Study the influence of the alignment and nearby metallic objects on the Hall sensor system for current measurement in Resistance spot welding machine

A technique for measuring the current of a stationary spot welding unit using a Hall sensor system is implemented. Hall Effect sensor is used to sense the strength of the magnetic field produced by the current, flowing through the welding electrodes, on the secondary side of welding transformer. In contrast to a current transformer the Hall Effect sensor can read a DC current and can thus be utilized in direct current welding equipments. In this paper the influence of the sensor position and presence of the tools or other materials in the proximity of the sensor that effect the sensor reading is investigated. COMSOL Multiphysics software is used to investigate these effects and a circuit design is implemented according to the conclusion drawn from the simulations.