DIGEP - unipv · control (ABS, ESC, …) Inside each node Sensors (temperature, pressure, 3‐axial...

Pavia, 5Pavia, 5th th February 2013February 2013

MagnetoMagneto--mechanical Energy Harvester mechanical Energy Harvester for wireless sensors for wireless sensors

in Tyre, Shoes and other components in Tyre, Shoes and other components

ElvioElvio BonisoliBonisoli

DIGEPDIGEPDepartment of ManagementDepartment of Managementand Production Engineeringand Production Engineering

Pavia, 5Pavia, 5thth February 2013February 2013 22 / 37/ 37

Aim: supply energy to remote wirelesssensors inside tyre, shoes or other items

Presentation of the Cyber Tyre project Requirements, source characteristics

and boundary constraints Description of the harvesting device dynamics Optimization aspects Performance index and comparison Other applications: shoes and mouse devices Conclusions

OutlinesOutlines


Cyber™Tyre

Cyber™Tyre

Cyber™Tyre

Processing UnitReceiver

Receiver User Applications

Control System

Cyber™Tyre

Cyber™Tyre

Cyber™Tyre

Processing Unit Receiver

Receiver

Vehicle Dynamics

Tyre like a sensor !

Pirelli Pirelli TyreTyre ProjectProject


Cyber™Tyre

Cyber™Tyre

Cyber™Tyre



Control System

Cyber™Tyre

Cyber™Tyre

Cyber™Tyre


Receiver

Vehicle Dynamics


Supply energy to remote wirelesssensors inside tyre

Why ? No time‐life constraintBatteries are not enough …“Green” meaning !

How ? Use tyre kinematicCharacteristics ? Small and powerful

Reliable and robust !Efficient and adaptive



Cyber™Tyre

Cyber™Tyre

Cyber™Tyre



Control System

Cyber™Tyre

Cyber™Tyre

Cyber™Tyre


Receiver

Vehicle Dynamics


Sensors inside tyreWhy ? Pressure and Temperature monitoring

Forces, wearing measurementsGrip and aquaplaning estimations

How ? High technologyIntegration on vehicle dynamics



University

Industrial partners

Car maker

Cyber™Tyre

Cyber™Tyre

Cyber™Tyre



Control System

Cyber™Tyre

Cyber™Tyre

Cyber™Tyre


Receiver

Vehicle Dynamics



Cyber Tyre: Temperature, pressure and

grip evaluation on each tyre Integrated vehicle dynamic

control (ABS, ESC, …)

Inside each node Sensors (temperature, pressure, 3‐axial accelerometer) Electronic circuits UWB Antenna + PAN on vehicle Energy Harvester (mechanical‐electro‐magnetic) Harvester Interface (active control)



Very long historical connection to the water wheel, windmills and waste heat

Ironically, before batteries (Volta, 1799) and the dynamo (Faraday, 1831), energy scavenging or energy harvesting was the only way to get any useful power !

Today, great interest in the community for powering ubiquitously deployed sensor networks and mobile electronics

All depends on the application (source characteristics, power density requirements, …) – No one-size-fits-all !

Energy Harvester historyEnergy Harvester history


Mean power and power density, obtained through scavengers, are usually small (µW, mW, W)

Source of power, excitation characteristics and harvesting technologies

Energy scavenging principles:• Radio waves• Vibrations• Electromagnetic• Electrostatics• Piezoelectric• Thermoelectric• Photovoltaic• Biological

ElectromagneticElectromagneticVibrationsVibrationsElectrostaticsElectrostaticsThermoelectricThermoelectric

PhotovoltaicPhotovoltaicPiezoelectricPiezoelectric

Examples ???Examples ???

Energy Harvester typologyEnergy Harvester typology


ShakeShake‐‐drivendrivenflashlightflashlight

Mechanical watchesMechanical watches

Piezoelectric pavementPiezoelectric pavement

ElectrostaticElectrostaticgeneratorgeneratorin shoesin shoes

Solar panelsSolar panels

PZT generators in shoesPZT generators in shoes

Some examples Some examples ……


depend heavily on the ambient excitation and harvesting technologies

Power densityPower density


Characteristics and operational requirements: Small dimensions: about 10x10x10 mm High power density Wake‐up velocity 20‐30 km/h Velocity range up to 300 km/h Voltage > 1.3 V Lowest mean power 2.5 mW

Nonlinear electro‐magnetic device

(resonant and adaptive)

Pirelli Pirelli TyreTyre HarvesterHarvester


Characteristics and operational requirements: Small dimensions: about 10x10x10 mm High power density Wake‐up velocity 20‐30 km/h Velocity range up to 300 km/h Voltage > 1.3 V Lowest mean power 2.5 mW

Nonlinear electro‐magnetic device

(resonant and adaptive)

Conicalrubberwedge

Peekcube

EnergyScavenger



How it works: A floating magnet slides

into the guide Around the guide are

wound two coils Preload obtained through

magnets Use of rare‐earth permanent

magnets (high power density) Electric‐magnetic coupling

with imposed dynamic



Time [s]

Z-RADIAL

Source characteristics: Variations in the radial acceleration impose dynamic

to a floating permanent magnet One‐wheel‐turn gives one pulse of energy

Radial acceleration [m

/s2 ]



0 50 100 150 200 250 300 350-6

-4

-2

0

2

4

6

8

10

12

14

Vel [km/h]

Energy Scavenger Simulator

Voltage min [V]Voltage max [V]Voltage rms [mV]Power [mW]

Friction [N]Velox z [m/s]

Time [s]Accel x_input [m/s²]Accel y_input [m/s²]Accel z_input [m/s²]Disp z_shaker [mm]Velox z_shaker [m/s]Accel z_shaker [m/s²]

Disp x [mm]Disp y [mm]Disp z [mm]Velox z [m/s]Accel z [m/s²] Force K [N]

Force C [N]

Force K [N]Force C [N]Current [A]Voltage [V]Voltage Core1 [V]Voltage Core2 [V]Power av [mW]

Magnet_3dof

Input

0

0

0.08359

0.0114

-0.0029958

-1.9771972

0

0

2.442971

-0.039

-0.051

-0.173

1.038

0.011

0.00151

38.931

41.411

833.131

0

0

0

-0.019

1.038

CoilMagnet

Bumpstop

Box

Rif. Inerziale

Shaker

GeometricalGeometricalparametersparameters

0.08 0.09 0.1 0.11 0.12 0.13 0.14-6

-5

-4

-3

-2

-1

0

1

2

3

4

Time [s]

Vol

tage

[V]

Test Rubber 1Test Rubber 2Test No RubberES simulator

EstimatedEstimatedperformanceperformance

ComparisonComparison

FEMFEM

CADCAD

SIMSIM

PrototypePrototypeand testsand tests

Simulated performanceSimulated performance





Force C [N]


Magnet_3dof

Input

0

0

0.08359

0.0114

-0.0029958

-1.9771972

0

0

2.442971

-0.039

-0.051

-0.173

1.038

0.011

0.00151

38.931

41.411

833.131

0

0

0

-0.019

1.038

CoilMagnet

Bumpstop

Box

Rif. Inerziale

Shaker

Floatingmagnet

Iron-coilcoupling

Elasticand/or

dissipativeterms

Tyrekinematic

State

Forces



CxFxm CyFym

emairbumpfricCz FFFFFzm

Dynamic equilibrium of the floating magnet:

xy

z

xgmF Cx

~ygmF C

y~zgmF C

z~

from Pirelli exp.

0if

if00if

limlim

limlim

limlim

bump

bumpbump

Fzzzczzk

zzzFzzzczzkF

limlimlimlim

limlim

if0,ifsign

yyyxxxyyxxzzfF fric

Rubbery bumpers

Adhesion and friction

Modelling aspectsModelling aspects


xy

z Pneumatic effects

airvis

airp

air FFF

12

2

4ppdF air

p

inpr

inpvisair

vis zzc

hdzzF

inpairairairp

airairairp

zzF

zzkF



xcFxm ,

ycFym ,

bumpfricemzc FFFFzm ,


xy

z

Electro-magnetic coupling from FEM

cemkemem FFF ,, zFF kemkem ,,

idzdN

zi

dtdN

zieF cem

,

ediC

iRRdtdiL

t

ll 0

1



xcFxm ,

ycFym ,



xy

z



idzdN

zi

dtdN

zieF cem

,

ediC

iRRdtdiL

t

ll 0

1 -3 -2 -1 0 1 2 30

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

Displacement [mm]

Forc

e [N

]

v = 7.4 % , m = 7.2 %

v = 7.4 % , m = 3.2 %

v = 5.3 % , m = 14.1 %

v = 5.3 % , m = 6.3 %



xcFxm ,

ycFym ,



xy

z



idzdN

zi

dtdN

zieF cem

,

ediC

iRRdtdiL

t

ll 0

1 -3 -2 -1 0 1 2 30

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

Displacement [mm]

Forc

e [N

]

v = 7.4 % , m = 7.2 %

v = 7.4 % , m = 3.2 %

v = 5.3 % , m = 14.1 %

v = 5.3 % , m = 6.3 %

-3 -2 -1 0 1 2 30

50

100

150

200

250

Displacement [mm]

Freq

uenc

y [H

z]

v = 7.4 % , m = 7.2 %

v = 7.4 % , m = 3.2 %

v = 5.3 % , m = 14.1 %

v = 5.3 % , m = 6.3 %



xy

z

30 km/h30 km/h60 km/h60 km/h

100 km/h100 km/h

Comparison of dynamicsComparison of dynamics


Velocity of 20 km/h not working … Magneto‐elastic preload confines magnet displacement

to no dynamic Electric‐magnetic coupling is close to be null

0.7 0.75 0.8 0.85 0.9 0.95 1 1.05 1.1-4

-2

0

2

4

Dis

p z-

z inpu

t [mm

]


0.7 0.75 0.8 0.85 0.9 0.95 1 1.05 1.1-0.4

-0.2

0

0.2

0.4

Vel

zd-

zdin

put [m

/s]

Time [s]0.7 0.75 0.8 0.85 0.9 0.95 1 1.05 1.1

-20

0

20

40

60

80

100

120

140

160

180

200

Acc

el z

ddin

put [m

/s2 ]

Time [s]


InputShaker



0.9 0.92 0.94 0.96 0.98 1 1.02 1.04 1.06 1.08 1.1-100

0

100

200

300

400

500

600

700

800

900

Acc

el z

ddin

put [m

/s2 ]

Time [s]


InputShaker

Velocity of 40 km/h full operative condition Wide amplitude resonant motion Electric‐magnetic coupling is equivalent to a viscous

damping effect

0.9 0.92 0.94 0.96 0.98 1 1.02 1.04 1.06 1.08 1.1-4

-2

0

2

4

Dis

p z-

z inpu

t [mm

]


0.9 0.92 0.94 0.96 0.98 1 1.02 1.04 1.06 1.08 1.1-1.5

-1

-0.5

0

0.5

1

Vel

zd-

zdin

put [m

/s]

Time [s]



Velocity of 80 km/h full operative condition Magnet presents an impulsive dynamic Electric‐magnetic coupling maintains a good power flow At higher speed the power reduces because the moving mass

does not have the time to reach the upper bumper

0.55 0.56 0.57 0.58 0.59 0.6 0.61 0.62 0.63 0.64 0.65-500

0

500

1000

1500

2000

2500

3000

3500

Acc

el z

ddin

put [m

/s2 ]

Time [s]


InputShaker

0.55 0.56 0.57 0.58 0.59 0.6 0.61 0.62 0.63 0.64 0.65-4

-2

0

2

4

Dis

p z-

z inpu

t [mm

]


0.55 0.56 0.57 0.58 0.59 0.6 0.61 0.62 0.63 0.64 0.65-6

-4

-2

0

2

Vel

zd-

zdin

put [m

/s]

Time [s]



Device Device behaviourbehaviour


PrototypesPrototypes


0.15 0.16 0.17 0.18 0.19 0.2-1.5

-1

-0.5

0

0.5

1

1.5

2

Time [s]

Vol

tage

[V]

ExperimentalSimulated

Test on shaker:• Resonance detection and nonlinearity weight• Tests with sinusoidal and road profiles

• Test with adapted load Rl = 2 x 210 :

• road profile accelerationswithout radialcomponent 60 km/h

Experimental comparisonExperimental comparison


0.15 0.16 0.17 0.18 0.19 0.2-1.5

-1

-0.5

0

0.5

1

1.5

2

Time [s]

Vol

tage

[V]


0 0.05 0.1 0.15 0.2 0.25 0.3 0.350

0.1

0.2

0.3

0.4

0.5

Time [s]

Pow

er [m

W]


Test on shaker:• Resonance detection and nonlinearity weight• Tests with sinusoidal and road profiles

• Test with adapted load Rl = 2 x 210 :

• road profile accelerationswithout radialcomponent 60 km/h



mm75.00 Y mm00.10 Y



mm75.00 Y mm00.10 Y

mm15.10 Y mm25.10 Y



mm75.00 Y mm00.10 Y

mm15.10 Y mm25.10 Y

mm35.10 Y mm50.10 Y



Goals: Verifying that the topology is optimal Improving the performance at low speed Optimization of components “weights”

Device optimizationDevice optimization


Multiple coils configurations Two (or more) spacers

between coils One or more floating

magnets

Flux

linkage [W

b]Displacement [mm]

Coils optimizationCoils optimization


Full parametric model Volume constraints Gradient or genetic

algorithms

0 20 40 60 80 100 120 140 1600

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

Uni

tary

erro

r [-]

Iteration

Mean po

wer [m

W]

Global optimizationGlobal optimization


Maximum available energy and power:

The system is more effective at low vehicle speed

samLE rext 2max

2

3

max 2rvsmsamfP r

Device efficiencyDevice efficiency


Work in progress Work in progress ……





Force C [N]


Magnet_3dof

Input

0

0

0.08359

0.0114

-0.0029958

-1.9771972

0

0

2.442971

-0.039

-0.051

-0.173

1.038

0.011

0.00151

38.931

41.411

833.131

0

0

0

-0.019

1.038

CoilMagnet

Bumpstop

Box

Rif. Inerziale

Shaker

Floatingmagnet

Iron-coilcoupling

Elasticand/or

dissipativeterms

Tyrekinematic

State

Forces



Time histories and frequency contents

From From tyretyre to to …… shoesshoes

0 10 20 30 40 50 60 70-250

-200

-150

-100

-50

0

50

100

150

200

250

Time [s]

Acc

eler

atio

n [m

/s2 ]

xddyddzdd


Optimization with conical springs



Prototypes



ResumeResume

Energy Harvester for power supplier of wireless sensors

Power density and suitability of sources Pirelli Cyber Tyre project Magneto-mechanical Energy Harvester Nonlinear dynamics, optimization and results From tyre to shoes and other device applications

Acknowledgements / People involved

Prof. Stefano TORNINCASA Ing. Elvio BONISOLI ([email protected]) Ing. Marco BRINO ([email protected]) Ing. Francesco DI MONACO Ing. Gabriele MARCUCCIO

DIGEP - unipv · control (ABS, ESC, …) Inside each node Sensors (temperature, pressure, 3‐axial...

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