A 3D Printed Compact and Intelligent Power Module Based on Vibration Energy Harvester Integrated with Self-Powered Triboelectric Sensor for Industry 4.0 IoT Applications

This paper proposes a compact, vibration-driven intelligent power module for Industry 4.0 IoT applications. It integrates a 3D-printed electromagnetic vibration energy harvester (VEH) with a triboelectric-based self-powered vibration sensor (SVS) for excellent energy harvesting and real-time condition monitoring. The module is designed to be the size of a standard D-battery.

• A compact, D-battery-sized intelligent power module for Industry 4.0.
• Integration of a VEH and a self-powered triboelectric sensor (SVS).
• Excellent energy harvesting over a wide frequency range (10-100 Hz).
• Demonstration of a self-powered smart wireless condition monitoring system using harvested energy.

A power module was designed with newly designed 3D-printed flat-circular Z-shaped springs. The module, containing the VEH, SVS, power management circuit, battery, and USB-C port, was tested using vibrations from an air-pump motor and a car engine. The harvested energy was used to power multiple sensors and a wireless transmission circuit.

The VEH delivers a maximum peak power of 1.95 W at 16 Hz, and the SVS exhibits excellent vibration sensitivity. The module successfully charged its built-in battery from industrial and automotive vibrations and powered a wireless condition monitoring system, demonstrating its feasibility for Industry 4.0 applications.