Purpose This study aims to develop a novel self-powered monitoring system that uses radio frequency (RF) energy harvesting and ultra-low-power management technologies for real-time condition monitoring of switch rails. Design/methodology/approach The system is designed for integration within the jump wire holes of switch rails, ensuring structural integrity and aesthetic appeal. It features a highly efficient energy harvesting mechanism combined with optimized power management for wireless sensor nodes. An on-board antenna captures ambient RF energy, managed by high-efficiency circuits to ensure stable wireless sensor operation. An ultra-low-power system-on-chip is used to acquire and transmit multimodal data on vibration and temperature from the switch rails. The data collection is enhanced through a two-threshold approach, adapting to harvested energy levels for self-energy balancing. Findings Testing revealed that the energy harvesting subsystem operated stably at distances up to 2.9 m from the RF source, charging a 200 µF capacitor to 4.2 V in just 220 s. The monitoring subsystem’s average power consumption is in the low microwatt range. Continuous operation over 30 days in real conditions resulted in only a 5 mV reduction in battery voltage, indicating successful self-powered operation and validating long-term reliability in unattended scenarios. Originality/value This research presents an innovative solution, integrating RF energy harvesting with ultra-low-power technology, which addresses the power and stability challenges faced by traditional monitoring systems.
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