Structural optimization of conveyor belt-architected triboelectric nanogenerator for enhanced energy harvesting performance

Purpose The development of a conveyor belt triboelectric nanogenerator (CB-TENG) based on sliding electrification aims to achieve synergistic integration of self-powered, self-sensing and self-diagnosing functionalities in mechanical systems; establish theoretical models and experimental benchmarks for interfacial optimization and operational adaptability in TENGs; and demonstrate the universality of finite element analysis (FEA) for TENG structural design and performance prediction. Design/methodology/approach FEA modeling: COMSOL multiphysics simulations were used to investigate the effects of dielectric material properties, electrode–dielectric interfacial gap distances and electrode configuration density on output performance. Experimental validation: prototype fabrication and testing under controlled rotational speeds and loading conditions were conducted to validate the reliability of simulation results. Interface optimization strategy: lubricant coating on electrode surfaces was introduced to evaluate lifespan enhancement while monitoring current output stability. Findings Output characteristics: linear proportionality between output current and rotational speed (I), with positive voltage-load correlation; charge accumulation saturation observed at 1,000 rpm; no signal degradation detected after 36 h of continuous operation. Lifespan enhancement: Lubricant coating significantly prolonged electrode durability without compromising current output. Research limitations/implications Narrow material and operational scope: limited to specific dielectric materials and sliding contact modes, excluding extreme temperature/humidity conditions; Unresolved dynamic mechanisms: microscopic charge migration dynamics remain unexplored. Practical implications Self-powered industrial solutions: enables maintenance-free, energy-autonomous sensing for conveyor systems, reducing reliance on external power; Interface design guidelines: simulation-driven dielectric material selection and electrode layout optimization accelerate TENG development; Durability strategy: lubricant coating offers a novel approach for wear-resistant applications (e.g. mining, logistics conveyors). Social implications Industry 4.0 Advancement: Promotes energy self-sufficiency and integrated condition monitoring in smart manufacturing; Carbon footprint reduction: Minimizes battery replacement and cabling needs, lowering industrial emissions; Sustainable technology development: Provides foundational insights for TENG applications in ocean energy harvesting and wearable devices. Originality/value First proposal of CB-TENG: innovative integration of TENG with conveyor belt mechanics, expanding industrial self-powered applications; Methodological breakthrough: a coupled FEA-experimental framework addresses the modeling gap in sliding-mode TENGs; Lubricant interface engineering: challenges conventional assumptions by demonstrating lubricant-induced durability enhancement without output trade-offs. Peer review The peer review history for this article is available at: Link to the website.