Jurnal Tribologi (Dec 2015)

New oil condition monitoring system, Wearsens® enables continuous, online detection of critical operating conditions and wear damage

  • Manfred Mauntz,
  • Ulrich Kuipers,
  • Jörn Peuser

Journal volume & issue
Vol. 7
pp. 10 – 19


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A new oil sensor system is presented for the continuous, online measurement of the wear in turbines, industrial gears, generators, hydraulic systems and transformers. Detection of change is much earlier than existing technologies such as particle counting, vibration measurement or recording temperature. Thus targeted, corrective procedures and/or maintenance can be carried out before actual damage occurs. Efficient machine utilization, accurately timed preventive maintenance, increased service life and a reduction of downtime can all be achieved. The presented sensor system effectively controls the proper operation conditions of bearings and cogwheels in gears. The online diagnostics system measures components of the specific complex impedance of oils. For instance, metal abrasion due to wear debris, broken oil molecules, forming acids or oil soaps, result in an increase of the electrical conductivity, which directly correlates with the degree of contamination of the oil. For additivated lubricants, the stage of degradation of the additives can also be derived from changes in the dielectric constant. The determination of impurities or reduction in the quality of the oil and the quasi continuous evaluation of wear and chemical aging follow the holistic approach of a real-time monitoring of an alteration in the condition of the oil-machine system. Once the oil condition monitoring sensors are installed on the wind turbine, industrial gearbox and test stands, the measuring data can be displayed and evaluated elsewhere. The signals are transmitted to a web-based condition monitoring system via LAN, WLAN or serial interfaces of the sensor unit. Monitoring of the damage mechanisms during proper operation below the tolerance limits of the components enables specific preventive maintenance independent of rigid inspection intervals.