Topics in Self-Powered Controllers Special Emphasis on Push Buttons and Switches for Industrial Applications Jason E. Harmon A Seminar submitted to the Faculty of Rensselaer at Hartford in partial fulfillment of the requirements for the Degree of MASTER of Science Major Subject: Engineering Science The original of the seminar is on file at the Rensselaer at Hartford Library. Approved by Seminar Advisor Ernesto Gutierrez-Miravete Rensselaer at Hartford Hartford, CT April, 2003 Contents 1 2 3 4 5 6 7 Abstract………………………………………………..3 Historical Background………………………………...3 Theory of Self-Powered Control………………………4 3.1 Solar Self-Power………………4 3.2 Mechanical Self-Power………..6 3.3 Piezoelectric Self-Power………7 3.4 Critical Characteristics………..7 Applications of Self-Powered Control………………..9 Developments in Self-Powered Control……………...12 5.1 Recent Developments………...12 5.2 Possible Future Applications…14 Conclusion……………………………………………16 References……………………………………………17 List of Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Semiconductors in a photovoltaic cell………….………5 Self-winding watch…………………………………….6 Piezoelectric effect…………………………………….7 User interface of a control panel……………….………10 View of push button controls………………………….10 Doorway of control panel………………….………….11 Hardwired 3-button control panel………….………….11 Power harvesting shoe inserts from MIT Media Lab…13 Power output from piezoelectric shoe generators…….13 Prototype of self-powered pushbutton control………..13 Various pushbuttons………………………………….16 List of Tables Tables 1 & 2 Summary information on current self-powered technologies…..8, 9 2 1 Abstract Traditional control signals travel from a controller to a device using energy derived from an outside electrical energy source that employs conductive material to carry the current, or from a battery integrated within the electronic circuitry of the controller. Both of these energy sources have disadvantages. The major disadvantage of an outside energy source is that it requires wires to transfer the energy, therefore is not easily mobile. The battery is mobile, but has the disadvantage of a finite life, thereby requiring replacement. Certain devices have been able to overcome both of these disadvantages by using other means to generate the energy required to operate. Devices such as self-winding watches and acoustic TV remote controls are able to generate the energy necessary to operate or send signals without outside electric sources or batteries. The movement necessary to actuate the device generates their operating energy. Researchers and engineers have started to apply this concept to switch and push-button devices. The energy the operator uses to push the button or flick the switch is transformed to create the energy necessary to send the signal to the down stream device. This paper elaborates on the history, theory, applications, and recent developments of such devices. A historical background is given to describe the progression and this technology, as well as the development of the need for this technology. Theory is discussed concentrating on the three main types of self-powering techniques: solar, mechanical, and piezoelectric. Several possible industrial applications are discussed. Recent developments centered on power harvesting, power scavenging, and piezoelectric applications are explored before wrapping up with final conclusions and a look to the future. 2 Historical Background Since the Industrial Revolution, the industrialized world has gone through several stages of technological evolution. As technologies advanced, the dominate technical trends touching every household have progressed from mechanical machines, to electrical machines, to electronic machines, and finally to computerized (microprocessor controlled) machines. Since the late nineteenth century when the first electrical distribution systems were developed, electric power developed into the primary driving force behind all devices in the factory, home, and office. Thomas Alva Edison was an early pioneer of electrical distribution. He developed the first DC power system at the Pearl Street Station in New York in 1882. A few years later, George Westinghouse and William Stanley pioneered an early single phase AC distribution system in Great Barrington, Massachusetts. Eventually AC distribution was determined to be superior to DC distribution. The first three-phase AC transmission line in the US was developed in 1893 in Southern California. This was the start of electric energy distribution as we know it today. On the residential level, little has changed in the fundamental concepts of energy distribution since that time. In the home, energy is still transferred using wires. The main user interface for most hard-wired electrically controlled devices in the home is 3 the hard-wired switch. Protection and safety features such as fuses and circuit breakers were developed in the early and mid-twentieth century to protect the wires in the residence from causing fires. For non-hard wired applications in the home, the battery is king. Typically a lithium-based battery is used to power household devices. Rechargeable types may come in Nickel or other material bases. Probably one of the most commonly used batterypowered, non-hard wired devices in a typical US home is the television remote control. The first commercially available television remote control was introduced by the Zenith in the early 1950’s. In 1957 Zenith released a television remote control that worked using ultrasonic waves. Although this remote control was self-powered, it eventually gave way to the battery operated infrared remote control. Since then, the battery has remained the dominant energy source for mobile control applications in the home. 3 Theory of Self-Powered Control Self-powered devices derive the power they need to operate on their own. Generally, they use the environment or operating conditions around them to generate power to operate. A solar calculator is an example of such a device. It uses a photovoltaic cell attached to the calculator to generate electric energy. However, its operation is limited to environments with light. This would not be acceptable for many control applications. A self-winding watch is another example of a self-powered machine. A selfwinding watch is an interesting mechanical device that generates energy from the movements of the arm of the person wearing the watch. This device relies on an assumption regarding the manner in which the watch will be used. Both of these devices operate without power being generated from outside sources such as batteries or “plug-in” electricity. Both make assumptions regarding the manner and environment in which the devices are to operate. The ability to make assumptions regarding how the device will be used seems to be a common theme in selfpowered devices. There are typically three general technologies that are used in self-powered devices. Each has pros and cons. 3.1 Solar Self-Power The solar powered calculator may be the most common self-powered device used today. Most rely solely on photovoltaic cells to transform photon light energy to electric current without the use of battery storage. Photovoltaic cells use semiconductor materials. The most common material used is silicon. Light actually contains waves of several different wavelengths. When light of the correct wavelength hits the cell some of the energy from the photons is absorbed within the semiconductor. This energy knocks electrons loose within the semiconductor. The electrons then move from one side of the semiconductor to the other in search of a hole, or free space, in which to reside. The electric field created by the junction of the two sides of the semiconductor creates a 4 voltage to move the electrons in a specific direction. This movement creates an electric current. This current and voltage from the electric fields creates the power needed to run the calculator. Figure 1: Semiconductors in a photovoltaic cell Wireless self-powered systems using photovoltaic cells have been developed in the past. Most of the solar self-powered designs have been made to power small electronic devices of low power consumption, such as infrared or RF remote control systems. On a sunny day a photovoltaic cell of only 2 cm^2 in diameter can generate 1 mWh of energy. This number drops to about .2 mWh for cloudy or inside conditions (E = 1000 lx). To operate a TV remote control requires approximately 60 mW. Assuming that the remote control is operated 60 times each day for a period of 1 second (remote would be operated a daily total of 1 minute), this means that the total daily energy to operate the TV remote control would be 1 mWh (60 mW for 1 operation * 60 operations of 1 second each = 60 mWminutes. 60 mWminutes = 1 mWh). Since this amount of power could only be obtained on sunny days, this would limit the applications for a selfpowered solar system. Typical push buttons have a button surface of approximately 5 cm^2. Therefore, a typical push button with a photovoltaic cell mounted on the face of the button could produce about .4 mWh in cloudy conditions. This would still not be enough to power the TV remote control under most conditions. Generally, 6 photovoltaic cells of 2 cm^2 connected in series would be recommended for an application such as a solar powered TV remote control. Such a circuit configuration using batteries and accumulators offers efficiencies of approximately 60 to 65%. This space may be available in some switching applications (perhaps on the face mounting plate of a standard residential light switch), but this space requirement would certainly limit applications at this time. Space constraints will continue to be a limiting factor to photovoltaic selfpowered systems until the efficiencies of photovoltaic cells can be increased. The trend is positive. Typical photovoltaic cell efficiencies have risen from about 4% in the 1950’s to efficiencies approaching 20% today. Efficiencies around 15% are most typical. The world record holder for photovoltaic cell efficiency is presently 24.5%. 5 Solar PV cells provide inexpensive power to operate the device, but their obvious disadvantage is that they can not be used in the absence of light. Battery storage is possible, but it is typically not used in this application because battery storage adds considerable cost and size to the system. Because of this rather significant disadvantage, photovoltaic cells can not be used to power the majority of household wireless devices. 3.2 Mechanical Self-Power Mechanical self-power typically relies on the storage of kinetic energy in the form of potential energy, then releasing it at the appropriate time. Taking advantage of mechanical springs, gears, and levers is a common way to achieve this. The self-winding watch is a great example of this at work. Swing arm Figure 2: Self-winding watch The semi-circular swing arm shown in Figure 2 is the key to the self-winding watch. This arm moves from gravity as the watch wearers arm moves. This swing arm is attached to a gear train. The gear train is like a mechanical transformer. It transforms the movement of the swing arm into the slow gear movement that is needed to actuate the hands on the watch. Each movement of the swing arm winds a spring. This spring stores the energy needed to keep the watch operating even when the swing arm is stationary. Typical self-winding watches can operate for about a day and a half without any movement. The self-winding watch is a clever device that accounts for the environment in which the watch is used to scavenge some energy to operate. The obvious disadvantage is that if the watch were to be left stationary for a period of time it would no longer have the stored energy necessary to operate. 6 3.3 Piezoelectric Self-Power One of the more recognizable piezoelectric self-powered devices in the home is the lighter in a gas BBQ. The gas grill lighter uses a spring-loaded button to hammer a piece of piezoelectric material to create a high voltage, low current spark. This spark is similar to the static electric spark after rubbing your feet on a rug. Quartz, Rochelle salt, and PZT ceramic (lead-zircononate-titanate) are common piezoelectric materials. Pierre and Jacques Curie discovered the piezoelectric effect in 1880. Piezoelectric materials become electrically charged when subjected to a mechanical stress. Conversely, when a voltage is applied to the material, the piezoelectric material can deflect. If an electric oscillation is applied to a piezoelectric material the material can respond with a vibration. The piezoelectric effect in quartz is very stable. This is the reason quartz is typically chosen as the time signal element in watches. Figure 3: Piezoelectric effect. One the left, applied strain creates a voltage. On the right, applied voltage creates a displacement. Piezoelectric materials are used in applications such as clocks, timers, speakers, microphones, sensors, oscillators. Because of the high voltage, low current nature of piezoelectricity, harvesting this energy to power electric devices can be difficult. Piezoelectric material-based devices mounted into the sole of shoes have been able to scavenge up to 1 W of energy. 3.4 Developing Critical Characteristics of Self-Powered Systems, An Example Knowing the pros and cons of the three most common general technologies for self-powered systems; how would one chose a technology for a particular application? This would depend very much on the application. Recent efforts in self-powered control seem to have two goals that represent the pinnacle of self-powered utopia. The first primary goal is to be able to power a stripped down lap top computer solely from selfpower, power harvesting, and/or energy scavenging devices. The second goal is to be able to create a battery-less/wireless television remote control. The energy needed to power a lap top computer is significantly more than the energy needed to power a TV remote control. Therefore, the quest for self-powered lap top computing involves a wide range of different devices still in the infancy stages from a technical standpoint. However, achieving the goal of a self-powered TV remote control is within the grasp of existing technology. 7 The TV remote control is an exciting pursuit for self-powered technology researchers because it is a device nearly everyone uses. Not only does nearly everyone use it, but also nearly everyone enjoys using it! In concept, the TV remote control is a multi-function switch. It sends a signal to a powered device to complete a particular command. Although the technologies are significantly different, this is essentially the same concept as a light switch sending a signal to a light to turn ON or OFF. The difference is that the light switch is simply “releasing the dam” on energy that is already there to for the purpose of powering the final device, while the TV remote control must generate energy from some outside source (a battery) to send a signal. The self-powered TV remote control would ideally send a signal as effortlessly as a light switch. In order to make a self-powered TV remote control one must consider what characteristics would make such a device successful, and what technologies would be best suited to achieve those characteristics. Table 1 shows some of the critical to quality characteristics for self-powered systems. The characteristics in this table apply very well to the TV remote control. An engineer would wish the device to have low power consumption requirements and enough space to fit all necessary components. However, the key factor for self-powered systems is not necessarily the device, but how the device is used. The TV remote control is not generally used in a high inertia environment like a wristwatch might be. Therefore, mechanical systems would probably not be suitable. Solar systems can quickly be eliminated for the obvious reason that light is required at all times. This leaves the engineer left with piezoelectric systems to consider. Most of the recent developments in self-powered switching control devices have taken advantage of piezoelectric technology. This technology is a natural fit to switch and push button applications because the force used to depress the button or flip the switch can be used to create the piezoelectric signal. Couple that with a spring loaded “booster” and a switch can fully take advantage of piezoelectric technology. This is especially true considering many industrial switches contain very large springs with over-centering mechanism features. Researchers estimate that they are less than 2 years away from producing a commercially viable self-powered TV remote control utilizing piezoelectricity. The key point is that self-power researchers must not only concentrate on the operational characteristics of a particular device, but also the way the user uses the device. This knowledge of the way in which the device is used is generally what alloys the developer to take advantage of self-power opportunities. Critical to Quality Characteristics for Self-Powered System Materials General CTQs Customer CTQs Engineering CTQs Reliability Ease of Use Size to power ratio Size Installation flexibility Life span, in time and operations Cost Backwards compatible Able to operate in variety of environments Safety Susceptibility to interference signals Low volume, not loud Efficiency Tables 1 & 2: Summary information on current self-powered technologies 8 Technology Solar System Individual Solar Cell Piezoelectric Mechanical 4 Efficiencies of Self-Powered Systems Approximate Percent Efficiency Notes 60-65 Several cells circuited together 15 .5-15 Mechanical to electrical energy 70 Friction is key player Applications of Self-Powered Control The progression of electronic devices into the homes of the future continues. Devices like cell phones, electronic organizers, and DVD-players are just a few of the devices that have become standard equipment in many lives. People continue to add an array of home electronics and smart devices to the already extensive list of electronic devices for the home. The advancement of electronic devices is not limited to the residential environment. Just like in the home, industrial and commercial entities are continually finding ways to use electronics to the advantage of their bottom lines. As electronic devices continue to grow and evolve, the control of these devices has generally remained constant; provided by either hardwired user interfaces or battery powered remote controls. Mobility and flexibility are limited with hardwired devices, while batteries require periodic replacement. Self-powered controllers have the potential to address both of these drawbacks, as well as address the expense associated with wiring or periodic battery replacement. Self-powered control could save significant labor and costs associated with hardwired devices. Figure 4 shows a hardwired user interface. The user 9 Figure 4: User interface of a control panel for industrial generator motor interface shown is a control panel for an industrial generator motor. This interface uses individually wired push buttons to transmit control signals. Figure 5 shows a close up of the push button controls. Since each pushbutton is wired individually, a substantial Figure 5: View of push button controls 10 amount of wiring is required to operate this user interface. Figure 6 shows a view of just one doorway of the generator control panel shown in figures 4 and 5. One could well Figure 6: One doorway showing wiring of a industrial generator control panel. imagine the expense and effort required to wire this type of control interface. Ignoring the many application details and concentrating on the concept, a significant amount of this wiring could possibly be eliminated if a self-powered wireless controller could send a control signal through air (RF, infrared, acoustic, etc.) to a central receiver. That is not to say that self-powered wireless controllers would only be beneficial in such advanced industrial applications. Even relatively simple hardwired interfaces could benefit from development of self-powered wireless controls. Figure 7 shows a simple 3-button control panel. Each push button used in this simple control panel uses a minimum of 3 wires. Figure 7: Hardwired 3 button control panel 11 Self-powered wireless control could possibly eliminate these wires. Additionally, a signal receiver could take on much of the work that the contact relay is presently performing in this control panel. So far, industrial and commercial/industrial applications have been explored. However, perhaps the most exciting applications for self-powered wireless controllers are in residential applications. Imagine a TV remote control operating without batteries, or a keyless entry remote for an automobile that never required battery replacement. Imagine a house in which the light switch were wireless. Central receivers could be placed at specified locations throughout the home. Since the switch would be wireless only the load device would need to be hardwired. This means that the switch wires no longer need to be protected. This would eliminate not only the need for wiring, but also the need for circuit breakers or fuses for that portion of the home electrical system. Light switches would no longer need to be stationary. Since they are not held immobile by the hardwiring requirement, switches could be moved from wall to wall of the home at will. The possibilities are limited only by the imagination. 5 Developments In Self-Powered Control 5.1 Recent Developments Piezoelectric energy generation has been the focus of much of the recent developments in self-powered control. The continued growth of portable electronic “gadgets” (lap top computers, electronic organizers, cell phones, beepers, digital cameras etc.) has driven the need for supplemental energy generation. The ground work for piezoelectric control was laid by researchers taking advantage of piezoelectric materials for energy “scavenging” or “parasitic power harvesting”. Energy scavenging is the concept of using normal body movements like walking, breathing, arm motion, and typing to generate energy to run personal electronic devices. Piezoelectric shoe inserts have been invented that generate energy while walking. This energy is used to compliment battery energy to run personal electronic devices. This work in piezoelectric energy harvesting laid the groundwork for developments in self-powered control. Some of the more exciting developments in self-powered control have taken place at the Massachusetts Institute of Technology Media Lab in Cambridge, Massachusetts. The MIT Media Lab is devoted to “the study, invention, and creative use of digital technologies to enhance the ways that people think, express, and communicate ideas, and explore new scientific frontiers.” This lab produced most of the recent technology advances in both parasitic power and self-powered control. Parasitic power research has been done using piezoelectric inserts in shoes to try to harvest the power generated from a foot strike during walking. The final goal of this research is to be able to scavenge enough power from normal human movement to power a lab top computer. Other applications that have been explored would be a self-powered RF tag system. In this system, the power-generating shoe would activate a RF transmitter to send signals while a person walked. This signal could be used to alert an area of the wearer’s presence. 12 This would allow the movement of the wearer to be tracked throughout a building. It could also give a particular area of a building advanced notice of the arrival of the wearer. This would allow lights to be turned on, doors opened, etc. in preparation for the arrival of the wearer. Figure 9 shows the power output capabilities of piezoelectric shoe inserts. A typical RF device requires about 60 mW of power to operate. Figure 9 shows that piezoelectric shoe inserts are certainly capable of achieving such power outputs. Figure 8: Power harvesting shoe inserts from MIT Media Lab Figure 9: Power output from piezoelectric shoe generators In April 2002 researchers Joseph Paradiso and Mark Feldmeier developed a prototype battery-less controller. The researchers modified a fireplace/cigarette lighter and an automobile keyless entry remote to create a self-powered device that can transmit digital codes at a distance of more than 20 meters. A picture of the prototype device is shown below in figure 8. The researches have visions Figure 10: Prototype of self-powered automobile keyless entry remote from MIT Media Lab 13 that such a device could eliminate the need for batteries in devices like TV remote controls. Although only in the prototype stage, the researchers are attempting to have commercial products using this technology on the market within 2 years. If successful, this technology has the potential to have significant impact on control of electronic devices. The self-powered device uses a spring-loaded pushbutton to strike the piezoelectric material. To get maximum energy output from the piezoelectric material, the material is allowed to vibrate at the resonate frequency. This produces a high voltage, low current electric pulse. A step-down electronic circuit is used to transform this electric energy to a usable form. The RF automobile keyless entry device requires approximately 7.5 mW at 3 Volts for 20 ms to create a 12-bit signal. This totals to an energy requirement of about 150 microJoules. The prototype device produces about .5 mJ of energy per button push. This is more than enough energy to power the RF device. The prototype was created for less than $5 dollars. The researchers at the MIT Media Lab proved that the concept of self-powered control could be achieved. Their concept used “recycled” parts just for the purpose of proving the concept. Refinement of the components could yield even better power generation, allowing for more features and functions to be added to the device. 5.2 Possible Future Applications The MIT Media Lab appears to be leading the way on expanding the concept of self-powered control to the many commercial battery-powered devices already commonly used. However, could this same technical concept be expanded to some of the industrial applications discussed in section 4? There are several issues that researchers would have to address before the concept of self-powered control could expand to industrial applications. Technical Issues: Most of the industrial devices shown in section 4 use a push-button interface to send control signals. The MIT Media Lab pushbutton produces 15 N of force. The typical industrial pushbutton requires a minimum of about 11 N of force to operate. Therefore, as they presently are designed the standard industrial pushbutton would not be able to deliver enough force to operate the MIT Media Lab piezoelectric circuit. However, the MIT Media Lab took advantage of a spring-loaded pushbutton to deliver an accelerated and very quick force. The traditional industrial pushbutton would most likely have to be re-designed to incorporate a spring-loaded mechanism for self-powered applications. RF seems to be the logical choice for most self-power wireless pushbutton control at this time. RF does not require a line-of-sight like infrared, and is capable of sending signals on the range of 50-100 feet in this application. Noise interference, receipt of data 14 (rather than transmit-only), array of signals, and security would be just some of the issues to address with RF technology. Reliability Issues: Industrial pushbuttons are typically rated for operations in the millions. 5 million operations are not out of the ordinary. This number of operations would most certainly tax the life expectancy of any spring-loaded mechanism. The reliability of piezoelectric materials also would have to be considered. Piezoelectric materials can often develop micro cracks that diminish the effectiveness of the material after time. This issue would have to be addressed in order to move the selfpowered push button technology into industrial applications. Cost Issues: Although cost is always an issue, is seems that it would not be a significant limiting factor for self-powered control. The prototype self-powered controller developed at the MIT Media Lab was constructed from components costing less than $5. When considering cost, the actual component cost is not the only factor. A system cost would have to be considered. Increased component cost could easily be made up by the reduced wire cost and labor cost of traditional hard-wired pushbutton interfaces. It is estimated that up to 1/3 of the cost of some industrial switchgear and motor control centers is for wire and wiring labor. Although this cost would not be eliminated, it could be considerably reduced with wireless control. Size Issues: Size is not usually the limiting factor in industrial applications. Industrial installations tend to be rather large in size, so there is typically ample space for the wiring involved in the hard-wired interface. With the small size of modern electronic components it is reasonable to assume that self-powered controls could be applied to industrial control applications without much impact to available space. Figure 9 shows the installation side of several types of pushbutton controls. It shows that some of these pushbuttons take up a relatively large volume of space on the installed side. Selfpowered controllers would have to consider making their package take up this same volume, or less. 15 Figure 11: Interface side of several styles of industrial pushbuttons (left). Installation side of several styles of industrial pushbuttons (right). Customer Acceptance: Customer acceptance of the new technology is more of a business issue rather than a technical or engineering issue, but still an issue that must be addressed. The industrial market can be adverse to radical technology change. This is true of all markets, but may be more of an issue in the industrial market where reliability and performance are often paramount. Industrial control often is responsible for complex machines and systems. If they go down because of a technical issue, it could cause the loss of significant amounts of productivity. This is not generally the case in residential applications. Although the TV remote control breaking is an inconvenience, it is not the same as having to close an entire factory floor because of non-functioning equipment. Self-powered control would have to clear this hurdle to get into the industrial market. 6 Conclusion Self-powered wireless control has some exciting potential. Researchers have made the first steps towards making self-powered wireless applications a reality. Piezoelectricity is the preferred energy source for the new self-power wireless control technologies. Devices such as self-powered TV remote controls may be on the market as soon as 2 years from now. Several obstacles are yet to be overcome to utilize self-powered wireless control technology in industrial applications. Customer acceptance, reliability, and technical design remain as the largest obstacles to overcome. Technologies such as MEMS (micro-electrical-mechanical systems) have great potential to open new doors for self-powered wireless controllers. As MEMS advances continue, hopes for breakthrough technologies continue in the area of self-powered control. 16 Taking this technology out to the furthest extreme yields the potential for some high impact concepts. The wireless house or control panel is perhaps the most exciting. Wireless automobiles are also an exciting concept to consider. Technical universities and corporate research centers are continuing to progress on self-powered wireless control technology. It is an emerging field that will certainly be heard from in the coming decades. 7 References 1) Kymisis, J., Kendall, C., Paradiso, J., Gershenfeld, N., “Parasitic Power Harvesting in Shoes,” Proc. Of the Second IEEE International Conference on Wearable Computing, (ISWC), IEEE Computer Society Press, October 1998. 2) Marshall, B., “Remote Car Entry,” website, Howstuffworks.com 3) Paradiso, J., Feldmeier, M., “A Compact, Wireless, Self-Powered Pushbutton Controller,” Responsive Environments Group, MIT Media Laboratory, 2002. 4) “Piezoelectric Materials,” Materials by Design, Article, Cornell University, 1996. 5) Shenck, N., Paradiso, J., “Energy-Scavenging with Shoe-Mounted Piezoelectrics,” IEEE Micro, Vol. 21, No. 3, May-June 2001, pp.30-42 6) Starner, T., “Piezoelectric Shoe Inserts,” website, http://web.media.mit.edu, November 9, 1996. 7) “The Piezoelectric Effect,” PZT Corporation Application Manual, Technical manual, 2001. 17