Rotation-Induced Airflow Energy Harvesting Using Transverse Galloping for Self-Powered Tool Condition Monitoring

A novel approach to powering wireless sensor nodes (WSNs) in high-speed rotating applications is proposed using a piezoelectric energy harvester. This is designed and tested to harness rotation-induced airflow using a cantilever bluff-body design through the galloping mechanism. Unlike traditional galloping energy harvesters, the bluff body is dynamic and rotated in a static fluid generating the same aerodynamic effect. A piezoelectric element mounted on the beam generates voltage as it deflects during galloping. The centrifugal force, which varies with rotational speed, self-tunes the harvester, ensuring beam oscillation near its resonant frequency. Analysis of experimental results demonstrates the successful power generation of 1.5 μW while using the largest of the 4 manufactured prototypes making it a viable solution for self-powering ultra-low powered MEMS accelerometers. This innovative approach addresses the challenge of self-sustaining power for WSNs in demanding industrial environments where Tool Condition Monitoring (TCM) systems are required.