Integrated mechatronic design of an industrial piezoelectric vibration energy harvester

Increased consumption of non-renewable energy sources, such as batteries, have led to increased environmental pollution and critical energy crises. Harvesting energy from vibration sources, using piezoelectric cantilevers, may be one of the main solutions to extending the life of the battery of some autonomous devices and either reducing or eliminating the need to replace them in service. This would make sensors self-powered, for instance. To minimize the volume of the Energy Harvester, a configuration with a circular frame supporting a radial set of bimorph piezoelectric beams with a proof mass at the tip is proposed. An analytic model is first developed to investigate the behavior of the electromechanical coupling, preliminarily sizing the design parameters, and to estimate the maximum power converted. A numerical model is then developed, in the COMSOL Multiphysics software, to analyze all of the system details. Some FEM analyses allow verifying the accuracy of the analytic model and predicting the dynamic system behavior under different load conditions. A critical issue in properly predicting the performance of such device is the electric circuit which is coupled to extract the charge produced. Therefore, the design of this read-out circuit is herein addressed. The LTspice XVII software is then used to model the charge readout circuit. The electronic components interconnected within the circuit are first determined, and their electrical dynamic behavior is studied when coupled with the mechanical system. The efficiency of charge production and energy storage is evaluated by integrating the whole electromechanical system, including the readout circuit with the numerical model. The performance looks compatible with the required values proposed for some practical industrial applications, being also described.