1. Introduction
Mitigation and adaptation to global warming and climate change represent a priority strategy for sustainable economic growth and development [
1,
2]. Air quality control through global and local monitoring of toxic gases is a powerful tool in view of achieving this final objective. Recent research has been directed toward the development of extended wireless networks of miniaturized and energy-sustainable sensors [
3,
4,
5] composed of power-efficient storage elements and small-sized nodes. Wireless sensor nodes (WSNs) are, in general, equipped with an energy-harvesting and storage section consisting of a photovoltaic (PV) module, battery storage and a power management system (PMS) [
6]. The amount of energy/power managed by these systems is mainly affected by the embedded sensors and the data transmission tasks. For gas monitoring tasks, optical-based carbon dioxide (CO
2) sensors, chemoresistive sensors, particulate sensors and catalytic sensors are among the most expensive in terms of energy demand [
7,
8,
9,
10]. This makes them virtually incompatible with ultra-low-power applications relying on harvesting sources. Indeed, the most popular and accurate CO
2 gas sensors exploit Non-Dispersive InfraRed (NDIR) technology [
7] based on an IR source, traditionally an incandescent lamp, which may have a typical power consumption of up to 300 mW [
8]. Recently, IR LED sources working in pulse mode have become available, with power consumption reduced to about 10 mW [
7]. Chemiresistive sensors, due to their high-temperature operation, have a power consumption of the same order of magnitude [
9], while particulate sensors may require even one order of magnitude higher [
10].
To manage such power consumption, traditional PV modules based on silicon, characterized by a 10–20% efficiency depending on its crystalline quality [
11], require a non-negligible size. Miniaturized devices can be obtained by means of next-generation PV modules characterized by considerably higher energy conversion efficiencies. Consolidated prototypes based on GaAs-based triple-junction solar cells, in fact, may achieve 30% efficiency under terrestrial Sun irradiation [
12], allowing the PV module’s effective area exposed to the Sun to be almost halved with respect to silicon-based devices.
A further advance in the node energy-harvesting architecture may concern the energy storage aspect, increasing the device’s eco-friendliness by excluding Li batteries, which have a non-negligible environmental impact due to their limited lifetime, flammability and toxicity. Supercapacitors recently emerged as a valid alternative to traditional batteries due to their advantages in terms of fast charging, high power density, long life cycle and wide temperature range of operation [
13,
14]. Their potential for high-performance self-powered wireless multi-sensing microsystems has been recently exploited [
15]. In fact, a WSN power supply system with a 35 cm
2 photovoltaic surface coupled with supercapacitors (2 × 25 F capacitance and 2.7 V voltage) for permanent operation was presented and discussed in [
15].
The activity proposed in this paper represents a significant improvement of this previous pioneering work by making use of a hybrid supercapacitor, characterized by higher capacitance, power and energy density [
16,
17,
18], in conjunction with a high-efficiency triple-junction PV module in place of the more common polycrystalline or monocrystalline silicon PV cells. These devices, once accurately characterized with laboratory instrumentation, were integrated into a small-size WSN to prove their permanent outdoor operation. The WSN is designed to have an average power demand of about 10 mW, which is the typical consumption of solid-state LED-based sensing devices for CO
2 monitoring [
7]. However, the obtained results can be generalized to various sensing devices for environmental and air quality monitoring, such as temperature and humidity sensors or electrochemical sensors for O
2, CO, NO
x and Volatile Organic Compound (VOC) measurements, which are characterized by power requirements similar to or lower than those experienced in the presented tests.
The system architecture and the PV module and supercapacitor characterization are presented in
Section 2 (Materials and Methods).
Section 3 describes the main experimental results obtained with the whole prototype, both in the laboratory with a Sun Simulator lamp and outdoors.
Section 4 presents the model developed from the test outcomes to optimize the WSN operating conditions in view of ensuring the virtually unlimited self-powering of the prototype. Finally, the conclusions and outlooks of the presented research are reported in
Section 5.
2. Materials and Methods
We prepared the prototype PV module starting from four GaAs-based solar cells (MSCM-4.5-14.8-30%) produced by Shanghai YIM Machinery Equipment Co., Ltd. (Shanghai, China) [
19]. Each solar cell is composed of a series of two triple junctions. They are dust- and waterproof in accordance with the IP67 protocol and guaranteed under (−80 °C, +80 °C) temperature conditions for 8 years of operation. The area of each cell is 17 × 16.4 mm
2, and its weight is 0.7 g; the cell active area is 2.1 cm
2. The nominal operating voltage and current are 4.5 V and 14.8 mA, respectively, and the efficiency is
= 29% at null Air Mass (AM0) and T = 25 °C, namely, standard conditions for characterizing photovoltaic modules for extraterrestrial applications. A photograph and the circuit schematics of the PV module we assembled as a series of two solar cells in parallel are shown in
Figure 1a,b. The operating current and voltage values expected in this configuration from nominal specifications are 29.6 mA and 9 V, corresponding to 266 mW peak power.
Table 1 shows the nominal specifications of the supercapacitor (C424000R) used in this study, manufactured by DongGuan GongHe Electronics Co., Ltd. (Dongguan, Guangdong, China), with a cylindrical shape, a 69 mm height, and a 24 mm diameter, characterized by the protection class IP30 and 70 g weight [
18]. A photograph of the hybrid supercapacitor used in this work is reported in
Figure 1c.
Finally, the sensor emulated in the following tests is the CozIR-LP by Gas Sensing Solutions Ltd. (Cumbernauld, Glasgow, UK) [
7], whose back and front pictures are presented in
Figure 1d. It is an NDIR sensor for CO
2 measurements (30 ppm of resolution) based on a solid-state LED, which dissipates less energy than other sensing solutions based on filament lamps. The low power consumption of the CozIR-LP and its supply voltage range make it compatible with battery-based operations, allowing it to be used in a wide range of Internet of Things applications. Moreover, communication through the UART interface makes it extremely versatile and easily integrable with several types of MCU platforms.
The used power management system (PMS) is from Waveshare, Shenzhen, China [
20]. It has a 65.2 mm × 56.2 mm size, is compatible with 6 V to 24 V solar panels and supports a 14500 Li-ion battery (850 mAh) or an equivalent rechargeable storage element. The voltage across the storage element must be between 2.9 V and 4.2 V. The system provides a regulated output at 5 V/1 A or 3.3 V/1 A to power up a connected load. The specifications of the PMS are given in
Table 2. In this study, we modified the battery case of the PMS to match the supercapacitor dimensions. The node is connected to the 3.3 V/1 A output. To select the maximum power point (MPP), this PMS applies the constant-voltage method, automatically setting the output voltage V
out as a fraction of the open-circuit voltage V
oc by a voltage divider. By selecting the open-circuit voltage V
oc = 9 V within the range of possible values (6–9–12–18–24 V), the actual voltage output fixed by the PMS is V
out = 7.65 V = 0.84 V
oc.
A picture of the whole system under study, composed of the PV module made of four triple-junction solar cells, the power manager system (PMS) carrying the supercapacitor (SC) and the wireless sensor node (WSN) with a resistive load emulating a sensor, is shown in
Figure 2a. The flowchart of the entire system is sketched in
Figure 2b.
Measurements were carried out both indoors and outdoors. Laboratory tests were carried out by means of a Sun Simulator 2000 (Abet Technology, Milford, CT, USA) based on a 150 W Xe lamp [
21]. The radiation intensity and the temperature of the module were continuously monitored by a Kipp & Zonen (OTT HydroMet B.V., Delft, The Netherlands) CMP3 pyranometer equipped with the SOLRAD read-out system [
22] and a Pt1000 thermometer. The CMP3 has a sensitivity S = 28 ± 4 μV/(W/m
2), a spectral range of 300–2800 nm and a response time of about 1 s. The uncertainty of the intensity measured was evaluated after repeated measurements in the same conditions, up to ten times, resulting in a 5% error. The Qmini WIDE VIS spectrometer (Broadcom Inc., Palo Alto, CA, USA) with a spectral resolution of 1.5 nm and a (225 nm, 1030 nm) measurement range based on a CCD, was used to monitor the radiation spectrum [
23]. A Keithley (Tektronix, Bracknell, UK) 2401 (source/electrometer was used to measure the PV module current–voltage (I–V) characteristics. The instrument is characterized by a maximum measured voltage V
max = 21 V, 100 μV resolution, accuracy ΔV = 0.015%V + 1.5 mV and maximum current supplied I = 105 mA. The uncertainty of the voltage measurement was experimentally determined by repeating measurements in the same operating conditions, up to ten times, yielding values within the instrument accuracy. A picture of the system running when the PV module is exposed to Sun Simulator illumination is shown in
Figure 2c. The voltage across the supercapacitor is measured by a Keithley DMM 199, which is able to perform voltage measurements in the range from 300 V to 1 μV with a 5 1⁄2-digit resolution. Data are collected through GPIB/NI protocols by means of the MATLAB R2020b instrument control toolbox. A block diagram of the whole measurement system is shown in
Figure 2d.
A prototype sensor node was exploited using a network infrastructure relying on long-range (LoRa) modulation and the associated LoRa Wide-Area Network (LoRaWAN) protocol [
24]. In detail, the sensor node transmitted the sampled data to a LoRa gateway according to the “class A” LoRaWAN standard implementation, and then the gateway was in charge of redirecting the packets to the Chirpstack cloud LoRaWAN server, which in turn decoded and decrypted the received packets and sent the retrieved information to an SQL database for storage. With the aim of testing the operation of a general-purpose device, a standard low-power consumption system architecture was designed, integrating a low-power 8-bit AVR ATtiny84 microcontroller by Microchip and an RFM95 LoRa module by HopeRF (Shenzhen, China). The MCU was programmed according to a sleep routine that foresaw the periodic wakeup of the MCU at fixed time intervals.
Concerning the radio transmission settings, a transmitting frequency of 868 MHz, output power of 14 dBm, coding rate (CR) of 4/8, spreading factor (SF) of 12 and bandwidth (BW) of 125 kHz were set. These settings were chosen as a tradeoff between the low-consumption requirement and transmission reliability in the case of a hypothetical outdoor application scenario, which may be affected by critical issues related to noise, signal attenuation, reduced radio coverage and long distances between sensor nodes and gateways. Indeed, CR = 4/8 guarantees the best error correction, while SF = 12 provides the highest receiver sensitivity and the lowest packet loss, which are important aspects to be accounted for in deployments of monitoring systems in remote and critical scenarios. Finally, a resistive load was embedded in view of emulating an average power consumption of 10 mW as typical sensor consumption. The node was programmed to wake up for 1 min to simulate its consumption during sensor measurement, and then a radio transmission was performed. The flowchart describing the program executed by the MCU is presented in
Figure 3.
2.1. PV Module Characterization
The PV module we assembled is a novel prototype with unknown performance under both outdoor terrestrial and indoor laboratory conditions. We measured the current–voltage (I-V) characteristics under 1000 W/m
2 in AM1.5G conditions (solar radiation, SR) and under Sun Simulator irradiation (SS) at 1000 W/m
2 intensity and with the AM1.5G filter. The results are shown in
Figure 4a,b, respectively, for current–voltage (I-V) and power–voltage (P-V) curves. The maximum power coordinates (V
max,I
max) and (V
max,P
max) are depicted in both plots, together with the actual output coordinates (V
out,I
out) and (V
out,P
out), respectively, due to the PMS selection at 85% V
oc. The relevant photovoltaic parameters obtained from measurements are reported in
Table 3. Here,
is the short-circuit current, and FF is the fill factor, while η
out and η
max are the energy conversion efficiencies, respectively, in the output and maximum power point conditions.
The measured parameters of the PV module are lower than the nominal ones, probably due to the irradiation conditions being different from nominal extraterrestrial parameters and characterized by a higher temperature. In general, the measurements evidence that the PV module performs better under solar irradiation than under Sun Simulator illumination. This is probably due to a spectrum mismatch of the Sun Simulator with respect to the actual solar radiation spectrum. This is shown in
Figure 5, which compares the two spectra measured with the Qmini spectrometer in the range 300–1030 nm for the same intensity (1000 W/m
2) in AM1.5G conditions. A decrease in efficiency of about 2% is due to the differences between the output current and voltage coordinates (V
out,I
out) selected by the MPP algorithm of the PMS and the maximum power point coordinates (V
max,I
max).
2.2. Supercapacitor Characterization
The hybrid supercapacitor is a novel prototype with unknown performance during charge/discharge. An Electro-Automatik EA-PS 9080-60 T (Viersen, Germany) source and Electro-Automatik EA EL 9080-45T (Viersen, Germany) were used to measure the charge/discharge cycles of the supercapacitor in terms of voltage vs. state-of-charge (SoC) characteristics. Charge/discharge cycles expressed in terms of voltage across the supercapacitor as a function of its state of charge (SoC) are shown in
Figure 6a. The currents flowing in the SC and voltage across electrodes during charge/discharge cycles are given in
Figure 7a,b. The hysteresis effect observed in the charge/discharge cycles of
Figure 6a can be explained in terms of equivalent internal resistance R
ESR (see
Figure 6c), adding a voltage contribution V
R = R
ESRI during measurements. R
ESR can be evaluated from the voltage difference between the two linear parts of the charge/discharge curves, ΔV = 2V
R = 160 mV, measured at the same current: I = 4 A. We obtain R
ESR = 20 mΩ, in agreement with the nominal value (see
Table 2). To evaluate the energy stored by the supercapacitor, we note that, considering the capacitance value, C = 4000 F, the highest voltage, 4.2 V, corresponds to a charge Q
max = CV
max = 16,800 C obtained at SoC = 100%. Then, we can determine the energy stored in the supercapacitor as
.
Figure 6b shows that the stored energy
U is linearly dependent on the voltage across the supercapacitor electrodes, V
SC, in the range (3.6 V, 4.2 V). Here, a change ΔV
sc = 1 mV corresponds to exchanged energy on the supercapacitor U
sc = 55.94 J = 15.54 mWh. We note that, for proper operation, the supercapacitor must be kept working within this voltage range.
4. Discussion
In the proper voltage range of the supercapacitor (3.6 V to 4.2 V), the energy stored in the SC is a linear function of the voltage across its electrodes,
Vsc (see
Figure 6b). This is useful, as we can discuss the exchanged energies in terms of changes in
Vsc during operation, a parameter easy to measure directly. To discuss the change in
Vsc as a function of time, we consider three contributions: Δ
Vout, Δ
Vin and Δ
Vquiesc. The first, which is always negative, is associated with the node activity; the second, which is always positive, is due to the PV module supply under radiation; and the third is associated with the consumption needed to power up the PMS. In terms of incremental contributions per unit time, we define the following:
From the measurements shown in
Figure 8a, taken when the node is sleeping, we can determine
from the slope of the
Vsc–time curve in the case of null radiation intensity. We obtain
. This corresponds to a power consumption of 9.3 mW and to an energy loss
Uquiesc = 0.14 Wh. From measurements at 350, 600 and 930 W/m
2 light intensity (see
Figure 8a), we can determine
from the slope of V
sc(t) at different radiation intensities. As a result, we obtain
as a function of radiation intensity, as shown in
Figure 10a (for error bar estimation, see
Section 2). The best fit of this curve is obtained by exploiting a polynomial of the second order. Then,
can be determined by evaluating the voltage loss after each transmission at any radiation intensity applied. As an example,
Figure 10c shows a plot of the voltage across the supercapacitor,
Vsc, measured as a function of time under irradiation equal to 350 W/m
2 and with node wakeups every 15 min. The voltage drop due to two consecutive node wakeups is evidenced by the difference between the intercepts of the best-fit lines immediately after the transmission takes place. The loss of voltage due to node consumption is evaluated as the difference between the change in the intercept of the voltage–time line when the node is sleeping between two consecutive transmissions. We obtain a voltage drop for each wakeup equal to Δ
Vtr = −0.18 mV, a value independent of the irradiation intensity. In terms of the corresponding energy stored in the supercapacitor, we obtain
Utr = 2.8 mWh.
Gtot is then determined as a function of the number of wakeups per unit time and of the radiation intensity, as shown in
Figure 10b.
From the plots in
Figure 10, knowing the insolation curve during the day, it is possible to compute the corresponding change in voltage per unit time. As an example,
Figure 11a,b show, respectively, the insolation curve measured on four days with a clear sky in 2023 (data from NREL database [
25]) and the corresponding voltage change per minute in the case of transmission every 15 min calculated with this model.
By summing up the contributions throughout the day, we obtain the voltage change per day for that particular insolation curve: as an example, in
Figure 12a, we show the voltage change calculated throughout the whole year in the case of transmission every 15 min.
Figure 12b shows the voltage across the supercapacitor evaluated in the case of sensing/transmitting, respectively, every 15 min and 30 min during the first year, starting with a 100% state of charge of the battery, corresponding to 4.2 V. We observe that, in the case of wakeups every 15 min (red line),
Vsc, at the end of the first year, is below the proper range required for the supercapacitor (
Vsc as low as 3.2 V), indicating that, energetically, the system is unbalanced. On the contrary, transmission every 30 min shows a
Vsc decrease at the end of the year only down to 3.8 V. The same calculation carried out for the second year, where
Vsc starts from this as the initial value, shows that
Vsc is still within the required range (blue line). The decrease in
Vsc observed in the wintertime is balanced by its increase during the spring-to-autumn period, guaranteeing the self-sufficiency of the WSN for two whole years. Moreover, during successive years,
Vsc should repeat the trend of the second year, so we can expect
Vsc to remain within the proper range (3.6 V, 4.2 V) for virtually unlimited operation periods.
This simple model was obtained from the outcomes achieved during the Sun Simulator tests. However, as we know that under solar radiation, the PV module is more efficient than under the Sun Simulator due to the better match of the triple-junction spectral response with the solar spectrum, even more promising results are expected for outdoor deployments. In fact, the total voltage change in the case of the complete night–day operation with a clear sky, as in
Figure 9c, is estimated by the model to be equal to 32 mV, slightly lower than what was actually measured, that is, 35 mV.
Before concluding, we need to mention here that the model discussed in this paper does not consider weather effects, such as partial insolation due to cloud coverage, and is based only on clear-sky insolation curves. To extend the discussion accordingly, a more detailed model should be used considering more realistic solar radiation intensity curves, directly measured at a specific location throughout the year and averaged over a significant number of years. In the case of Italy, these curves are available from a database by ENEA, Italy [
26], as a listing of the average daily radiation intensities as a function of each month of the year, averaged for the years from 2006 to 2022 for several locations. As an example, the monthly curve of normal global average daily radiation for Siena, Italy, is shown in
Figure 13. Error bars due to 5% uncertainty in the intensity are added to the plot (see
Section 2).
In the case of March, we have ϕ
day = 4.1 kWh/m
2. Considering our PV module, with an active area of 8.4 cm
2 and 24% efficiency when connected to the PMS, the average energy released daily by the panel would be U
PVtheo = 0.86 Wh, a value that compares favorably to the one we can extract from the outdoor measurements reported in
Figure 9c. In fact, our 24 h outdoor measurements made in March corresponded to U
sc = 0.54 Wh energy stored in the supercapacitor. As the power consumption of the system is 0.14 Wh and the energy due to the WSN activity throughout the whole day, in case of transmission every 30 min, is U
WSN = U
tr × 24 × 2 = 0.13 Wh, the total solar panel energy from the PV module can be calculated at U
PVexp = 0.81 Wh, a value in agreement with what is expected from the data shown in
Figure 13.