A compact-size and high-power energy harvester using stacked flexible-PCB coils for rotational shaft applications

In this Letter, a compact-size and high-power energy harvester (EH) based on multilayer flexible printed circuit board (F-PCB) sheets is presented for wireless sensor system (WSS) applications on propulsion shafts. A 2 mm thin rotor is designed using two F-PCB sheets that integrate 12 coil bundles with a total number of coil turns of 368. A stator is designed in a fixture that can be installed in the bearing housing. Voltage and power of the fabricated EH were measured and analyzed at a rotational speed of 10–100 rpm. At 80–100 rpm, the average voltage and output increased linearly with increasing speed. In particular, at 100 rpm, the average voltage and power were 5.43 V and 1714 mW, respectively. This performance represents a significant improvement compared to previously published EHs. The proposed EH features the straightforward structure, facilitating easier power design and prediction, and it is adaptable to various rotational shaft applications.