Energy-Harvesting Sensor Module for Wire-Free PCB Integration
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Solution Overview
Problem
Existing wireless sensors require multiple wires for power and data transmission, leading to installation complexity, space constraints, and maintenance challenges, while wireless power transfer technologies have limited range and application limitations.
Innovation Solution
A sensor module with a housing part and carrier part, allowing for wireless energy harvesting and data transmission without wires, using a separable design with mechanical fixtures for attachment and integration with various transducers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple wires are used for power supply and data transmission in wired sensors, then reliable power and data connection is achieved, but installation complexity and space requirements increase
Solution Approach 1:
The patent replaces the mechanical wire-based power and data transmission system with a wireless electromagnetic field-based system. The sensor module uses wireless power transfer to receive power without physical connections, and wireless communication for data transmission, eliminating the need for multiple wires and connectors while maintaining reliable power and data connection.
Solution Approach 2:
The patent extracts and removes the wires and physical connectors from the sensor system. By using wireless power transfer and wireless communication technologies, the power supply wires, data transmission wires, and connectors are completely taken out of the system, simplifying installation while maintaining functional reliability.
2Device complexity
If wireless power transfer technology is used to eliminate wires, then installation complexity is reduced, but power transfer range is limited
Solution Approach 1:
The patent optimizes parameters of the wireless power transfer system including operating frequency, power transmission level, and antenna design to achieve effective power transfer within a specific range. By adjusting these parameters, the system maintains reliable power transfer while minimizing the limitations on operating distance.
3Ease of operation
If batteries are used for power supply, then wireless operation is enabled, but maintenance requirements and logistics complexity increase
Solution Approach 1:
The patent implements self-powered operation where the sensor module harvests power from the environment (electromagnetic fields, vibration, or wireless power transfer) to continuously operate without batteries. This self-service approach eliminates battery replacement and charging maintenance while enabling wireless operation.
4Adaptability or versatility
If separable design with mechanical fixtures is used, then adaptability and integration flexibility are improved, but device complexity increases
Solution Approach 1:
The patent divides the sensor system into separable modules including the sensor module, transducer module, and mounting fixtures. Each module can be independently manufactured, tested, and assembled, providing flexibility for different applications while using standardized mechanical interfaces to minimize overall complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables flexible installation, reduced production costs, and eliminates the need for power and communication wires, ensuring independence from batteries and simplifying logistics.
Implementation Method 1
a sensor module, an energy harvesting transducer, preferably configured to convert an energy from a measured physical quantity
Implementation Method 2
obtain the energy from the energy harvesting transducer, store the energy
Implementation Method 3
transmit a measured data wirelessly
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to wireless energy harvesting sensors, and more precisely to a measuring device with a sensor module with sensor electronics and a transducer module. The invention discloses sensor module comprising: a housing part (1), and a carrier part (2). The carrier part (2) comprising a front panel (3) and a holding part (4) attached to the front panel (3), wherein the front panel (3) comprises connecting means (5) suitable for transmitting electrical signals through the front panel (3). The holding part (4) comprising an interior side (6) configured to hold at least one printed circuit board (7), PCB. The housing part (1) is configured to receive the carrier part (2) such that the holding part (4) is enclosed within the housing part (1), preferably the housing part (1) comprising at least one interior wall (9)with at least one guide (8) which is suitable and configured to have the carrier part (2) inserted. The invention discloses a measuring device comprising: a sensor module, an energy harvesting transducer (13), preferably configured to convert an energy from a measured physical quantity, at least one printed circuit board (7), PCB, configured to obtain the energy from the energy harvesting transducer (13), store the energy, indicate a level of the energy being stored, measure the measured physical quantity, and transmit a measured data wirelessly. The printed circuit board (7), PCB, is mounted on a carrier part (2) of the sensor module and the PCB (7) is electrically coupled, through connecting means (5) in a front panel (3) of the carrier part (2) of the sensor module, with the energy harvesting transducer (13).