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The Design Secrets for Commercially Successful EH-Powered Wireless Sensors

Steve Grady & Jeff Mullin Cymbet


Energy Harvesting for Powering WSN Symposia

Designing Commercially Successful Energy Harvesting Powered Systems


Identify key trends and market forces driving Click to edit Master text styles the need for Energy Harvesting-based power Second level Theeconomics behind Energy Harvesting Third level Fourth level Identify important design considerations Fifth level Utilize Energy Harvesting technologies that enable cost effective EH-powered products Review reference designs for important info Commercial EH-powered sensor deployments
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Key Trends Driving Innovation


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Ultra Low Power Processors & Electronics Smart Devices Second level and Sensors

Third level

Everywhere

Wireless is pervasive

Integration with other components

Miniaturization

Eco-Friendly and Renewable Energy

Convergence of Trends into Products Fourth level Fifth level

New innovative products are smarter, smaller and wireless Smart devices that must communicate status/control There will be billions of new networked smart devices Health, Industrial, Buildings, Appliances, Transportation New Powering solutions are required
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Introducing Energy Harvesting:


Life of Product Energy Generation and Storage Energy can be harvested from almost any environment: Light, vibration, flow, motion, pressure, magnetic fields, RF, etc. Click to edit Master text styles

Second level Energy Harvesting applications found in every industry segment


EH-powered systems need reliable energy generation, storage and delivery: Fourth level Must have energy storage as EH Transducer energy source is not always Fifth@night, level motor vibration at rest, air-flow, etc.) available: (Solar Longer operating times high-efficiency minimizes charge loss Self-Powered allows remote locations & lower installation costs High cycle life enables extended operation fewer service calls Ideal solution is a highly-efficient, eco-friendly, power generation system that can be cycled continuously for the life of the product
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Third level

EH Powering The Internet Of Things


Displays

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Second level
Third level
Fourth level Wireless Fifth level Network
Sensors Awnings Vehicles Windows

Lights

Signals

Toys PCs Clothing Media Players Purses

Phones

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HP CeNSE, IBM Smarter Planet


Giving the Planet a Voice with Sensors

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Second level
Third level
Fourth level Fifth level

IBM Smarter Planet

Trillions of digital devices connected to the Internet, are producing a vast ocean of data

Whos going to change 1 Trillion Batteries????!


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Energy Harvesting Market in 2012 $0.7Bn


Source: IDTechEx Energy Harvesting Report

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Second level
Third level
Fourth level Fifth level
Mobile Phones 0.2 million/ $1.8 million Other - including medical 0.2 million/$2 million Wristwatches 33 million/ $26 million Wireless Mesh Networks 0.2 million/ $2 million

Consumer Electronics 630million/ $420 million

Military & Aerospace 0.05 million/ $175 million

Bicycle Dynamo 6.3 million/ $63 million

Industrial - non mesh 2 million/$16 million

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Energy Harvesting Market in 2017 $1.5Bn


Source: IDTechEx Energy Harvesting Report
Consumer Electronics 900 million/ $630 million

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Second level
Third level
Fourth level Fifth level
Healthcare 1 million/$9 million

Military & Aerospace 0.07 million/ $210 million

Wireless Mesh Networks 20 million/$200 million

Industrial - non mesh 40 million/ $140 million

Wristwatches 43 million/ $33.4 million

Laptops/ebooks 5 million/$80 million

Mobile Phones 20 million/ $100 million

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Energy Harvesting Market Forecasts


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Second level
Third level
Fourth level Fifth level

From the IDTechEx EH Study: 90% of envisaged use of wireless sensor networks are impractical without EH Many installations are inaccessible or prohibitively expensive for replacement Sensors such as bionics or embedded devices need life of product power Many standalone products need off-the-grid powering solutions
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Total Market Value by EH Technology 2019


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Second level
Third level
Fourth level Fifth level

From the IDTechEx EH Study: EH from light is 60% of applications Electrodynamic/Electromagnetic is 27% Vibration and Thermal 13% but may be low by some estimates What new energy harvesting technologies are coming???
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EH-Powered Autonomous Wireless Sensor Block Diagram


Click to edit Master text styles Sensor
Second level
Third level
Input Fourth level Power
Light

MCU + Radio

(e.g., temperature, pressure, occupancy)

Fifth level

Energy Aware Communications and Control

Energy Harvesting Power Supply


T

Motion

EH Transducer Electrical Interface Discrete Components

IC - Energy Conversion Battery Management Power Management

EM Field

Rechargeable Energy Storage Device

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4 Key Design Considerations for EH


1. Determine energy available from your environment
Indoor solar is in tens to hundreds of microwatts Click to edit in Master text styles Thermoelectric tens to hundreds of microwatts based on delta Temp

Second level 2. Harvest energy as efficiently and cost effectively as possible Design for Maximum Peak Power Point Third level

3. Calculate application power requirements in all operation Fifth level modes and minimize to fit available input EH power
Use sleep modes of components when possible Write Energy- Aware code -> no polling loops, check Vcc before running

Avoid components with excessive leakage or quiescent current Fourth level

4. Size storage for times when ambient energy is not available


Bigger battery is not always better: dont fill the pool with a paper cup!
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EH vs. Battery Business Case Realities


Small device designs that do not have a charging source either AC/DC, Energy Harvesting or Wireless Power use a primary battery Primary batteries have reached commodity status with billions/yr shipped Click to edit Master text styles To compare rechargeable battery $/mAh metric you must use the Lifecycle capacity of thelevel rechargeable battery - #charge cycles x Depth of Discharge Second per cycle in uAh. This gives the total lifetime energy delivery cost. Third Example usinglevel 3Volt batteries 1K Qty on Digi-Key : Fourth CR2032 coin + level holder: $.36/225mAh x 1 cycle = $0.0016/mAh Tadiran coin: $4.82/1000mAh x 1 cycle = $0.0048/mAh Fifth level Alkaline 2 AAA + holder: $1.71/1000mAh x 1 cycle = $0.0017/mAh IPS MEC TFB : $13.09/700uAh x 10,000 cycles= $0.0019/mAh Cymbet EnerChip: $2.70/50uAh x 10,000 cycles = $0.0054/mAh To charge rechargeable batteries, need to add the Cost for EH power system Supercapacitors can be used, but electrical characteristics are a concern

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Calculating the Cost of the Energy Harvester


Think of the Energy Harvester as a variable capacity battery The output energy will depend on the ambient energy conditions Energy Harvester will have a min/max energy output range Click to editdesigns Master text styles Calculate the EH cost based on the energy output average Second level Cost is Transducer + interface components + conversion electronics (IC)

Example: Simple Solar Energy Harvester at 200Lux with 24/7 operation Fourth level Sanyo AM1815 4.9V solar cell $4.39 (1K pcs) output is 147uW Fifth level Assume simple conversion electronic components for $1.25 3.3V x Current = 147uW. Current = 44.7microAmps output Total capacity over 10 year 24/7 life = 3,916 mAh $/mAh for Solar EH = $0.0014. Lower than AAA and Coin cell costs Fewer light hours increases cost, brighter light decreases costs Energy Harvesters can be designed as cost effectively as Primary Batteries
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Third level

Assigning $ Value to other Attributes


What is the product power lifetime requirements 200mAh, 1Ah, 5Ah? Life of product duration expectations 3, 5, 10, 20 years? Click to edit Master text styles Battery Footprint and overall product size Second level Battery Height and overall product size 3 - how much energy for $ in how small a space? Third level $cost/uAh/mm Assembly Issues and Costs Fourth level Primary Battery Change-out Fifth level device access and cost of replacement Product Physical design No doors or customer access Electrical Characteristics - flat voltage, fast recharge, low discharge Aging Characteristics chemical leakage, seals drying out Transportation Restrictions UN and Country Air Safety shipping laws Safety and End-of-Life Disposal - what are the procedures and costs

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EH Power System Cost vs. Benefit


Click to edit Master text styles Sensor
Second level
Third level
Input Fourth level Power
Light

MCU + Radio

(e.g., temperature, pressure, occupancy)

Fifth level

Energy Aware Communications and Control

Energy Harvesting Power Supply


T

Motion

EH Transducer Electrical Interface Discrete Components

IC - Energy Conversion Battery Management Power Management

EM Field

Rechargeable Energy Storage Device

$ Cost vs. $ Benefit vs. Requirements

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Industry is Providing Cost Effective Sensor Building Blocks


Low Power Microprocessors with nanoAmp sleep currents. Click Low Power Radio Transceivers: to edit Master text styles
IEEE 802.15.4 standards 2.4Gigahertz MilliAmp to tens of milliAmps currents for transmitters and receivers Second level Quick startup with low sleep power

Energy Efficient Radio Protocols: Fourth level power protocols Proprietary Ultra-low Fifth level ZigBee andZigBee Green
Bluetooth LE ANT+, EnOcean Alliance Dust Networks IP 6LoWPAN

Third level

Micropower Sensors with low sleep currents:


Passive IR, Temp, Humidity, Acceleration, Pressure, etc.

Lower quiescent current peripheral circuits:


Clocks, power management chips, etc.
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EH Overview Summary
Billions of smart devices deployed over the next 10 years need: Powered autonomously and be off-grid Click to a edit Master text styles Have power source that lasts the life of the device Second level Be small, integrated and cost effective Cost Energy Harvesting solutions can power products effective Third level SuccessisFourth based on the EH Ecosystem converging: level Fifth level EH Transducers High Efficiency power conversion Life of Product Energy storage Ultra low power Microcontrollers and Sensors Low power wireless radios and protocols Optimized system architecture, hardware and firmware
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EH Design Sections
1. Click Advancements in Energytext Harvesting Transducers to edit Master styles

Second level 2. High Efficiency Designs for Energy Conversion Third level 3. New Technologies Fourth level for ULP MCUs, Sensors and Actuators
4. Wireless Transceivers, Protocols, SoCs and Architectures 5. Successful Commercial Energy Harvesting Deployments 6. Final Thoughts
Fifth level

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Walk Through the Power Chain


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Energy Harvester

SecondEnergy levelManagement
Third level
Pow er Fourth level M anagement Fifth level

Energy Storage

Application

Ambient Energy Harvesting Transducer

Battery

WSN

Photovoltaic Electro-Mechanical Thermo-Electric Radio Frequency

Energy Conversion Manage Energy Storage Powers Application

Solid State Battery Capacitor Traditional Battery

Wireless Sensor Powered Card Implantable Medical Many, many more

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EH Commercial Transducers
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Second level
Third level
Fourth level Fifth level

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EH Transducers
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Second level
Third level
Fourth level Fifth level

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EH Transducer Power Management Challenges


Energy Source Challenge
Conform to small surface area; wide input voltage range

Light Click to edit Master text styles


Second level
Vibrational
Thermal
Varies with light input Low k to 10s of k Constant impedance 10s of k to 100k Variability of Third level vibrational frequency Fourth level Fifth level Small thermal gradients; efficient heat sinking Coupling & rectification

Typical Impedance

Typical Voltage

Typical Power Output


10W-15mW (Outdoors: 0.15mW15mW) (Indoors: <500W) 1W-20mW

Cost
$0.50 to $10.00

DC: 0.5V to 5V [Depends on number of cells in array] AC: 10s of volts

$2.50 to $50.00

Constant impedance 1 to 100s of Constant impedance Low ks

DC: 10s of mV to 10V

0.5mW-10mW (20 C gradient)

$1.00 to $30.00

RF & Inductive

AC: Varies with distance and power 0.5V to 5V

Wide range

$0.50 to $25.00

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How Much Power is Available at the LOAD?


Available Load power depends on:

1. Click to edit Master text styles Energy source


Second level 2. Transducer characteristics 3. Power conversion efficiency Third level
Fourth level Fifth level energy source

Each

needs to be quantified

Each source requires an optimized transducer Each source requires an optimized power manager

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Energy Harvesting Power Range for WSN


100W

Peak Power

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Second level
Third level
Fourth level 100W Fifth level
10W 1W 100nW 10nW RFID Tag Watch/Calculator Real Time Clock (RTC) P Standby 1mW 10mW 100mW

10W Power Tools Laptop Computer GSM Cell Phone

1W

GPS Bluetooth Transceiver Hearing Aid/Wireless Sensor

Sensor/Remotes

Texas Instruments MSP430 RF2500 Wireless Sensor Demo (~60mW Peak)

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Various EH Tracking Methods


to edit Master text styles Click MPPT algorithms
Hill climbing Incremental conductance (P/V) Second level algorithms P&O Third level Fractional OCV Fourth level Fractional OCV (Open Fifth level Circuit Voltage) MPP voltage has a fixed ratio to open circuit voltage (0.7 0.8) But: Ratio not constant and different for every generator

Perturb & Observe


Generic algorithm Oscillates around MPP

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Utilize MPP Tracking


edit Master text styles Click What to is the Maximum Power Point?
Second level
Third level
Fourth level Fifth level

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MPPT with Variable Impedance EH Transducer


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Second level
Third level
Fourth level Fifth level Example: Photovoltaic Cell

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MPPT with Constant Impedance EH Transducers


Examples: Thermoelectric Generators, Piezoelectric Materials, Electromagnetic

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Second level
Third level
Fourth level Fifth level

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Energy Harvesting Needs New Storage Solutions


INCREASING PROLIFERATION OF ELECTRONIC DEVICES THAT ARE SMALLER, PORTABLE AND/OR CONNECTED

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Second level Wireless Smart
Ultra-Low Power Processors

Third level

Devices & Sensors Everywhere

Component Integration and Miniaturization

Eco-Friendly & Renewable Energy

Fourth Key level Trends Driving Billions of New Devices Fifth level
HOWEVER, EXISTING ENERGY STORAGE SOLUTIONS ARE INADEQUATE
LARGER PROFILE / BULKY SIZE LOW ENERGY FOR SPACE USED INTEGRATION ISSUES HIGH WEAR-OUT AND FAILURE ISSUES TOXIC CHEMICALS SAFETY & DISPOSAL ISSUES

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Rechargeable Solid State Batteries


Solid State Cathode EnerChip Co-packaged
Anode Current Collector

Solid State Electrolyte


Electrolyte

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Cathode Substrate

EnerChips on Silicon Wafers

Solid State Battery & PMU

Protective Coating Current Collector

Charging

Discharging

EnerChipTM Solid State Batteries


Second level
Third level

Key Features: small footprint, long cycle life, fast recharge, ultra-low self-discharge, environmentally friendly Solid state energy storage solutions on silicon using common semiconductor manufacturing processes Fourth level EnerChips are 150 microns thick (less than two human hairs ) or 1/20th the thickness of a comparable battery Fifth level EnerChips are efficiently co-packaged with other chips: Power Management, RTCs and MCUs Packaged Power

EnerChip with Integrated Power Management/RTC and Energy Processor CBC915

The EnerChip battery is designed to integrate with other ICs; Cymbet has commercialized the EnerChip CC, a co-packaged Solid State Battery and custom Cymbet Power Management ASIC for a drop-in solution a UPS in a Chip. The EnerChip RTC integrates a Real Time Clock chip with the EnerChip CC CBC3105. To enable high efficiency Plug and Play Energy Harvesting (EH) solutions, the custom Cymbet EnerChip CBC915 Energy Processor uses an advanced patent-pending Maximum Peak Power Tracking algorithms for high efficiency energy conversion and management

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Key EH Battery Requirements


High Cycle Life
Capacity with Cycling
70 60 50

Flat Output Voltage Profile

Capacity (Ah)

40 30 20 10 0 0

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4.2V 4.15V 4.1V 4.3V

Second level
Third level
100 200 300 400

4.0V

Discharge Cycle #

Fast and Simple Charge


120

Fourth level Fifth level


500 600 700 800

900

1000

Low Self-Discharge
4.5

Charge Current & Charge Capacity vs, Charge Time

Self-Discharge
15

Charge Current/ Battery Capacity

4.0
100

14

Percent of Charge

Charge Loss %

3.5 3.0

13 12 11 10 9 8 7 6 5 4 3 2 1 0

80

Non-Recoverable

2.5
60

2.0 1.5 1.0

40

Recoverable

20

0.5
0

10

20

30

40

50

60

Time (Minutes)

Stand Time (Years)

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Rechargeable Solid State Batteries


Click to edit Master text styles SSB
Second level
Third level
Super Cap Higher Drive Current, Higher Leakage

= Best of Both Worlds

High Drive Current High Energy Density


50 X SuperCap

Fourth level Fifth level

Lowest Leakage
4,000 X < SuperCap

Rechargeable / Long Life

Battery

Superior Lifetime Energy never replace a battery

Higher Energy Density & Lower Leakage

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Example of Wireless EH-Powered Intra-Ocular Pressure Sensor


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Second level
Third level
Fourth level Fifth level

University of Michigan ISSCC Paper: http://www.cymbet.com/design-center/wirelesssensors.php

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Power Design Tips Summary


Most power available if load source matches Click to edit Master text styles Power management ensures Second level maximum power output Third level Energy storage always required Fourth level Transducer size can be reduced Fifth level due to more efficient power management System costs significantly lower when transducers are smaller

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Each EH Transducer has Different Harvesting Circuitry


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Second level
Third level
Fourth level Fifth level

Example: Cymbet CBC-EVAL-09 Energy Processor Universal Energy Harvesting Eval kit

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Low Voltage EH DC or AC Solar, Thermal, Electromagnetic


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2 1 4 5 3

Second level
Third level
Fourth level Fifth level 6
1. 2. 3. 4. 5. 6. 7. 8. AC-DC Rectifier Over Voltage Clamp Filter/Voltage Divider Input Energy Reservoir Boost Converter/Switched Rectifier Kick Starter Charge Pump Negative Bias Voltage Charge Pump Always On Depletion Mode JFET

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High Voltage DC or AC Piezoelectric, Thermoelectric


3 6

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5

Second level
1

Third level
Fourth level Fifth level
2 9

1. 2. 3. 4. 5. 6. 7. 8.

9.

AC-DC Rectifiers 5V Clamp Input Energy Reservoir Filter/Voltage Divider Over Voltage Clamp Flyback Down Converter Negative Bias Voltage Charge Pump Always On Depletion Mode JFET Kick Starter Charge Pump

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Energy Processor MPPT


4

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3

Second level
Third level
Fourth level Fifth level
1 6 5

1. 2. 3. 4. 5. 6.

Cymbet Energy Processor Status LEDs also shunt regulator while finding MPPT Output Voltage Feedback Divider Output Isolation Switch Level Switcher FETs Serial Port for Energy Aware communications

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Battery Charging, Powering Load and Comms


4 7

1. 2. 3. 4.

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6

Second level
Third level
1

Fourth level Fifth level 2

5. 6.

7.
3 8

8.

Cutoff Trip Point Bias EnerChip Low Voltage Cutoff EnerChip Solid State Batteries Boost Capacitor Charge Isolation Output Boost Cap (Radio) Output Isolation Switch Isolation Switch to CBC915 Serial Port Isolation

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Focus on MCU, Radio and Sensors


Click to edit Master text styles Sensor
Second level
Third level
Input Fourth level Power
Light

MCU + Radio

(e.g., temperature, pressure, occupancy)

Fifth level

Energy Aware Communications and Control

Energy Harvesting Power Supply


T

Motion

EH Transducer Electrical Interface Discrete Components

IC - Energy Conversion Battery Management Power Management

EM Field

Rechargeable Energy Storage Device

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1uW MCU Operation


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Second level
0.5uA 1uA

1uW target = 2V x 0.5uA

Third level
Fourth level Fifth level

1V

2V

3V

4V

time

Target MCU operating range = 1.8V 3.6V


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Optimized Code is Critical


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Second level 0% CPU Load! Third level 0.01% Load
// Setup timer output unit CCTL1 = OUTMOD0_1; _BIS_SR(CPUOFF); MCU GPIO

Fourth level Fifth level#pragma vector=WDT_VECTOR

_interrupt watchdog_timer (void){ P1OUT ^= 0x01; // Toggle }

100% CPU Load

while (1){ P1OUT ^= 0x01; __delay_cycles(10000); }

// Toggle // Delay

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Ultra-low Power Activity Profile


1mA Click to edit Master text styles
Second level 100uA
Third level
10uA 1uA

Fourth level Fifth level

Reduce Standby Current Average


time

Reduce Active Time

Average approaches standby


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1uW Computing + Sensor Processing


uW 1000

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100 10

1000x Reduction

Fourth level Fifth level


2KPS

1,000,000IPS

Third level

1,000,000IPS

Second level

10SPS Sensor ~1KPS CPU

Active Active Active CPU=1MHz CPU=1MHz CPU~1KHz Flash RAM 2V 3V 2V

Standby CPU=1MHz Burst 2V

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Tips for Achieving 1uW Computing


Off-the-shelf F20xx is capable of 1uW computing
Performance 1-2KIPS text styles Click to editof Master Including Sensor sample 1-10 Samples Per Second Second level ULP standby clock Third level Instant-on and very accurate high-speed clock Fourth level I/O, interrupt capability, BOR and all RAM retained Fifth level Traps Firmware Temperature increases leakage significantly Floating inputs Multiple voltage domain satiation Watch for un-deterministic clocking Where to get a 2V supply in a real application?
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Wireless Evolution
Click to edit Master text styles
Second level
Power

Third level
Fourth level Fifth Focus market forlevel
Energy Harvest

(internet) IEEE802.11x

Wi-Fi

(short-range voice)

Bluetooth

(usb2 cable replacement)

UWB

(hundreds of applications) IEEE802.15.4

WSNs

IEEE802.15.1

250 kbps

1 Mbps

11-54 Mbps

200+ Mbps

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Comparing Wireless Options


Increasing priority
Co-existance with other networks Large-scale Networking stack Small-scale Networking stack Implementation Price Wireless Microcontroller design route Interoperability Encryption

Second level
Low Bluetooth Third level BT LE Low

High Low

Power

Poor Poor

No No No

Yes Yes No

No No Yes

Yes Yes No

Fair Fair No

High High Low

Fourth level Proprietary Low Low No Fifth Low level Good 802.15.4 Low
WiFi High High Good

Yes
Yes

Yes
Yes

Yes
No

Yes
Yes

Good Low
Good High

IEEE802.15.4 offers optimal solution


Designed to operate in large networks of devices Lowest cost. Flexible design solution for many different applications No application-profiles ensures design flexibility Lowest power with prospect of interoperability Co-existence with other wireless networks (e.g. Wi-Fi)
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Datarate

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Bluetooth versus 802.15.4


When to use Bluetooth

Problems with Bluetooth

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Stereo Audio

Second level

Cell phone Third alreadylevel has BT Fourth level No WiFi interference or use AFH

Spec changes every 18 months

Channel hopping will cause interference

Fifth level Benefits of 802.15.4


Coordinator

Router

Router

End device
Router

End device

Multiple channels

Network of devices

Large number of connections

Fast connect times of 6mS

Coexist by locking onto a clear channel

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Using Wireless Mesh Networks


Multiple Devices 802.15.4 device connections limited by bandwidth (100s ) NXP JenNet is 16 devices Click to edit Master ZigBee depends on profile

text styles

Second level
Third level

Fourth level Fifth level Multiple Channels Separate PAN id



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Separate channels Connects to its router

No division of bandwidth

802.15.4 Current Profile (Minimum Required) Click to edit Master text styles
Second level
Third level
Fourth level Fifth level
Very low overall energy consumption due to very low TX current Significantly lower energy usage than competing single chip products

Ramp up from sleep

Full solution is achieved using just 50uC of charge (100uJ at 2v)


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EH Sensors and Controls Example


Owner: Local Government Lombardei OEM-Partner: Siemens
Situation Click to edit Master text styles 39 Floors

Second level
Third level

530 ft. 72.000 sqm Floorspace

Fourth level Solution Flexible BMS Fifth level 400 EnOcean-KNX-Gateways for FullRadio Coverage 1580 EnOcean-Rocker for Lighting Control (DALI) 2500 EnOcean Room-Units Temp./Setpoint Benefit Flexible Roomstructure Quick and easy installation Saving of time Initialinstallation and RetrofitSeite 52
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Click to edit Master text styles - Irvine, CA


Second level
Third level
Fourth level Fifth level

Glumac Office of the Future


- New Construction, Lighting/HVAC - 8,500 sq. ft. EnOcean wireless extension to wired BACnet Occupancy based-lighting and climate control Task-ambient luminaires & controls helped Glumac beat California Title 24 lighting allowances by 75%

USGBC LEED PLATINUM (file picture)

Echoflex Solutions, Tambient

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Summary
Cost effective Energy Harvesting power based systems can be designed using new technologies and intelligent design techniques

Click to edit Master text styles

Second level Utilize appropriate EH transducers Third level Implementhigh efficiency energy conversion, rechargeable Fourth level energy storageand Fifthenergy level aware power management
Ultra low power MCUs, Wireless links/protocols and sensors Ideal solutions are highly-efficient, eco-friendly, power generation systems that can be cycled continuously for the life of the product
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