Tri-stable oscillators have been widely used to develop various nonlinear broadband energy harvesters. Focusing on further achieving high-performance piezoelectric energy harvester under broadband vibrations, a novel M-shaped 2-DOF piezoelectric energy harvester (M-PEH) with built-in outer-inner magnetic tri-stable oscillators is proposed, in which an inner magnetic tri-stable oscillator is built-in into a U-shaped outer magnetic tri-stable oscillator using its cut-out cantilever beam, assisted by the coupling interface to further enhance the dynamic responses. A complete physical model by considering the nonlinear coupling interaction between the outer-inner magnetic tri-stable oscillators is established to describe the dynamic performances under different system parameters. The theoretical model is well validated by experiments, which show that the proposed M-PEH has more compact size, wider operating frequency and higher power generation, offering an effective bandwidth of 20.1 Hz (5.1–25.2 Hz) at base excitation A = 5 m/s2, and achieving maximum output voltage 8.5 V and total peak power 26.7 μW. Compared to the original magnetic-coupling nonlinear tri-stable PEH, the effective bandwidth and total power have increased by 300 % and 662 % respectively, and the average power density is increased by 917 %. In addition, four main coupling interaction modes between the outer and inner built-in tri-stable oscillator are observed, in which the nonlinear synchronous coupling interaction is conducive to generating inter-well motion, leading to more mechanical energy being transferred from the outer tri-stable oscillator to the inner built-in tri-stable oscillator, thereby improving power generation capacity. Besides, the coupling interaction between these two tri-stable oscillators produces two close resonances which can be easily tuned to form a wide operating bandwidth. Practical applications prove that the proposed M-PEH has the ability to power low-powered electronic products, meeting the power supplying requirements of engineering community.
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