Mid Sweden University

The need for wireless condition monitoring and control of hydraulic systems in an autonomous and battery-free manner is attracting increasing attention in an effort to provide improved sensing functionality, monitoring of system health, and to avoid catastrophic failures. The potential to harvest energy from hydraulic pressure ripples and noise is particularly attractive since they inherently have a high energy intensity, which is associated with the hydraulic mean pressure and flow rate. This paper presents a comprehensive overview of the state of the art in hydraulic pressure energy harvesting, which includes the fundamentals of pressure ripples in hydraulic systems, the choice of electroactive materials and device structures, and the influence of the fluid–mechanical interface. In addition, novel approaches for improving the harvested energy and potential applications for the technology are discussed, and future research directions are proposed and outlined. 

Investigating the coil–magnet structure plays a significant role in the design process of the electromagnetic energy harvester due to the effect on the harvester’s performance. In this paper, the performance of four different electromagnetic vibration energy harvesters with cylindrical shapes constrained in the same volume were under investigation. The utilized structures are (i) two opposite polarized magnets spaced by a mild steel; (ii) a Halbach array with three magnets and one coil; (iii) a Halbach array with five magnets and one coil; and (iv) a Halbach array with five magnets and three coils. We utilized a completely automatic optimization procedure with the help of an optimization algorithm implemented in Python, supported by simulations in ANSYS Maxwell and MATLAB Simulink to obtain the maximum output power for each configuration. The simulation results show that the Halbach array with three magnets and one coil is the best for configurations with the Halbach array. Additionally, among all configurations, the harvester with two opposing magnets provides the highest output power and volume power density, while the Halbach array with three magnets and one coil provides the highest mass power density. The paper also demonstrates limitations of using the electromagnetic coupling coefficient as a metric for harvester optimization, if the ultimate goal is maximization of output power. 

Condition monitoring devices in hydraulic systems that use batteries or require wired infrastructure have drawbacks that affect their installation, maintenance costs, and deployment flexibility. Energy harvesting technologies can serve as an alternative power supply for system loads, eliminating batteries and wiring requirements. Despite the interest in pressure fluctuation energy harvesters, few studies consider end-to-end implementations, especially for cases with lowamplitude pressure fluctuations. This generates a research gap regarding the practical amount of energy available to the load under these conditions, as well as interface circuit requirements and techniques for efficient energy conversion. In this paper, we present a self-powered sensor that integrates an energy harvester and a wireless sensing system. The energy harvester converts pressure fluctuations in hydraulic systems into electrical energy using an acoustic resonator, a piezoelectric stack, and an interface circuit. The prototype wireless sensor consists of an industrial pressure sensor and a low-power Bluetooth System-on-chip that samples and wirelessly transmits pressure data. We present a subsystem analysis and a full system implementation that considers hydraulic systems with pressure fluctuation amplitudes of less than 1 bar and frequencies of less than 300 Hz. The study examines the frequency response of the energy harvester, the performance of the interface circuit, and the advantages of using an active power improvement unit adapted for piezoelectric stacks. We show that the interface circuit used improves the performance of the energy harvester compared to previous similar studies, showing more power generation compared to the standard interface. Experimental measurements show that the self-powered sensor system can start up by harvesting energy from pressure fluctuations with amplitudes starting at 0.2 bar at 200 Hz. It can also sample and transmit sensor data at a rate of 100 Hz at 0.7 bar at 200 Hz. The system is implemented with off-the-shelf circuits. 

The growing interest in the Internet of Things has created a need for wireless sensing systems for industrial and consumer applications. In hydraulic systems, a widely used method of power transmission in industry, wireless condition monitoring can lead to reduced maintenance costs and increase the capacity for sensor deployment. A major problem with the adoption of wireless sensors is the battery dependence of current technologies. Energy harvesting from pressure fluctuations in hydraulic systems can serve as an alternative power supply and enable self-powered devices. Energy harvesting from pressure fluctuations is the process of converting small pressure fluctuations in hydraulic fluid into a regulated energy supply to power low power electronics. Previous studies have shown the feasibility of pressure fluctuation harvesting. However, for the development of self-powered sensor systems, the methods and techniques for converting pressure fluctuations into electrical energy should be further investigated.

This thesis explores the methods, limitations, opportunities and trade-offs involved in the development of pressure fluctuation energy harvesters in the context of self-powered wireless devices. The focus is on exploring and characterizing the various mechanisms required to convert pressure fluctuations into electrical energy. In this work, an energy harvesting device consisting of a fluid-to-mechanical interface, an acoustic resonator, a piezoelectric stack, and an interface circuit is proposed and evaluated. Simulations and experimental analysis were used to analyse these different components for excitation relevant to hydraulic motors.

The results of this work provide new insights into the development of power supplies for self-powered sensors for hydraulic systems using pressure fluctuation energy harvesters. It is shown that with the introduction of the space coiling resonator for pressure fluctuation amplification and a detailed analysis of the fluid interface and power conditioning circuits, the understanding of the design and optimization of efficient pressure fluctuation energy harvesters is further advanced.

Pressure fluctuation energy harvesting devices are promising alternatives to power up wireless sensors in fluid power systems. In past studies, classical Helmholtz resonators have been used to enhance the energy harvesting capabilities of these harvesters. Nevertheless, for fluctuations with frequency components in the range of less than 1000 Hz, the design of compact resonators is difficult, mostly for their poor acoustic gain. This paper introduces a space-coiling resonator fabricated using 3D printing techniques. The proposed resonator can achieve a better acoustic gain bounded by a small bulk volume compared to a classic Helmholtz resonator, improving the energy harvesting capabilities of pressure fluctuation energy harvesters. The resonator is designed and evaluated using finite-element-method techniques and examined experimentally. Three space-coiling-resonators are designed, manufactured and compared to classic Helmholtz resonators for three frequencies: 280 Hz, 480 Hz and 920 Hz. This work displays the possibility of compact, high-performance pressure fluctuation energy harvesters and the advantages of the space-coiling printed resonators to enhance the harvesting performance.

The fourth industrial revolution is here and with it a tidal wave of challenges for its prosperous implementation. One of the greatest challenges frustrating the development of the internet of things, and hence the next industrial revolution, is the powering of wireless sensors, as these depend on batteries with a limited lifetime. Recent advances have shown that energy harvesting technologies can be employed to extend the lifetime of batteries and ultimately replace them, thus facilitating the deployment of autonomous self-powered sensors, key components of the internet of things.

Energy harvesting is the process of capturing ambient energy and convertingit into electric power. For energy harvesting devices it is crucial that the transduction of energy is as efficient as possible, meaning that the methods for capturing, interfacing and converting the ambient energy should be understood and characterized for every application. This thesis investigates the harvesting of the energy found in pressure fluctuations in hydraulic systems, a widely used power transmission system used in the industry and consumer applications; the focus is on the fluid interface and energy focusing methods.

In summary, the contributions in this thesis show that the methods for converting pressure fluctuations in hydraulic systems to electrical power depend on the hydraulic system environment, in essence, the static pressure and the frequency of the pressure fluctuations. The results can serve as a starting point in the research, design, and development of hydraulic pressure energy harvesters.

Den fjärde industriella revolutionen är här vilket innebär en rad utmaningar för att dess utveckling ska bli framgångsrik. En av de största utmaningarna som begränsar utvecklingen av sakernas internet för industriella tillämpningar är strömförsörjningen av trådlösa sensorer då dessa är beroende av batterier med begränsad livslängd. Nya framsteg har emellertid gjorts med tekniker för energiskördning som gör att livslängden för batterierna kan förlängas ochi förlängningen helt ersätta batterierna. Det, i sin tur, möjliggör autonoma sensorer som är självförsörjande på energi som är viktiga komponenter i sakernas internet. Energiskördning är den process som omvandlar energi som finns i omgivningen till elektrisk energi. För att kunna få ut så mycket energi som möjligt så är det avgörande att energiskördarna gör energiomvandlingen så effektivt som möjligt. Det gör att inhämtning av omgivande energi samt gränssnitt och energiomvandling måste förstås och karakteriseras för varje tillämpning. Den här avhandlingen undersöker energiskördning för hydrauliskasystem där tryckfluktuationer i dessa system är energikällan. Syftet med den här studien är att ta fram metoder för uppskattning och karakterisering av de nödvändiga gränssnitten för inhämtning, fokusering, och omvandling av fluktuationer i hydraultryck till elektrisk energi. Sammanfattningsvis visar avhandlingen att metoder för att omvandla tryckfluktuationer i hydraulsystem till elektrisk energi beror på den hydrauliska systemmiljön där det statiska trycket och frekvensen av tryckfluktuationerna är de viktigaste parametrarna. Resultaten kan fungera som utgångspunkt för fortsatt forskning och utveckling av energiskördare för hydrauliska system.

Hydraulic pressure fluctuation energy harvesters are promising alternatives to power up wireless sensor nodes in hydraulic systems. The characterization of these harvesters under dynamic and band-limited pressure signals is imperative for the research and development of novel concepts. To generate and control these signals in a hydraulic medium, a versatile apparatus capable of reproducing pressure signals is proposed. In this paper, a comprehensive discussion of the design considerations for this apparatus and its performance is given. The suggested setup enables the investigation of devices tailored for the harvesting of energy in conventional hydraulic systems. To mimic these systems, static pressures can be tuned up to 300 bar, and the pressure amplitudes with a maximum of 28 Bar at 40 Hz and 0.5 bar at 1000 Hz can be generated. In addition, pressure signals found in commercial hydraulic systems can be reproduced with good accuracy. This apparatus proves to be an accessible, robust, and versatile experimental setup to create environments for the complete performance estimation of pressure fluctuation energy harvesters. 

Wireless sensor nodes in state of the art fluid power systems used in monitoring and maintenance prediction demand long lasting power sources that do not rely on batteries. Energy harvesting is a promising technology that can provide the required energy to power wireless sensors. Pressure fluctuation energy harvesters can be employed in conventional hydraulic systems to convert the acoustic pressure fluctuation to electrical power. Present studies have explored the overall efficiency of these devices while experimentally describing losses in piezoelectric and circuit interfaces, nevertheless there is no study on the fluid to mechanical force transmission efficiency. In this paper we investigate the pressure to force transmission rate of two types of fluid to mechanical interfaces: a flat metal plate and a conventional hydraulic piston. The interfaces are investigated in conditions similar to those found in conventional hydraulic systems. The study shows that flat plate exhibit good force transmission for low pressure applications with a constant rate across frequencies, while exhibiting a decrease in force transmission at higher pressures. On the other hand the piston exhibit a more robust pressure design, with a constant force transmission rate at all pressures but with a dampening of force at higher frequencies. It is shown that small differences in force transmission ratios can have a considerable impact on the power generation.

The need for wireless sensor networks that can run for long times without the need of battery replacement has risen the need for energy harvesters. Industrial environments have plenty of energy sources that can be harvested; pressure fluctuations are a high energy density source that can be harvested using piezoelectric devices. Present devices have introduced flat metallic plates as the main force transmission elements for hydraulic fluctuations energy harvesters. In this paper, we analyze the force transmission efficiency of flat plates when used as the primary fluid coupling interface in hydraulic energy harvesters. Previous work has been focused on the optimization of circuit matching and pressure ripple amplification. In this work, we offer a look into the efficiencies of flat plates in different configurations and pressure loads. The analysis shows that despite the reasonable force transmission efficiency of flat plates in low-pressure environments, the overall efficiency of hydraulic energy harvesters can be improved if instead of flat plates, conventional hydraulic actuators, such as piston cylinders, could be used.