Patented wide-range energy meter based on Hall sensor

Creativity knows no bounds, and innovation continues to flourish. Today, we bring you details about a national-level invention patent for a wide-range energy meter based on Hall sensors. This groundbreaking patent was developed by Wasion Group Co., Ltd., and received its official authorization notice on July 18, 2017. The patent introduces a novel approach to measuring electrical energy with exceptional accuracy and adaptability. Traditional electromagnetic current transformers, often used in energy meters, face limitations due to magnetic saturation and a restricted bandwidth. These drawbacks make it challenging to accurately detect high-frequency components and direct currents. As power grids increasingly incorporate non-linear devices like power electronics, the demand for more sophisticated solutions has grown. Hall sensors, known for their ability to detect both AC and DC magnetic fields, present a promising alternative. However, standard open-loop Hall sensors typically have a narrow dynamic range, limiting their effectiveness in applications requiring extensive bandwidth and precision, such as electric energy meters. For instance, a typical energy meter may require a current detection dynamic range of up to 1200:1, while the average open-loop Hall sensor can only handle around 200:1, making them unsuitable for demanding scenarios. Additionally, strong magnetic interference can compromise measurement accuracy. To address these issues, this invention provides a wide-range energy meter based on Hall sensors, boasting a broad frequency band, expansive dynamic range, high precision, and robust resistance to external magnetic interference. The meter consists of several key components, including a Hall current detection module, a voltage detection module, an MCU signal processing control module, a metering module, a display alarm communication module, and a power module. The Hall current detection module senses changes in current and sends the data to the metering module and the MCU signal processing control module. Meanwhile, the voltage detection module measures voltage levels and transmits the results to the metering module. The metering module performs A/D conversion on the signals, and the corrected output is sent back to the MCU for further processing. The MCU applies temperature compensation to ensure stable performance across varying environmental conditions and stores the data for later use. The display alarm communication module then presents real-time power consumption information on an LCD screen, triggers alarms if current or voltage exceeds safe limits, and communicates externally via multiple channels such as infrared, GPRS, carrier communication, and 485 communication. One of the innovative aspects of this meter lies in its dual-Hall-sensor design. It features two open-loop Hall current sensors positioned vertically on a U-shaped PCB. The first sensor has a broader current detection range compared to the second, and both can be adjusted dynamically by a programmer. Each sensor is housed in a unique shielding configuration—U-shaped for the first sensor and C-shaped for the second—to optimize performance. The voltage detection module employs a resistor divider network to measure voltage, while the power module ensures stable power delivery using a transformer, switching power supply chip, and linear low-dropout regulator. This invention demonstrates remarkable capabilities, capable of measuring currents ranging from 0.05A to 200A and operating effectively in environments with external magnetic interference up to 330mT. It supports both AC and DC detection and can identify high-frequency nonlinear components. By utilizing an open-loop Hall sensor, the design eliminates the need for complex magnetic circuitry found in closed-loop alternatives, simplifying construction. Nonlinearity is kept below 5‰, and temperature drift is managed within 50ppm/°C through advanced algorithms. Furthermore, the meter's testing range can be adjusted in real time, allowing it to adapt to diverse applications. By integrating a metal strip beneath the Hall sensor, the system can even handle currents up to 2000A. In summary, this invention represents a significant leap forward in energy meter technology, offering unparalleled precision, adaptability, and reliability. Its potential applications span numerous industries, from residential electricity management to industrial monitoring systems.

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