Smart bearing housings transform your bearings from simple rotating mechanical elements into sensors that generate real-time data. Thanks to HCP Sense technology, you can instantly monitor load, lubrication and bearing health, and easily move towards predictive maintenance. As Barnar Global, we help you integrate HCP Sense solutions into your projects in Türkiye and the wider region.
What Are Smart Bearing Housings?
Smart bearing housings are built on standard rolling bearings and rely on the HCP Sense sensor platform, which monitors operating conditions inside the bearing via electrical signals. The bearing geometry does not change; the housing, shaft and housing design remain as they are. The only addition is a thin electrical connection that measures across the bearing.
With this approach you can:
- Upgrade to sensorized bearings without changing your existing machine design,
- Commission both new design projects and retrofit applications quickly,
- Measure bearing behaviour during operation, without having to stop the machine.
Bearing → Sensor Conversion with HCP Sense
HCP Sense tracks changes in the electrical impedance inside the bearing. As this signal passes through the bearing and the lubrication film, it changes and is processed by advanced algorithms. The resulting data provides clear information about load, lubrication regime and friction.
- 🔩 Load profile: Shock loads, overloads and unbalanced operating conditions become visible.
- 🛢️ Lubrication film: Grease film thickness, lubricant ageing and contamination level are monitored.
- 🧰 Assembly quality: Misalignment, overtightening or incorrect preload are detected as assembly faults.
- ⚠️ Early damage indicators: You receive warnings based on friction and film loss before damage actually begins.
In this way, smart bearing housings can reveal problems much earlier than vibration sensors often can.
Which Data Can You Measure?
With HCP Sense, your bearings that have been turned into sensors can continuously report the following parameters:
- Instant load variations: You can see process fluctuations and the real operating loads, and validate your design calculations.
- Lubrication regime: By tracking boundary, mixed or hydrodynamic friction regimes in real time, you ensure operation at the correct lubrication point.
- Grease life and contamination: You can see when the grease needs to be changed, when contamination starts, and the risk of overlubrication.
- Post-assembly behaviour: You monitor whether the bearing runs stably from commissioning onwards or is exposed to unusual loads.
With this information, your maintenance teams can move from “time-based maintenance” to “condition-based maintenance” and significantly reduce the risk of unplanned downtime.
Application Areas of Smart Bearing Housings
HCP Sense-based smart bearing housings are used in many industries where loads are high and downtime is costly:
- 🏭 Machinery and production lines: Presses, gearboxes, conveyors, mixers.
- ⚙️ Heavy industry: Steel, cement, mining and process plants.
- 🔋 Energy and renewables: Wind turbines, pump and fan systems.
- 🚆 Rail and mobility: Locomotives, wagons and off-highway vehicles.
- 🧪 Test rigs & R&D: Measuring real load and lubrication behaviour on prototype machines.
In short, if you have critical bearings and the cost of downtime is high, smart bearing housings can deliver a strong return on investment (ROI).
Advantages of HCP Sense for Smart Bearing Housings
- ✅ Non-invasive design: Bearing dimensions do not change; no modification of housing or shaft is required.
- ✅ Real-time monitoring: Load and lubrication parameters are measured continuously and trends are tracked.
- ✅ Predictive maintenance: Potential failures are visible weeks in advance, allowing you to plan maintenance with confidence.
- ✅ Energy efficiency: With correct lubrication, friction losses and motor load are reduced.
- ✅ Longer equipment life: Bearing damage and secondary component failures are significantly reduced.
- ✅ Industry 4.0 compatibility: Data can be integrated into PLC/SCADA, edge devices or cloud-based predictive maintenance platforms.
HCP Sense Projects with Barnar Global
Barnar Global, as the official partner for HCP Sense solutions in Türkiye, provides end-to-end support for your smart bearing housing projects:
- 🔍 Feasibility and suitability assessment,
- 🧪 Pilot implementation and commissioning on test or pilot lines,
- 📊 Data analysis, reporting and joint definition of the maintenance strategy,
- 🛠️ On-site installation support and long-term technical assistance.
Whether you want to start with a single critical bearing or roll out smart bearing housings across entire lines, our team is by your side throughout the project.
📩 Contact & Quotation Requests
To transition to smart bearing housings with HCP Sense, request a demo or schedule a technical meeting, please contact us:
