Piezo stack energy harvesters with protection components for railway applications

Piezo stack energy harvesting from railway vibrations shows substantial potential for powering wireless sensor networks responsible for monitoring railway infrastructure. Nevertheless, assuring the safety and durability of these energy harvesters in the condition of the dynamically fluctuating railway vibrations remains a considerable challenge. In this paper, we present two innovative protection methods designed for piezo stack energy harvesters with a frequency up-conversion mechanism. These methods involve the incorporation of ring-type and circular stoppers within the resonant system and the utilisation of proposed impact protection components within the impact system. Two distinct harvesters incorporating the proposed protection components, Harvester Types I and II, are designed to align with their respective operating acceleration targets, which are determined based on the amplitudes of railway vibration acceleration. Finite element modelling is used to guide the design process, involving the evaluation and selection of various design parameters aligned with the acceleration target and stress limits. The protection mechanisms’ effectiveness and impact on energy harvesting performance have been validated through experimental testing under measured rail vibration signals, and their performance has been further assessed through stress analyses. Harvester Type I operates seamlessly within a 5 g threshold, effectively mitigating the increase in maximum output acceleration and stress beyond this limit. In contrast, Harvester Type II efficiently dissipates excess energy, enabling the harvester to operate at a 15 g acceleration while reducing the rate of acceleration and stress growth. The results demonstrate that both proposed harvesters provide effective protection from unexpected railway vibration overloads. This research makes a significant impact on the practical, real-world implementation of piezo stack energy harvesters operating within the dynamic environment of railway vibrations.