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In this paper, we demonstrate a novel robust miniature three-axis vibrational energy-harvester using a mechanical-piezoelectric configuration. Using the configuration, the harvester employs Newton’s law of inertia and the piezoelectric effect to convert either the $x$ -axis or $y$ -axis in-plane and $z$ -axis out-of-plane ambient vibrations into piezoelectric voltage-responses. Under the $x$ -axis vibration (sine-wave, 75 Hz, 3.5 g), our modeled, finite-element analyzed/simulated, and experimental root mean square voltage-response with power-outputs of the harvester (stimulated in resonant with the optimum load) is 525.36 mV with 0.477 $\mu \text{W}$ , 516.51 mV with 0.461 $\mu \text{W}$ , and 548 mV with 0.519 $\mu \text{W}$ , respectively. Under the $z$ -axis vibration (sine-wave, 95 Hz, 3.8 g), the modeled, finite-element analyzed/simulated, and experimental root mean square voltage-response with power-output of the harvester (stimulated in resonant with the optimum load) is 157.35 mV with 0.066 $\mu \text{W}$ , 170.25 mV with 0.0772 $\mu \text{W}$ , and 168 mV with 0.075 $\mu \text{W}$ , respectively. These show that not only both of our modeling and finite-element analysis/simulation can successfully predict the experimental results, but also our harvester is capable of harnessing three-axial ambient vibrations. Moreover, through the piezoelectric lead–zirconate–titanate-connected-in-series approach, the voltage and power outputs are increased. According to these achievements, we believe that our harvester would be an important design reference in industry for future development of microfabrication-based (MEMS-based) three-axial piezoelectric energy harvesters and accelerometers.

To date, researchers have utilized energy harvesters to power wireless sensor nodes as self-powered wireless sensors to create many innovative wireless sensors network applications such as medical monitoring, machining-condition monitoring, and structural-health monitoring. Regarding to energy harvesters, some researchers demonstrated wideband or frequency up-converted vibrational energy harvesters using magnetic force together with piezoelectric materials. However, these harvesters are not able to harness 3-D or three-axial mechanical energy through using one single mechanism or configuration. To address this problem, we report a novel magnetic-force-configured three-axial frequency-tunable piezoelectric energy harvester in this paper. Due to the magnetic-force configuration, the harvester converts ambient three-axial mechanical vibration/motion to piezoelectric voltage-response (i.e., three-axial energy harvesting). Simultaneously, the harvester also converts the ambient vibration/motion at a lower frequency to higher frequency without mechanical wear-out (i.e., noncontact frequency up-conversion). Through modifying the configuration, the oscillating frequency is tunable. By frequency tuning, the harvester's oscillating frequency and ambient vibration frequency are able to be matched to maximize the power output. Experimental results show the peak voltage, peak power, and frequency conversion of one single piezoelectric beam of the harvester under an in-plane and out-of-plane vibration is up to 800 mV, 640 nW, and from 7 to 56 Hz, and 27 mV, 729 pW, and from 1 to 294 Hz, respectively. These results confirm the harvester is capable of harnessing energy from 3-D and three-axial mechanical motion/vibration, addressing frequency-mismatching issue, avoiding mechanical wear-out problems, and producing a stable voltage output. Due to these, the energy-harvesting approach will enable more novel and practical wireless sensors network applications in the future.

In this paper, we demonstrate a novel miniature three-axis piezoelectric energy harvester. The energy harvester consists of four piezoelectric lead zirconate titanate cantilever beams, connector, proof mass, and mechanic frame. Through the connector, a special configuration with a well-constrained mechanism of the energy harvester is achieved. Due to the configuration/mechanism of the energy harvester, the Newton’s law of inertia and piezoelectric effect are utilized to convert the in-plane (either x-axis or y-axis) and out-of-plane (z-axis) environmental vibrations into voltage responses. This achieves energy harnessing from 3-axial environmental vibration.Copyright © 2013 by ASME

In this paper, we demonstrate an attachable energy-harvester-powered wireless vibration-sensing module for milling-process monitoring. The system consists of an electromagnetic energy harvester, MEMS accelerometer, and wireless module. The harvester consisting of an inductance and magnets utilizes the electromagnetic-induction approach to harvest the mechanical energy from the milling process and subsequently convert the mechanical energy to an electrical energy. Furthermore, through an energy-storage/rectification circuit, the harvested energy is capable of steadily powering both the accelerometer and wireless module. Through integrating the harvester, accelerometer, and wireless module, a self-powered wireless vibration-sensing system is achieved. The test result of the system monitoring the milling process shows the system successfully senses the vibration produced from the milling and subsequently transmits the vibration signals to the terminal computer. Through analyzing the vibration data received by the terminal computer, we establish a criterion for reconstructing the status, condition, and operating-sequence of the milling process. The reconstructed status precisely matches the real status of the milling process. That is, the system is capable of demonstrating a real-time monitoring of the milling process.

An attachable electromagnetic-energy-harvester driven wireless vibration-sensing system for monitoring milling-processes and cutter-wear/breakage-conditions is demonstrated. The system includes an electromagnetic energy harvester, three single-axis Micro Electro-Mechanical Systems (MEMS) accelerometers, a wireless chip module, and corresponding circuits. The harvester consisting of magnets with a coil uses electromagnetic induction to harness mechanical energy produced by the rotating spindle in milling processes and consequently convert the harnessed energy to electrical output. The electrical output is rectified by the rectification circuit to power the accelerometers and wireless chip module. The harvester, circuits, accelerometer, and wireless chip are integrated as an energy-harvester driven wireless vibration-sensing system. Therefore, this completes a self-powered wireless vibration sensing system. For system testing, a numerical-controlled machining tool with various milling processes is used. According to the test results, the system is fully self-powered and able to successfully sense vibration in the milling processes. Furthermore, by analyzing the vibration signals (i.e., through analyzing the electrical outputs of the accelerometers), criteria are successfully established for the system for real-time accurate simulations of the milling-processes and cutter-conditions (such as cutter-wear conditions and cutter-breaking occurrence). Due to these results, our approach can be applied to most milling and other machining machines in factories to realize more smart machining technologies.

In this paper, we report a micro 3-D kinetic energy harvester demonstrating an energy conversion from environmental mechanical-energy (3-D mechanical motion) to electrical energy (voltage output). In addition to energy harvesting/conversion from 3-D motion, we demonstrate a non-contact frequency-up rectification approach which converts an incoming lower vibration frequency to a higher frequency in order to increase the power output of the harvester.