Self Powered Wireless Sensor System for Power Generation Applications

Condition-based Maintenance (CBM) systems significantly improve the effectiveness of maintenance programs for complex systems by optimizing the timing and focus of the maintenance. Wireless condition monitoring systems can be installed without the need for cabling infrastructure. This provides considerable life cycle cost savings. This project develops a waste heat harvesting power supply that powers wireless condition monitoring systems enabling real time sensor data collection. The target application is power generation plants with their considerable sources of heat. The Department of Energy and the gas turbine engine community place a high priority on the development of sensors for harsh environment. A pressure sensor, capable of operation at 800 degrees Celsius, and measuring pressures up to 1000 pounds per square inch is also being developed under this program. The wireless sensor power supply utilizes Thermo-electric Generator devices to supply an adjustable output voltage of 3.3 to 12 volts direct current. The power supply can be used with existing wireless systems in the market, potentially enabling them for real time data collection. An advanced generation wireless condition monitoring network node using the 802.15.4 protocol is being developed. It contains temperature, vibration, pressure, and general sensor inputs and is designed for real time sensor operation. The pressure sensor is a standalone component that can also be used in the wireless condition monitoring system. Commercial Applications and Other Benefits: The harsh environment pressure sensor is a high priority development for gas turbine engines. It can be used for developmental testing or operational environment condition monitoring. The TEG PS will benefit existing off-the-shelf wireless condition monitoring systems by providing power for their network node/sensor interfaces and potentially enabling real time sensor data collection. The wireless condition monitoring system can be used for critical real time monitoring applications in power generating plants and other industrial applications.