High performance flexible thermoelectric generator for integrated self-powered sensors in high voltage switchgear contacts

High voltage switchgear plays a critical role in modern electrical systems, yet its reliable operation faces critical challenges, including inefficient heat dissipation from the lap contacts and the need for continuous monitoring of the contact conditions. Traditional monitoring systems often rely on external power sources, limiting their applicability in harsh and hard-to-access environments. This study introduces a transformative solution: a novel flexible thermoelectric generator (TEG) engineered to simultaneously address heat dissipation and enable self-powered contact monitoring. The TEG design incorporates two key innovations: a sandwich substrate for mechanical flexibility and direct-soldered copper-foam heat sink, which not only conforms to the complex geometries of switchgear contacts but also enhance the TEG performance. Experimental validation demonstrates that the copper-foam heat sink increases the TEG's maximum output power (Pmopt) by 200 % (10.267 mW vs. 3.426 mW without the heat sink). Additionally, a two-layer star topology sensor network structure was further developed by integrating with an energy management module, a multi-sensor monitoring module, a Bluetooth module, achieving continuous, self-powered monitoring of switchgear contact health, offering real-time data transmission and stable operation without external power.