This paper introduces a customisable high-power push-button energy harvester (EH) designed for powering various smart sensor systems [Figure 2]. It is part of an innovative, energy self-sufficient intelligent control system aimed at reducing energy consumption for air conditioning and lighting in warehouse and industrial buildings [Figure 1]. The EH produces more energy than commercially available systems of the same size due to its high energy density [1][2]. A provided guideline allows the harvester and power management system (PMS) to be tailored to specific use cases. The paper first details the design and functional principles of the EH, followed by an analysis of parameters using FEM simulations.

This analysis led to optimisation of the PCB coils, selecting a thickness of 0.8 mm, four copper layers with eight coils each, and 25 windings [Figure 3]. Additionally, the energy harvester’s structure was optimised regarding the positioning and thickness of 1 mm for the permanent magnets, ferromagnetic discs, and air gaps between magnets and coils. The effect of rotational speed on induced voltage was studied, with simulations showing a maximum induced peak voltage of 4.8 V at 1,000 rpm. An integrated PMS system was adapted to match impedance and efficiently convert AC to DC voltage without rectifier diodes [Figure 4].

The EH demonstrated the ability to generate a peak voltage of 2.1 V at 500 rpm, harvesting 11.8 mJ with an electrical load of 80-90 Ω. These values are 2 to 3 times greater than those of commercial harvesters [3]. The simulations, mechanical design, and integrated power management provide a guideline that can be easily adapted for individual needs. With its compact design and high energy collection capability, the EH opens new possibilities for IoT devices in the future.