Development of a tunable low-frequency vibration energy harvester and its application to a self-contained wireless fatigue crack detection sensor

In this study, a tunable electromagnetic energy harvesting system, consisting of an energy harvester and energy harvesting circuits, is developed for harnessing energy from low-frequency vibration (below 10 Hz) of a bridge, and the harvesting system is integrated with a wireless fatigue crack detection sensor. The uniqueness of the proposed energy harvesting system includes that (1) the resonance frequencies of the proposed energy harvester can be readily tuned to the resonance frequencies of a host structure, (2) an improved energy harvesting efficiency compared to other electromagnetic energy harvesters is achieved in low-frequency and vibration, and (3) high-efficiency energy harvesting circuits for rectification are developed. Furthermore, the developed energy harvesting system is integrated with an on-site wireless sensor deployed on Yeongjong Grand Bridge in South Korea for online fatigue crack detection. To the best knowledge of the authors, this is the very first study where a series of low-frequency vibration energy harvesting, rectification, and battery charging processes are demonstrated under a real field condition. The field test conducted on Yeongjong Grand Bridge, where fatigue cracks have become of a great concern, shows that the proposed energy harvester can generate a peak voltage of 2.27 V and a root mean square voltage of 0.21 V from 0.18-m/s² root mean square acceleration at 3.05 Hz. It is estimated the proposed energy harvesting system can harness around 67.90 J for 3 weeks and an average power of 37.42 µW. The battery life of the wireless sensor is expected to extend from 1.5 to 2.2 years. The proposed energy harvesting circuits, composed of the AC–DC and boost-up converters, exhibit up to 50% battery charging efficiency when the voltage generated by the proposed energy harvester is 200 mV or higher. The proposed boost-up converter has a 100 times wider input power range than a conventional boost-up converter with a similar efficiency.