Design and Modelling of a Novel Hybrid Vibration Converter based on Electromagnetic and Magnetoelectric Principles

Supplying wireless sensors from ambient energy is nowadays highly demanded for a higher flexibility of use and low system maintenance costs. Vibration sources are thereby especially attractive due to their availability and the relatively high energy density they can provide. The aim of this work is to realize a hybrid energy converter for vibration sources having low amplitude and low frequency. The idea is to combine two diverse harvesters to realize a higher energy density and at the same time to improve the converter reliability. We focus on the design, modeling, and test of the hybrid vibration converter. For an appropriate converter design, the vibration profiles of several ambient vibration sources are characterized. The results show that the typical frequency and acceleration ranges are between 5 Hz to 60 Hz and 0.1 g to 1.5 g respectively. The proposed converter is based on the magnetoelectric (ME) and electromagnetic (EM) principles. These two principles can be easily combined within almost the same volume, because they generate energy form the same varying magnetic field coupled to the mechanical vibration of the source. Thereby, the energy density is improved as the ME converter is incorporated within the relatively large coil housing of the electromagnetic converter. The proposed converter is based on the use of a magnetic spring instead of the typically used mechanical springs, which applies the repulsive force to the seismic mass of the converter. The applied vibration is transmitted to the converter based on the magnetic spring principle instead of the conventional mechanical springs. Due to the nonlinearity of the magnetic spring, the converter is able to operate for a frequency bandwidth instead of resonant frequency which is the case while using a mechanical spring. Hence, this leads to realize a high converter efficiency even under random vibrations characterized by frequency bandwidth. As well, using magnetic spring principle enables to adjust the resonant frequency of the converter relative to the applied vibration source easily by just adjusting the moving magnet size. For the converter design, a parametric study is conducted using finite element analysis. Two main criteria are thereby taken into account, which are the compactness and the efficiency of the converter. Parameters affecting these two criteria are classified in mechanical, electromagnetic and magnetoelectric parameters. Results show that the combination of the EM and ME principles leads to an improvement of the energy output compared to a single EM or ME converter. The novel hybrid converter is realized and tested under harmonic and real vibration profiles. It comprises two main parts: A fixed part, where the coils and the ME transducer are fixed in order to ensure a good reliability of the converter by avoiding wire movements. A moving part, where the moving magnet of the magnetic spring and the magnetic circuit are placed. The presented converter is reliable and compact, which is able to harvest energy with a maximum output power density of 0.11 mW/cm³ within a frequency bandwidth of 12 Hz for a resonance frequency of 24 Hz under an applied harmonic vibration with an amplitude of 1 mm.Die Versorgung von drahtlosen Sensoren aus der Umgebungsenergie ermöglicht heutzutage eine hohe Einsatzflexibilität und die Senkung des Systemwartungsaufwands. Schwingungsquellen sind aufgrund ihrer Verfügbarkeit und der damit erreichbaren Energiedichte besonders attraktiv. Ziel dieser Arbeit ist es, einen hybriden Energiewandler für Vibrationsquellen mit geringer Amplitude und niedriger Frequenz zu realisieren. Der Ansatz dabei ist, zwei verschiedene Wandler zu kombinieren, um eine höhere Energiedichte zu erreichen und die Zuverlässigkeit zu verbessern. Der Entwurf konzentriert sich auf die Modellierung und den Test des hybriden Vibrationswandlers. Für einen geeigneten Wandlerentwurf werden die Schwingungsprofileigenschaften mehrerer Umgebungsschwingungsquellen untersucht. Die Ergebnisse zeigen, dass die typische Frequenz zwischen 5 Hz und 60 Hz und der Beschleunigungsbereich zwischen 0,1 g und 1,5 g liegen. Der vorgeschlagene Wandler kombiniert das magnetoelektrischen (ME) Prinzip mit dem elektromagnetischen (EM) Prinzip. Diese beiden Prinzipien können innerhalb des fast gleichen Volumens leicht integriert werden, da sie Energie aus der Variation des gleichen Magnetfeldes, das mit der mechanischen Schwingung gekoppelt ist, erzeugen können. Dadurch wird die Energiedichte verbessert, da der ME-Wandler in das relativ große Spulengehäuse des elektromagnetischen Wandlers eingesetzt werden kann. Darüber hinaus basiert der vorgeschlagene Wandler auf der Verwendung von Magnetfedern, um die Repulsivkraft auf die seismische Masse zu realisieren. Aufgrund der Nichtlinearität der Magnetfeder, kann der Wandler in einem breiteren Frequenzbereich betrieben werden, anstatt nur bei der Resonanzfrequenz, wie es bei der Verwendung einer mechanischen Feder der Fall ist. Dies führt dazu, dass der Wandler auch bei zufälligen breitbandigen Schwingungsquellen effizient betrieben werden kann. Darüber hinaus ermöglicht die Verwendung des Magnetfederprinzips eine einfache Einstellung der Resonanzfrequenz des Wandlers in Bezug auf die Schwingungsquelle, durch Einstellen der Größe des beweglichen Magneten. Für den Wandlerentwurf wird eine Parameterstudie mit Hilfe der Finite-Elemente-Analyse durchgeführt. Zwei Hauptkriterien werden dabei berücksichtigt: Die Kompaktheit und die Energieeffizienz des Wandlers. Parameter die diese beiden Kriterien beeinflussen, können in mechanische, elektromagnetische und magnetoelektrische unterteilt werden. Die Ergebnisse haben gezeigt, dass die Kombination der EM- und ME-Prinzipien zu einer Verbesserung der Energieausbeute im Vergleich zu einem einzelnen EM- oder ME-Wandler geführt hat. Der neuartige Hybrid-Wandler wurde realisiert und unter harmonischen und realen Schwingungsprofilen getestet. Der Wandler besteht aus zwei Hauptteilen: Ein festes Teil, an dem die Spulen und der ME-Wandler befestigt sind, um eine hohe Zuverlässigkeit zu gewährleisten indem auf einen beweglichen Draht verzichtet wird, und ein bewegliches Teil, das sich aus einem beweglichen Magneten zusammensetzt. Der vorgestellte Wandler ist zuverlässig, kompakt und in der Lage, Energie mit einer maximalen Ausgangsleistungsdichte von 0,11 mW/cm 3 und einer Bandbreite von 12 Hz bei einer Resonanzfrequenz von 24 Hz unter einer angelegten harmonischen Schwingung mit einer Amplitude von 1 mm zu gewinnen

Design study of a magnetoelectric-electromagnetic vibration energy converter for energy harvesting

The aim of this paper is to design a combination of a magnetoelectric-electromagnetic (ME-EM) vibration converter in order to reach an improved energy outcome. In this paper, the influence of magnets polarization and magnetoelectric transducer and coil direction are investigated. For this purpose, a finite element model is developed using one coil, one ME transducer in a magnetic circuit. Simulation results show that a better magnetic field distribution and variation is reached, if the magnetic circuit magnets are placed in attraction. Radial polarization shows decisive advantages in comparison with axial polarization. The placement of coil parallel to the magnetic circuit direction and the magnetization of the ME transducer along its width is the optimal direction relative to the magnetic circuit

Design study of a nonlinear electromagnetic converter using magnetic spring

In this paper, an experimental and theoretical study for designing a nonlinear electromagnetic converter-based magnetic spring is performed. The governing equation of the converter is investigated. A special focus is given to the magnetic force acting on the moving magnet in dependence of its volume and the geometry of the two fixed magnets, i.e., disc or ring. For the developed analytical and numerical model, the same converter volume has been used for all conducted investigations. Several parameters have been studied that can be used to tune the nonlinearity behavior. Further, the coil axial position was investigated analytically and experimentally. An energy harvesting prototype consisting of an oscillating cylindrical magnet levitated between two stationary magnets is fabricated and evaluated through experiments. The open-circuit voltage obtained through the analytical model has been compared to the experiment and solutions to tune the harvester resonant frequency while maintaining its output power density were proposed

Vibration Converter with Passive Energy Management for Battery-Less Wireless Sensor Nodes in Predictive Maintenance

Predictive maintenance is becoming increasingly important in industry and requires continuous monitoring to prevent failures and anticipate maintenance processes, resulting in reduced downtime. Vibration is often used for failure detection and equipment conditioning as it is well correlated to the machine’s operation and its variation is an indicator of process changes. In this context, we propose a novel energy-autonomous wireless sensor system that is able to measure without the use of batteries and automatically deliver alerts once the machine has an anomaly by the variation in acceleration. For this, we designed a wideband electromagnetic energy harvester and realized passive energy management to supply a wireless sensor node, which does not need an external energy supply. The advantage of the solution is that the designed circuit is able to detect the failure without the use of additional sensors, but by the Analog Digital Converter (ADC) of the Wireless Sensor Nodes (WSN) themselves, which makes it more compact and have lower energy consumption. The electromagnetic converter can harvest the relevant energy levels from weak vibration, with an acceleration of 0.1 g for a frequency bandwidth of 7 Hz. Further, the energy-management circuit enabled fast recharging of the super capacitor on a maximum of 31 s. The designed energy-management circuit consists of a six-stage voltage multiplier circuit connected to a wide-band DC-DC converter, as well as an under-voltage lock-out (UVLO) circuit to connect to the storage device to the WSN. In the failure condition with a frequency of 13 Hz and an acceleration of 0.3 g, the super capacitor recharging time was estimated to be 24 s. The proposed solution was validated by implementing real failure detection scenarios with random acceleration levels and, alternatively, modus. The results show that the WSN can directly measure the harvester’s response and decide about the occurrence of failure based on its characteristic threshold voltage without the use of an additional sensor

Vibration Converter with Passive Energy Management for Battery-Less Wireless Sensor Nodes in Predictive Maintenance

Predictive maintenance is becoming increasingly important in industry and requires continuous monitoring to prevent failures and anticipate maintenance processes, resulting in reduced downtime. Vibration is often used for failure detection and equipment conditioning as it is well correlated to the machine’s operation and its variation is an indicator of process changes. In this context, we propose a novel energy-autonomous wireless sensor system that is able to measure without the use of batteries and automatically deliver alerts once the machine has an anomaly by the variation in acceleration. For this, we designed a wideband electromagnetic energy harvester and realized passive energy management to supply a wireless sensor node, which does not need an external energy supply. The advantage of the solution is that the designed circuit is able to detect the failure without the use of additional sensors, but by the Analog Digital Converter (ADC) of the Wireless Sensor Nodes (WSN) themselves, which makes it more compact and have lower energy consumption. The electromagnetic converter can harvest the relevant energy levels from weak vibration, with an acceleration of 0.1 g for a frequency bandwidth of 7 Hz. Further, the energy-management circuit enabled fast recharging of the super capacitor on a maximum of 31 s. The designed energy-management circuit consists of a six-stage voltage multiplier circuit connected to a wide-band DC-DC converter, as well as an under-voltage lock-out (UVLO) circuit to connect to the storage device to the WSN. In the failure condition with a frequency of 13 Hz and an acceleration of 0.3 g, the super capacitor recharging time was estimated to be 24 s. The proposed solution was validated by implementing real failure detection scenarios with random acceleration levels and, alternatively, modus. The results show that the WSN can directly measure the harvester’s response and decide about the occurrence of failure based on its characteristic threshold voltage without the use of an additional sensor