means that even the smallest particles in the bearing can be identified at an early stage. 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 field tests. 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 pumps and household appliances.
For more information:
‘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