I'd like to build a battery charger control circuit using an Arudino, a relay module, and a current sensor.
I'd use the relay to turn on AC power to a "smart charger" for one or more sets of lithium cells in bike headlights (and other types of battery chargers too. This is just a typical use-case). One of the headlights will draw as much as 2 amps at 5 volts. I suspect the other one only draws 500 mA, or perhaps 1A.
I want to sense the current being drawn by the charger(s), and detect when they switch off and their 5V current use drops from 500-2500 mA to the trivial amount of power used energize the power supply and drive their display LEDs (probably <50 mA at 5V.)
500 mA at 5V, the lowest expected "active" current, will be a very small amount of current at 125 VAC. (about .02A, by my calculations)
I COULD cut the USB charging cable and put my current sensor on the low voltage side, but I'd like to make this a versatile charger controller that I could hook to just about any smart mains-powered battery charger by just plugging the charger's AC power cable into my controller. (And possibly adjusting the threshold current, although I'm hoping to make it smart enough to measure a baseline charging current and detect the drop in current when charging completes.)
What could I use to measure the AC current and feed that information into the Arduino? Ideally a digital signal would be best. A variable input voltage driven by current would be my second choice, and a logic 1 that drops to a logic zero when the current drops below a set threshold would be my third choice.
I'm interested in either an off-the-shelf current sensing module, or something I can build.
If this is a more appropriate question for the Arduino Stack Exchange, I apologize. It seems like a decent fit for this site.
I've built a home-brew passive current sensor myself before that lets me switch my shop-vac on and off when I turn on my drill press or other power tool. I wound bell wire around a ferrous rod (a nail, if memory serves) and then wound the load wires from the drill press around that, creating a crude transformer. I fed the output of that into a full-wave rectifier diode I had lying around, and attached the positive output from the rectifier to an electrolytic capacitor, and tied both negatives to ground. Then I connected the positive lead of the capacitor to the positive input of a solid state relay. Finally, I ran the mains power into through the load side of the solid state relay. When I draw enough current through the power tool load, it generates a stiff enough output to raise the voltage out of the capacitor enough to turn on the solid state relay. However, this rig only detects several amps of current. I want something much more sensitive.
I'm expecting to need to use active components here. I might be able to build an analog circuit using an op-amp, but my electronics knowledge is a bit weak (I'm a software guy) so I would struggle to figure out to configure it. I seem to remember that the ratio of a resistor on the input and a "feedback" resistor lets you adjust the sensitivity of an op-amp circuit, but I'd have to do some serious digging to figure out what type of op-amp to use and what resistor values would be appropriate. I guess I could use a properly sized potentiometer to adjust the current threshold, but again, my preference would be a way to convert the current measurement to digital information that I could then handle through software on the microcontroller.