Global Horizontal Irradiance Estimation Using a Hybrid Physical-Machine Learning Soft Sensor Based on a Low-Cost Photovoltaic Measurement Platform

Accurate measurements of global horizontal irradiance (GHI) are fundamental for solar energy assessment. However, the cost and deployment constraints of standard pyranometers limit their widespread use. This work presents a low-cost pseudo-pyranometer based on photovoltaic current measurements combined with a hybrid physical-machine learning approach. A custom data acquisition system was developed and deployed in Piatra-Neamț, Romania, consisting of a Raspberry Pi 5, INA219 current sensor, and a 0.3 W photovoltaic panel mounted horizontally. One-minute resolution measurements were collected between August 2024 and June 2025 and augmented with modeled solar geometry and clear-sky irradiance using pvlib. Temporal effects were encoded using sinusoidal representations of the time of the day and the day of the year. Clear-sky current samples were identified using a tolerance-based normalization with respect to modeled clear-sky irradiance and used to train an artificial neural network to estimate the clear-sky panel current. Feature importance was assessed using SHAP analysis, highlighting the dominant role of solar geometry and temporal encoding. The resulting clear-sky current model was combined with measured current through a clearness index formulation to estimate GHI. To evaluate performance, the system was redeployed in parallel with a reference pyranometer in Cluj-Napoca, Romania, enabling direct comparison under real operating conditions. The results demonstrate that the proposed hybrid approach can approximate pyranometer measurements with low-cost hardware, supporting scalable and redeployable solar monitoring networks in geographically localized regions.