Design & Performance Optimization of a Micro Piezoelectric–Electromagnetic Hybrid Energy Harvester for Self-Powered Wireless Sensor Nodes ⚡🔬 #WorldResearchAwards

Introduction

Low-amplitude and low-frequency vibration energy is abundant in natural and industrial environments; however, effectively harvesting this energy remains a major challenge for self-powered wireless sensor nodes. Conventional single-mode energy harvesters, particularly piezoelectric-only systems, suffer from low conversion efficiency under such conditions, limiting their long-term autonomous operation. To overcome these limitations, hybrid energy harvesting approaches that combine multiple transduction mechanisms have gained increasing research attention. This study introduces a micro-scale piezoelectric–electromagnetic hybrid energy harvester designed specifically for low-frequency and low-amplitude vibration environments, aiming to significantly enhance energy capture efficiency through structural integration and systematic parameter optimization using numerical simulations.

Coaxial Integrated Hybrid Harvester Architecture

The proposed energy harvester adopts a coaxial integrated architecture that combines a piezoelectric cantilever beam array with an electromagnetic induction module within a compact structure. This integrated configuration enables simultaneous mechanical excitation of both transduction mechanisms, improving overall energy utilization compared to separated hybrid systems. The piezoelectric component employs PMN-PT solid solution material with a thickness of 0.2 mm, selected for its high piezoelectric coefficient and superior energy conversion characteristics. The electromagnetic module consists of finely wound copper coils paired with high-performance N52-type NdFeB permanent magnets, ensuring efficient electromagnetic coupling under low-frequency excitation.

Multi-Physics Numerical Modeling and Simulation Framework

A comprehensive multi-physics coupling model is developed using ANSYS Workbench 2023 to accurately simulate the structural dynamics, piezoelectric response, and electromagnetic induction behavior of the hybrid harvester. The simulation framework integrates mechanical vibration, electric field generation, and magnetic flux variation within a unified environment. A mesh size of 0.1 mm is applied to ensure numerical accuracy while maintaining computational efficiency. The model evaluates energy output characteristics across vibration frequencies ranging from 0.3 to 12 Hz and amplitudes between 0.2 and 1.0 mm, representing realistic low-frequency vibration scenarios.

Orthogonal Parameter Optimization Strategy

To maximize energy harvesting efficiency, an orthogonal experimental design is implemented to optimize key structural and electromagnetic parameters. The optimization variables include the length-to-thickness ratio of the cantilever beam, the mass of the tip mass, the number of coil turns, and the spacing between permanent magnets. Each parameter is evaluated at four distinct levels, allowing systematic analysis of their individual and combined effects on performance. This multi-parameter optimization approach enables efficient identification of optimal design configurations while reducing simulation complexity and computational cost.

Energy Output Performance and Efficiency Enhancement

Simulation results demonstrate that the optimized coaxial hybrid harvester significantly outperforms conventional designs. Within the 0.3–12 Hz low-frequency range, the proposed structure achieves a 45% increase in energy conversion efficiency compared to a single piezoelectric harvester and a 31% improvement over traditional separated hybrid configurations. At a vibration frequency of 6 Hz and an amplitude of 0.6 mm, the device delivers a power density of 3.5 mW/cm³, with a peak open-circuit voltage of 4.1 V and a peak short-circuit current of 1.3 mA. These results confirm the effectiveness of structural integration and parameter optimization in enhancing low-frequency energy harvesting performance.

Reliability, Environmental Stability, and Application Potential

The long-term reliability and environmental adaptability of the proposed energy harvester are evaluated through numerical analysis under varying humidity (20–88%) and temperature (−15 to 65 °C) conditions. The device maintains over 94% stability in energy output across these environmental ranges. Furthermore, after 1.2 million vibration cycles, the harvester retains more than 96% structural integrity, with energy conversion efficiency degradation limited to less than 5%. These results highlight the robustness and durability of the design, making it a strong candidate for powering self-sustaining wireless sensor nodes in real-world low-frequency vibration environments.

Hashtags

#worldresearchawards #energyharvesting #piezoelectricharvester #electromagneticharvester #hybridenergyharvesting #lowfrequencyvibration #wirelesssensornodes #selfpowereddevices #microsystems #numericalsimulation #ansysworkbench #multiphysicsmodeling #structuraloptimization #renewableenergyresearch #smartmaterials #piezoelectricmaterials #electromagneticinduction #engineeringresearch #vibrationenergy #sustainabletechnology

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