Impedance-based sensor bearings and measurement technology for real-time monitoring of lubrication, force and condition in rolling and plain bearings
HCP Sense GmbH
DarmstadtNew on Amplifa
About HCP Sense
HCP Sense GmbH is a technology-driven startup from Darmstadt that transforms standard bearings into sensors for lubrication, load and condition. The basis is a non-invasive, impedance-based measurement method that evaluates the electrical behavior of the rolling bearing contact and captures the lubrication condition – from boundary friction to hydrodynamics – in real time on the machine, without any design changes to the bearing or the machine. The technology works with all bearing types, from small deep groove ball bearings to plain bearings and up to spherical roller bearings for heavy industry. The portfolio includes the series integration of sensor technology (HCP-LubeSecure, HCP-Surface), contract measurements on prototypes, test rigs and problem machines including project planning, installation, execution and evaluation, the development of IIoT sensor prototypes as well as software and cloud services for predictive maintenance. Customers come from robotics, pump and plant engineering, mechanical and plant engineering, and heavy industry; reference customers include Sumitomo Drive Technologies. The company was founded in 2021 with funding under the EXIST research transfer program and is located at Robert-Bosch-Straße 7 in Darmstadt.
- Site
- Darmstadt
- Processes
- Impedance measurement on rolling bearings (electrical bearing monitoring), Lubrication monitoring (HCP-LubeSecure), Force measurement in bearings (HCP-Surface), Damage detection / condition monitoring / predictive maintenance, Conversion of standard bearings into sensor bearings (non-invasive sensor integration), Contract measurement: project planning, installation, execution and evaluation of measurements, Coating of housing, shaft or bearing (insulation by supplier), Test rig measurement on plain bearings and rolling bearings
- Materials
- Rolling bearing steel (standard bearings), Impedance measurement on rolling bearings, HCP-LubeSecure lubrication monitoring, HCP-Surface force measurement, Damage detection / condition monitoring, Non-invasive sensor integration
- Founded
- 2021
- Industries
- Robotics, Pump and plant engineering, Mechanical and plant engineering, Heavy industry
- 01
Analysis of the tribological system and definition of objectives
- 02
Constructive integration of sensor technology into standard bearings
- 03
Commissioning and measurement
- 04
Data processing and evaluation
- 05
Presentation of results and optimization of operating strategies
Processes and Measurement Technology
Impedance measurement on rolling bearings
Electrical measurement of the bearing contact displays the lubrication condition live on the machine.
HCP-LubeSecure lubrication monitoring
Continuous monitoring of the lubricating film to prevent lubricant starvation, over-lubrication and lubricant contamination.
HCP-Surface force measurement
Acquisition of bearing forces directly in the force flow for design validation and process monitoring.
Damage detection / condition monitoring
Very early detection of incipient damage, even at low speeds and in the presence of interference noise.
Non-invasive sensor integration
Conversion of standard bearings into sensor bearings without redesign, merely requiring electrical contacting.
Locations
Darmstadt
DEHeadquarters, development and measurement technology
- Lot size
- Prototype
- Materials
- Steel (rolling bearings)
- Bearing test rig LP-2
- HCP Sense impedance measurement system
Products and Applications
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Impedance measurement on rolling bearings (electrical bearing monitoring)Testing | – | – | – | – | Steel (rolling bearings) |
| Lubrication monitoring (HCP-LubeSecure)Testing | – | – | – | – | – |
| Force measurement in bearings (HCP-Surface)Testing | – | – | – | – | – |
| Damage detection / condition monitoring / predictive maintenanceTesting | – | – | – | – | – |
| Conversion of standard bearings into sensor bearings (non-invasive sensor integration)Assembly | – | – | – | – | – |
| Contract measurement: project planning, installation, execution and evaluation of measurementsEngineering | – | – | – | – | – |
| Coating of housing, shaft or bearing (insulation by supplier)Surface | – | – | – | – | – |
| Test rig measurement on plain bearings and rolling bearingsTesting | – | – | – | – | – |
2 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Bearing test rig | LP-2 | 1 | 2 radially loaded bearings SKF 6205, up to 1750 rpm, 2 kN | – | HCP Sense |
| Impedance measurement system | HCP Sense | – | – | – | – |
Additional services
Reference customers
History
- 2021
Founding of HCP Sense GmbH; funding under the EXIST research transfer program by the BMWi and the European Social Fund
- 2022
Publication of first technical papers on impedance-based lubrication monitoring
- 2023
Cooperation with Sumitomo Drive Technologies for sensor integration in robotics actuators (TUAKA series)