WearSens® - a new approach to gearbox and bearing failure prevention, online and continuous

Condition Monitoring System, Oil Condition Monitoring, Oil Condition Monitor, Gearbox Damage Prevention, Bearing Failure, Wear Detection

Source: Wintus, Wind Turbine Specialists, Aichtal, Germany, WC 03034 2003
  • Early warning before damage starts
  • Optimise load/reduce wear
  • Timely predictive maintenance
  • Prevent abrasive wear
  • Detect consumption of additives
  • Easy retrofit
  • Patented measuring method

WearSens® - ideal for early fault detection, changes in the machine detected from the start - long before failure states.

WearSens® Sensor
  Applications include,

  • Wind turbines, including offshore
  • Oil insulated turbines, including cogen plants
  • Lubricant performance analysis
  • Test benches for automotive and marine applications

WearSens® detects early changes in the "quality of the machine" from day 1 - before damage occurs. This represents a great improvement on vibration monitoring systems, oil particle analyzers and oil filtration systems which detect after damage occurs.

cmc Instruments together with their academic and industrial partners have a thorough understanding of how abrasive wear damage occurs. First, a very small hairline crack appears as a result of roller bearing passage. Oil enters this crack. Localized vibration and temperature rises cause the oil to degrade into oil soaps, acids and hydrogen. The hydrogen then causes embrittlement of the surrounding metal accelerating the possibility of shearing and consequent pitting of the bearing.

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® sensor system can identify critical operating states early, so that corrective action can be initiated before serious damage.

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 electrical conductivity of oil is very low. However, it is possible to measure down to to 0.1 pS/m with the high precision WearSens®. Results are temperature compensated taking into account the unknown and varying amounts of impurities.

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

The 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


 WearSens® (Datasheet)
 WearSens® (Poster)

[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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