OSCAR Research Project: In-line monitoring of technical fluids under high pressure

The goal of the OSCAR research project is the development of a novel optical high-pressure sensor system capable of monitoring the condition of technical fluids directly within the process and under real operating conditions.

In numerous industrial applications, the condition of a fluid determines a machine's performance and service life. Whether in hydraulic power units, mobile machinery, or cranes, continuous monitoring of the medium is essential to detect wear at an early stage, plan maintenance effectively, and avoid unplanned downtime.

This is precisely where the OSCAR research project comes in. The project aims to develop a novel optical high-pressure sensor system capable of monitoring the condition of technical fluids directly within the process and under real operating conditions.

Why existing solutions reach their limits
Inline monitoring of technical fluids often involves compromises today. Many available sensor systems capture only aggregate parameters, providing limited insight into the medium's actual condition. Other measurement methods require complex bypass installations or are unsuitable for high operating pressures.

This results in additional installation effort, higher costs, and measurements that often do not reflect actual process conditions.

Optical measurement technology as a key technology

Optical measurement methods offer a decisive advantage: they enable direct analysis of the fluid and provide precise information about its chemical and physical state. Changes in the medium can be detected early, before they lead to damage in machinery or systems. Optical inline measurement technology thus opens up new possibilities for condition monitoring and predictive maintenance in modern industrial plants.

The goal of the OSCAR project

The project involves developing a compact sensor system that can be integrated directly into existing plants. At the heart of the solution is a high-pressure-resistant optical cell—made of silicon, for example—combined with modular optomechanical components and integrated electronics and firmware. The goal is to create a robust screw-in solution that:

• enables direct in-process measurements
• operates reliably even under high pressures and temperatures
• is resistant to various media
• can be installed without additional bypass systems
• delivers reproducible and precise measurement results

Particular emphasis is placed on an optimized optical measurement path with minimal stray light, as well as a durable, resilient design suitable for industrial use.

From research to industrial application

As the project progresses, the developed sensor system will be tested and validated as a demonstrator under real-world conditions. The insights gained will form the basis for a market-ready solution that enables the next generation of inline fluid condition monitoring.

OSCAR represents an innovative approach that simplifies the integration of modern sensor technology, enhances measurement reliability, and sustainably strengthens the competitiveness of industrial facilities.

This development demonstrates the potential inherent in combining optical measurement technology with intelligent sensor integration—an important step toward more efficient, safer, and more cost-effective industrial processes.