Title Batteryless IoT sensing using thermoelectric energy harvesting from industrial motor waste heat
Authors Bancik, Kamil ; Konecny, Jaromir ; Stankus, Martin ; Hercik, Radim ; Koziorek, Jiri ; Markevičius, Vytautas ; Andriukaitis, Darius ; Prauzek, Michal
DOI 10.3390/s26051644
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Is Part of Sensors.. Basel : MDPI. 2026, vol. 26, iss. 5, art. no. 1644, p. 1-22.. ISSN 1424-8220
Keywords [eng] Industry 4.0 ; battery-free sensing ; energy harvesting ; predictive maintenance ; thermoelectric generator ; waste heat recovery
Abstract [eng] This study presents the design, implementation, and validation of a thermoelectric energy harvesting system that exploits waste heat from an industrial electric motor to power an autonomous wireless sensor device. The proposed prototype integrates a single thermoelectric generator directly onto the motor housing and leverages the built-in cooling fan to maintain a stable thermal gradient of approximately 4-5 °C. Under real factory conditions, the system harvested 6.17 J of energy over 9612 s, sustaining continuous operation and 41 successful Long Range (LoRa) data transmissions with a positive energy balance. Compared with related works, the prototype achieved competitive or superior performance while operating at a lower motor rating of 0.25 kW, highlighting its efficiency relative to system scale. Key innovations include a hybrid DC/DC conversion chain bridging ultra-low input voltages to modern microcontrollers, and an adaptive transmission strategy that ensures predictable energy management and reliable wireless communication. These results demonstrate the feasibility of battery-free sensing in industrial environments and underline the potential of thermoelectric harvesting as a cost-effective, maintenance-free, and environmentally responsible solution for predictive maintenance and Industry 4.0 applications.
Published Basel : MDPI
Type Journal article
Language English
Publication date 2026
CC license CC license description