Oil Sensor System - high performance condition monitoring, early detection of damage fault states

Ölqualität, Condition Monitoring System, Oil Condition Monitoring, Oil Condition Monitor, Aging of Oil and Cellulose, Transformer Oil, Dissolved Gas Analysis (DGA), Monitor Water in Oil

  • Early warning before damage starts
  • Optimise load/reduce wear
  • Timely preventative maintenance
  • Detect consumption of additives
  • Monitor water in oil
  • Easy retrofit
  • Patented measuring method

WearSens® - Condition monitoring for early change/damage detection in turbines, compressors, gears, bearings, and OilQSens® for transformers, online and web based. Applications include,

  • Wind turbines
  • High voltage transformers
  • Large compressor systems
  • Oil lubricated turbines
  • Lubricant performance analysis
  • Test benches for automotive and marine applications
  • ... many more being tested

Find out more by discussing your application with our engineers today.

WearSens® can detect early changes in oil quality/condition from day 1 - before damage occurs. This is unlike vibration monitoring systems, oil particle analyzers and oil filtration systems which detect after damage occurs.

Extensive system of corrosion fatigue cracks in a roller bearing from an industrial gearbox
  Premature bearing failures in industrial gearboxes usually result from friction-induced vibration loads due to cracks in the raceway surface [1].

The early detection of critical lubricant states allows preventative maintenance on the transmission - before damage occurs.

Early failures of bearings in wind turbines due to surface cracking and subsequent corrosion fatigue represent a technical problem that can lead to unnecessary downtime and costly repairs. Accessibility of offshore turbines presents an even greater problem. The WearSens® oil sensor system can identify critical operating states early, so that corrective action can be initiated before serious damage.

The monitoring of transformer oil is an important parameter for the efficiency of a high voltage transformer. The measurement of permittivity/dielectric constant by OilQSens® makes a statement about water ingress and a modification of the insulating strength of the oil.

Electrical conductivity of oil is extremely low. However, the highly sensitive OilQSens® measures conductivity down to 0.1 picosiemens per metre and all values are accurately temperature compensated taking into account the unknown, changing quantity of unknown pollutants.

The web based, decentralised monitoring system is perfect for remote or inaccessible locations. Measurements are transmitted via LAN, WLAN or the serial interface.

The patented measurement method (Patentnr.: EP 2 163 887 B1, Method and circuit assembly for measuring physical parameters in fluids and their application) combines a high sensitivity at a low noise with a broad measurement range.

The OilQSens® and WearSens® sensor system was developed in collaboration with the Competence Platform "center for strategic corrosion protection" Prof. Dr.-Ing. Kuipers of the University of Applied Sciences, South Westphalia.


Consultant for tribology, lubrication technology, etc., Prof. Dr. rer. nat. habil. Jürgen Gegner,
Institute of Materials Engineering, University of Siegen


 Online Sensor System (Poster)


 Article in "Technisches Messen"

 Article in "Tribology - Fundamentals and Advancements"

[1] Gegner, J.: Tribological Aspects of Rolling Bearing Failures. In: Kuo, C.-H. (Hrsg.), Tribology - Lubricants and Lubrication, Chap. 2, InTech, Rijeka/Kroatien, 2011, S. 33-94 (Free Download)

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