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Should I use hall sensors to measure high current in Electric Vehicles (EVs)

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samshabz

Student
Jan 22, 2025
1
I would like to know some more information about Hall effect sensors. My project entails measuring high current (hundreds of Amps) in an EV and using an ADC on a microcontroller to read the current. This product will be put in an EV for a long-term period to monitor power and send to a cloud platform continuously. The shunt is not always accessible and resistance not always known (takes time to find) and CAN bus protocols apparently differ per manufacturer (time delay to find); the solution is meant to be compact and plug and play in any EV without a time and effort delay. As I am not too familiar with the hall effect sensors, are there any considerations I need to make (also side note, where should I be looking for useful information). I am particularly worried about effects such as hysteresis, having the wire off-centre in the hole causing an error, having the wire significantly thinner than the hole (will this cause only partial absorbtion of the magnetic field and subsequently a lower reading?), requirement for calibration per-vehicle or recalibration over-time, external EMI rejection, interfacing via ADC, robustness to vibration/temperature etc. I need to be able to quantify what kind of error I can expect from this method. Is the hall effect sensor the way to go or should I stick to shunt, or is there other solutions? And closed or open loop? Please detail as much as possible and potentially product examples. Thank you
 
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