Model and Implementation of a Novel Heat-Powered Battery-Less IIoT Architecture for Predictive Industrial Maintenance

The research and management of Industry 4.0 increasingly relies on accurate real-time quality data to apply efficient algorithms for predictive maintenance. Currently, Low-Power Wide-Area Networks (LPWANs) offer potential advantages in monitoring tasks for predictive maintenance. However, their applicability requires improvements in aspects such as energy consumption, transmission range, data rate and constant quality of service. Commonly used battery-operated IIoT devices have several limitations in their adoption in large facilities or heat-intensive industries (iron and steel, cement, etc.). In these cases, the self-heating nodes together with the appropriate low-power processing platform and industrial sensors are aligned with the requirements and real-time criteria required for industrial monitoring. From an environmental point of view, the carbon footprint associated with human activity leads to a steady rise in global average temperature. Most of the gases emitted into the atmosphere are due to these heat-intensive industries. In fact, much of the energy consumed by industries is dissipated in the form of waste heat. With this scenario, it makes sense to build heat transformation collection systems as guarantors of battery-free self-powered IIoT devices. Thermal energy harvesters work on the physical basis of the Seebeck effect. In this way, this paper gathers the methodology that standardizes the modelling and simulation of waste heat recovery systems for IoT nodes, gathering energy from any hot surface, such as a pipe or chimney. The statistical analysis is carried out with the data obtained from two different IoT architectures showing a good correlation between model simulation and prototype behaviour. Additionally, the selected model will be coupled to a low-power processing platform with LoRaWAN connectivity to demonstrate its effectiveness and self-powering ability in a real industrial environment.