Powering a Low Power Wireless Sensor in a Harsh Industrial Environment: Energy Recovery with a Thermoelectric Generator and Storage on Supercapacitors

Wireless sensor networks are widely used for monitoring in remote areas. They mainly consist of wireless sensor nodes, which are usually powered by batteries with limited capacity, but are expected to last for long periods of time. To overcome these limitations and achieve perpetual autonomy, an energy harvesting technique using a thermoelectric generator (TEG) coupled with storage on supercapacitors is proposed. The originality of the work lies in the presentation of a maintenance-free, robust, and tested solution, well adapted to a harsh industrial context with a permanent temperature gradient. The harvesting part, which is attached to the hot spot in a few seconds using magnets, can withstand temperatures of 200˚C. The storage unit, which contains the electronics and supercapacitors, operates at temperatures of up to 80˚C. More specifically, this article describes the final design of a 3.3 V 60 mA battery-free power supply. An analysis of the thermal potential and the electrical power that can be recovered is presented, followed by the design of the main electronic stages: energy recovery using a BQ25504, storage on supercapacitors and finally shaping the output voltage with a boost (TPS610995) followed by an LDO (TPS71533).