Adaptive Magnetic Field Compensation for High-Precision Current Sensing in Eccentricity-Prone Circular Hall Sensor Arrays

This article addresses the conductor eccentricity error inherent in circular array Hall-effect current sensors through a novel magnetic field compensation algorithm that synergizes numerical integration and adaptive conductor position estimation. The algorithm’s efficacy was validated via MATLAB simulations and a 1000-A dc test platform featuring digital signal processing (DSP) real-time processing. By implementing an automatic feedback loop that monitors Hall element voltage variations (DAQ6510 acquisition) and dynamically adjusts magnetic field coefficients, the method reduces measurement errors from 4.5% (uncompensated) to 0.6% full scale (FS)-an 86.7% accuracy improvement. Experimental results under ±500-A bidirectional currents and 0-2-cm eccentric displacements confirm compliance with IEC 61869-10 Class 0.5 requirements (<1% error), demonstrating exceptional robustness against mechanical misalignment in high-density applications like electric vehicle (EV) powertrains (500-A/mm2 current density) and aerospace power systems.