A Self-Powered Rotational Speed Monitoring System Based on Triboelectric Nanogenerators: An Innovative Solution for Industry 4.0

This study presents a self-powered rotational speed monitoring system (RSMS) utilizing triboelectric nanogenerators (TENGs) to address limitations in conventional speed measurement technologies. By integrating polytetrafluoroethylene (PTFE) and nylon friction layers within a modular inter digital electrode configuration, the system achieves enhanced triboelectric charge transfer efficiency while adapting to diverse shaft geometries. A frequency-domain signal processing algorithm, employing fast Fourier transform analysis of triboelectric waveforms, attains 99.68% measurement accuracy. The RSMS assembly demonstrates second-level temporal resolution and exceptional durability, outperforming Hall-effect sensors in electromagnetic interference environments. Wireless data transmission modules enable real-time cloud analytics of rotational speed fluctuations, eliminating reliance on external power sources. Validated under operating conditions, the RSMS provides a maintenance-free solution for high-RPM applications in automotive, aerospace, and energy systems. This work advances smart manufacturing infrastructure through synergistic integration of triboelectric sensing and edge computing, fulfilling critical requirements for Industry 4.0-compatible condition monitoring.