Design Of Electromagnetic Self-powered Equipment Status Monitoring System

With the rapid development of wireless sensing technology,various wireless sensing technologies are widely used in industrial production.Smart devices for device status monitoring are more popular.At present,mature intelligent monitoring devices all need batteries or wires to power them.With the increase of the number of terminal equipment,the problems of high battery replacement cost or inconvenient wire layout have become the most important problems to be solved in the process of intelligent production.A good alternative to battery power is to capture the energy generated during the operation of the production equipment and power the terminal equipment.The conveyor belt in the factory often affects the operation of the whole work line due to the problems of the idlers.Researchers have proposed a number of intelligent idler designs.However,these schemes all require idlers and intelligent devices to be adapted during the design stage,which is low in applicability and cannot be used on idlers installed in factories.This paper presents a non-contact energy harvesting method.According to the kinetic energy generated in the process of idler rotation,an equipment condition monitoring system based on electromagnetic self-power is designed.The monitoring system is designed without changing the parts and assembly of existing conveyor belts.The system does not contact with the idler under test.Part of the kinetic energy of the idler is converted into electricity in the test system through the magnetic field.This energy is used to power and store energy for terminal wireless sensing devices.The system includes self-power module,power management module and wireless sensor module.The functions of self powered terminal wireless sensor nodes,contactless system installation,and real-time data cloud display have been successfully implemented.In order to realize the above functions,this paper mainly does the following work:(1)A self-power supply module based on electromagnetic is designed and analyzed theoretically.A set of modeling scheme using ANSYS Maxwell and MATLAB co-simulation is proposed.The output voltage waveform of the self-powered module under different working conditions can be predicted by the model.(2)The co-simulation model is used for theoretical analysis.The first generation self-power supply module is optimized and analyzed from many aspects.Under different excitation conditions,the output power of the optimized second-generation self-supply module is better than that of the first-generation self-supply module.Under the external excitation condition of 700 rpm,the output power of module increased by 40.9% from 22 m W of the first generation to 31 m W of the second generation.(3)A power management module is designed,which includes rectifier circuit,energy storage element,voltage regulator circuit and hysteresis circuit.These circuits all use low power devices to realize circuit functions.(4)The wireless sensor module is designed for data acquisition and communication.ZigBee was chosen as the communication protocol due to its low power consumption characteristics.The power consumption of the wireless sensor module is 41 m W.After entering the PM2 sleep mode,the working current is only 1μA.(5)A self-powered equipment condition monitoring system with 15 sensor nodes is developed.The system was tested on a conveyor belt simulation platform.On the conveyor belt simulation platform,the rotation speed of the simulated idler(turntable)is between 500 rpm and 1600 rpm.Two minutes after the analog platform was started,each wireless sensor node started and sent the rotary speed data to the Ali Cloud platform.This test fully verifies the feasibility of a self powered equipment status monitoring system.