Abstract This paper presents the process optimization of some key parameters, such as the size of the air gap and distance between fixed neodymium magnets to enhance the vibration-based energy harvesting effect in the tri-stable energy harvesting systems and the improved tri-stable energy harvesting system being the proposed solution under weak excitation. In order to do it, firstly the distributed parameters model of the magnetic coupling energy harvesting system, including macro fiber composites of the 8514 P2 with a homogenous material in the piezoelectric fiber layer and nonlinear magnetic force, was determined. The performed numerical analysis of the conventional and the improved tri-stable energy harvesting system indicated that introducing an additional magnet to the tri-stable system leads to the shallowing of the depth of a potential well by decreasing the air gap between magnets and consequently generating higher power output and improving the effectiveness of the proposed improved tri-stable energy harvesting system. Experiments carried out on the laboratory stand allowed us to verify the numerical results as well as determine the optimal parameters of the magnetic coupling system. Due to it, the effectiveness of the proposed system versus the conventional tri-stable energy harvesting system is most enhanced.
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