In this study, an optimal vibration-based energy harvesting system using magnetostrictive material (MsM) was designed and tested to enable the powering of a wireless sensor. In particular, the conversion efficiency, converting from magnetic to electric energy, is approximately modeled from the magnetic field induced by the beam vibration. A number of factors that affect the output power such as the number of MsM layers, coil design and load matching are analyzed and explored in the design optimization. From the measurements, the open-circuit voltage can reach 1.5 V when the MsM cantilever beam operates at the second natural frequency 324 Hz. The AC output power is 970 μW, giving a power density of 279 μW cm-3. The attempt to use electrical reactive components (either inductors or capacitors) to resonate the system at any frequency has also been analyzed and tested experimentally. The results showed that this approach is not feasible to optimize the power. Since the MsM device has low output voltage characteristics, a full-wave quadrupler has been designed to boost the rectified output voltage. To deliver the maximum output power to the load, a complex conjugate impedance matching between the load and the MsM device is implemented using a discontinuous conduction mode (DCM) buck-boost converter. The DC output power after the voltage quadrupler reaches 705 μW and the corresponding power density is 202 μW cm~(-3). The output power delivered to a lithium rechargeable battery is around 630 μW, independent of the load resistance.
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