Accepted Manuscript Title: Cutting tool vibration energy harvesting for wireless sensors applications Author: Vytautas Ostasevicius Vytautas Markevicius Vytautas Jurenas Mindaugas Zilys Mindaugas Cepenas Laura Kizauskiene Virginija Gyliene PII: S0924-4247(15)30068-6 DOI: http://dx.doi.org/doi:10.1016/j.sna.2015.07.014 Reference: SNA 9246 To appear in: Sensors and Actuators A Received date: 10-3-2015 Revised date: 12-6-2015 Accepted date: 13-7-2015 Please cite this article as: Vytautas Ostasevicius, Vytautas Markevicius, Vytautas Jurenas, Mindaugas Zilys, Mindaugas Cepenas, Laura Kizauskiene, Virginija Gyliene, Cutting tool vibration energy harvesting for wireless sensors applications, Sensors and Actuators: A Physical http://dx.doi.org/10.1016/j.sna.2015.07.014 This is a PDF file of an unedited manuscript that has been accepted for publication. As a service to our customers we are providing this early version of the manuscript. 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Cutting Tool Vibration Energy Harvesting For Wireless Sensors Applications Vytautas Ostasevicius 1*, Vytautas Markevicius 2, Vytautas Jurenas 1, Mindaugas Zilys 2, Mindaugas Cepenas 2, Laura Kizauskiene 3, Virginija Gyliene 1 1 Institute of Mechatronics, Kaunas University of Technology, Studentu st. 56-123, Kaunas LT-51368, Lithuania; E-Mail: [email protected] 2 Faculty of Electrical and Electronics Engineering, Kaunas University of Technology, Studentu 48-211 St. 27, Kaunas LT-51368, Lithuania; E-Mail: [email protected] 3 Faculty of Informatics, Kaunas University of Technology, Studentu St. 48-213, Kaunas LT-51368, Lithuania; E-Mail: [email protected] *Author to whom correspondence should be addressed; E-Mail: [email protected]; Tel.: +370- 698-12588. Highlights • A wireless sensor node architecture composed from energy harvesting transducer, energy accumulating capacitor, sensors, microcontroller and RF link is proposed and fabricated. • The elaborated algorithm and the created detector could reach no more than 100-150 nA current consumption. • The created wireless sensor energy harvester prototype satisfies the energy needs for sensors and is capable of transmitting the information at the distance of 20 metres. • For cutting tool performance evaluation the limitary moment, when cutting tool starts manufacturing inappropriate quality parts, is defined experimentally and statistically. • The created device opens a way for wireless sensors networks in manufacturing technologies. Graphical abstract Vitae Vytautas Ostasevicius graduated from Kaunas University of Technology - engineer mechanic in 1971, doctor of sciencies in 1974, doctor habilitus in 1988. Director of the Institute of Mechatronics, Member of Lithuanian and and Foreign Member of Swedish Royal Engineering Academies of sciences. His research focuses on Mechatronic systems dynamics, manufacturing technologies, product development. Vytautas Markevicius graduated MSc in1973 and received PhD in Electronics Engineering in 1983. He works at Department of Electronics Engineering, Faculty of Electrical and Electronics Engineering, Kaunas University of Technology. The leader of the research group on Interactive electronic systems. His research focuses on finding solutions for the issues related to the Interactive electronic systems, integrated information systems or WSN. Vytautas Jurenas graduated from Kaunas University of Technology (KTU) in 1979 and received degree in Mechanical Engineering. He was awarded his PhD in 1993 in the field of Mechanical Engineering. He is a senior researcher in KTU Mechatronics Institute. His research interests include piezomechanics and diagnostics of mechanical systems. Mindaugas Zilys graduated MSc in1996 and received PhD in Electronics Engineering in 2001. He works as a researcher at Department of Electronics Engineering, Faculty of Electrical and Electronics Engineering, Kaunas University of Technology and in industry. His research focuses on electronic system efficiency, energy harvesting, low power management and wireless smart sensors. Mindaugas Cepenas graduated from Kaunas University of Technology (KTU) in 2012 with Master's degree in Electrical engineering. Currently, PhD study in Electrical and Electronics Department of Electronics Engineering studies KTU. Research areas - interactive design of microprocessor systems and low-power wireless networks. Laura Kizauskiene is an associate professor at the Department of Computers, and researcher at the Real-time Computer Systems Centre at Kaunas University of Technology. She has gained doctors' degree in Technology Science in 2009. Her main research interests are multi-agent systems, artificial intelligence, wireless sensor networks, embedded real time systems and smart environments. Since 2007, she has been working at Kaunas University of Technology and has participated in several research projects, developing smart house and sensor network technologies. Virginija Gyliene received her License Professional degree (Conception and Fabrication assisted by Computers) from the University of Maine (France) in 2001. She gained a Master degree in Manufacturing Engineering in 2002 and Ph. D. degree in 2007 from Kaunas University of Technology. Now, she is the Lecturer in the same University and her research field is numerical and experimental study of cutting processes. Abstract This paper presents a method of cutting tool vibration energy harvesting for wireless applications, the created devices and the results of the accomplished experiments. The proposed high frequency piezo generator assures energy harvesting, accumulation and appropriateness for wireless sensors applications. The proposed architecture composed from energy harvesting transducer, energy accumulating capacitor, sensors, microcontroller and RF link opens a way for wireless sensors networks in manufacturing technologies providing the effective integration of information, delivered by sensors of different nature, to achieve a wholesome description of the status of the monitored process. The elaborated algorithm and the created detector could reach no more than 100-150 nA current consumption during capacitor charging. This method makes possible the accumulation of necessary energy during turning tool vibrations. According to the experimental results, the created wireless sensor energy harvester prototype satisfies the energy needs for sensors and is capable of transmitting the information at the distance of 20 metres. For cutting tool performance evaluation the limitary moment, when cutting tool starts manufacturing inappropriate quality parts, was defined experimentally and statistically. Keywords: vibration energy harvesting, piezo generator, wireless sensor node 1. Introduction Rapidly increasing numbers of wireless sensor nodes and their networks necessitate t he development of continuously powered systems avoiding the most expensive issue of its maintenance –periodical battery replacement or recharge [1]. Capturing small amounts of energy from the surrounding vibrations, accumulating them and storing for later use is one of the perspective techniques in recent years [2], recently realized by magnetostrictive, electrostatic, electromagnetic or piezoelectric transduction mechanisms [3]. Most attractive frequencies for the harvesters are less than 100 Hz [4]. Piezoelectric transduction was chosen from the other available motion-to-electricity conversion methods due to its high energy density, favorable dynamic response as well as self-contained power generation materials [5]. Piezoelectric converters are a right choice for converting mechanical energy to electricity because energy density is more than three times higher as compared to electrostatic and electromagnetic energy generation methods. The concept of multi functionality is related to the combination of several functions in the components made from the same material. Possible system performance improvement possibilities using multifunctional materials are discussed in the paper [6]. Structural power systems, from the denoted four classes of multifunctional material systems, enabling the integration of energy storage capability with the structural function, are most interesting for applications. Energy capturing from different sources could be obligatory in cases when the amount of energy scavenged from the unique source is not sufficient for allowing the alimented system to remain online. Hybrid energy harvesting results, presented in [7] demonstrate the effectiveness of simultaneous application of piezoelectric. There are different mounting ways of piezoelectric generators, but the most common are cantilever beams [8]. The stability of a constant energy flow between the energy source and the load is a key element of the energy harvesting system. As the piezoelectric energy harvesting devices do not ensure enough current to power MEMS sensors, the development of storage devices and the enhancement of charge density are essential. Investigation of methods for improving electrical charge density for the circuitry and signal processing reduction are needed as well. The most fruitful efforts will likely come from hybridized power supplies, which offer both, on-board storage and energy harvesting from environmental sources.