Magnetic Core Current Sensing for Solar Combiners
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Solution Overview
Problem
Current methods for sensing current in solar power systems, particularly in combiner elements of solar power arrays, face accuracy issues due to temperature variations and heat fluctuations, especially when using Hall effect sensors, which are prone to errors when measuring direct current and are not suitable for outdoor environments with significant current flows.
Innovation Solution
The system employs current sensing elements coupled with magnetic cores and flux sensors, along with compensation mechanisms using control logic and current mappings to accurately measure current, while minimizing power loss and accounting for temperature and coil turn variations, and incorporates a communication module for remote monitoring and data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If Hall effect sensors are used to measure current, then power loss is minimized since the sensor is not in-line, but measurement precision deteriorates due to temperature variations and heat fluctuations
Solution Approach 1:
The patent introduces a magnetic core as an intermediary element that concentrates and guides the magnetic flux generated by the current-carrying conductor. This magnetic core works in conjunction with the Hall effect sensor to enhance the magnetic flux density at the sensor location, thereby improving measurement precision without requiring the sensor to be in-line with the current path, thus maintaining low power loss.
Solution Approach 2:
The patent employs temperature compensation techniques that involve measuring the temperature near the sensor and adjusting the sensor output accordingly. By changing the operational parameters (temperature compensation factors) based on environmental conditions, the system maintains measurement precision across varying temperature ranges while continuing to use the non-invasive Hall effect sensing method.
2Measurement precision
If in-line current sensors are used, then measurement precision is improved, but power loss increases due to power usurped by the sensor
Solution Approach 1:
The magnetic core serves as a mediator that amplifies the magnetic flux signal without requiring direct electrical contact with the current path. This allows the Hall effect sensor to achieve high measurement precision similar to in-line sensors while remaining electrically isolated and consuming minimal power.
3Device complexity
If Hall effect sensors are used in outdoor combiner elements, then device complexity is reduced, but reliability deteriorates due to susceptibility to temperature variations and heat
Solution Approach 1:
The magnetic core acts as a stable intermediary that concentrates magnetic flux in a controlled manner, providing consistent measurement signals despite external temperature variations. This enhances the reliability of the simple Hall effect sensor system in outdoor combiner element environments.
Solution Approach 2:
The system dynamically adjusts operational parameters including temperature compensation factors and potentially sensor excitation currents based on environmental conditions. This parameter adaptation maintains measurement reliability across the wide temperature ranges encountered in outdoor solar power installations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides accurate and reliable current measurement in solar power systems, compensating for temperature and coil turn variations, and enables efficient monitoring and performance evaluation of solar power arrays, reducing operational issues and power loss.
Implementation Method 1
sensing the magnetic flux generated by the current as it is flowing through a conductive medium
Implementation Method 2
current sensing elements coupled with magnetic cores and flux sensors
Data Source
AI summary
A system for combining current from solar power arrays comprises a combiner element and a plurality of solar power arrays, including at least a first solar power array and a second solar power array. The combiner element is configured to receive and combine current from the solar power arrays thereby providing a combined current signal that is based on current from each of the solar power arrays. The combiner element has a current sensing element coupled to one of the solar power arrays and is configured to receive current from the one solar power array. The current sensing element also has a sensor configured to sense a magnetic flux induced by the current from the one solar power array, and the sensor is configured to transmit data indicative of the sensed magnetic flux. The current sensing element further has a magnetic core and a conductive coil for carrying the current from the one solar power array. The magnetic core has a plurality of segments, and the conductive coil passes around at least one of the segments. In addition, the sensor is positioned within a gap between at least two of the segments.