벤롱 
단상 계량기 자동 생산 라인
Custom single‑phase 2P DIN rail meter automatic production line with semi‑auto calibration (0.05%), PCBA dust removal, hi‑pot/insulation test, terminal screw torque check, laboratory‑grade aging bench, and MES traceability. Output 800‑1,500 units/shift. Ideal for high‑volume smart meter manufacturing.
Fully Integrated Single‑Phase DIN Rail Meter Production Line
Designed specifically for high-volume production of smart meters, the single-phase rail-mounted (2P) smart meter automatic production line includes automated feeding and manual assembly stations as well as testing (terminal screw torque; semi-automated calibration) and other processes used to produce these smart meters. The complete production line will cover the entire process, including all processes required for assembling the components on the meter to packing the smart meters into boxes for shipment, hence improving the overall efficiency, consistency and reliability of the manufacturing process.
The modular line integrates a semi-automatic calibration bench (with a reference accuracy of 0.05 %) an automatic high-pot and insulation resistance tester and a multi-station aging bench (for simulated load verification), with optional MES connectivity to ensure complete traceability of all data (per meter). This meter manufacturers’ production line allows for improved throughput while complying with IEC 62053-21/22 and utility acceptance standards (Yes). The typical output range per shift, based on configuration and level of automation, is from 800 to 1,500 meters produced.
Standard delivery: 45-60 days | Semi‑auto calibration | Integrated aging bench | MES ready
What is a Single‑Phase Meter Automatic Production Line?
A single-phase automatic production line is a modular manufacturing solution for single-phase DIN rail (2P) electric meters – the most widely used form of residential and light commercial energy meter. The single-phase automatic production line consists of several workstations, including: automatic feeding of the meter bases; manual or semi-automated assembly (such as terminal screw tightening); dusting & cleaning the PCBA to ensure there are no insulation failures; semi-automated calibration of active and reactive energy; dielectric withstand (hi-pot) and insulation resistance testing; laser engraving of the serial number, model number, and ratings; and an aging test fixture to ensure long-term reliability. The single-phase automatic production line has a capacity of 800 to 1,500 meters per shift and can be connected to an MES for complete traceability. As we build a custom solution that meets your needs, the production line will be configured for your specific meter design, accuracy class, and communication protocols (such as RS485, PLC, or wireless).
Automated feeding + manual assembly cells for flexible production.
0.05% reference accuracy, operator‑assisted load/unload.
Ionizing air or vacuum system ensures insulation integrity.
Multi‑position simulated load aging for reliability validation.
Production Line Features & Process Flow
기술 사양
| Meter type | Single‑phase two‑wire (2P), DIN rail mount, direct or CT connection |
|---|---|
| Calibration accuracy | Reference standard 0.05% class; semi‑automatic, operator‑assisted |
| Hi‑pot test voltage | Programmable up to 4,000V AC, 1‑99 seconds, automatic pass/fail– |
| Insulation resistance test | 500V or 1000V DC, measurement up to 100 MΩ– |
| PCBA dust removal | Ionizing air blow or vacuum, optional HEPA filtration– |
| Aging test bench | Multi‑position (up to 48 meters), programmable voltage/current cycles, real‑time monitoring– |
| Screw torque test station | Automated or manual torque check for terminal screws (left and right sides)– |
| Laser marking | Fiber laser (20W), marking of serial number, rating, barcode– |
| MES integration | Barcode scanning per meter, test data upload via OPC UA / Modbus TCP– |
| 전원 공급 장치 | 380V ±10% 50Hz | Compressed air 0.5-0.7MPa– |
핵심 기술적 이점
Terminal screw torque verification – left & right sides
Loose terminal screws cause overheating and meter failure. The line includes a dedicated station (manual or automated) that checks the tightening torque of both left and right terminal screws to a preset value (e.g., 0.8‑1.2 N·m). Results are logged per meter.
PCBA dust removal prevents hi‑pot failures
An ionized air or vacuum cleaning station removes dust and debris from the PCBA before dielectric testing. This reduces false hi‑pot failures caused by contamination, improving first‑pass yield and product reliability.
Laboratory‑grade aging bench without external chamber
The integrated aging test bench applies rated voltage and current to multiple meters simultaneously, simulating weeks of field operation in hours. Real‑time monitoring of accuracy drift and communication stability catches early failures before shipment.
Full MES traceability – from assembly to shipping
Each meter receives a unique barcode at the start of the line. All test results (torque, calibration, hi‑pot, insulation, aging) are linked to this barcode and uploaded to MES. Utilities and certification bodies require this data for compliance.
Customer Success Story – High‑Volume Meter Manufacturer
A leading meter manufacturer supplying energy meters in India was looking to increase the production capacity of their 2P single-phase meters (Class 1) from 5 thousand units per shift to 12 thousand units per shift. The existing line used manual calibration and did not utilize an aging test, resulting in a field return rate of 2%. Benlong supplied a fully automated metering line, including the following features: a semi-automated calibration process, a PCBA dust removal system, an integrated aging bench, and MES connectivity. Results of the first six months are as follows:
In less than 1 year (11 months) this line will have paid for itself and assisted the customer in obtaining a large utility contract that required IEC 62053-21 compliance and complete traceability.
응용 프로그램 및 통합
맞춤형 엔지니어링 및 납품
Request a Custom Single‑Phase Meter Production Line Quote
Our engineers will create an individualized line, equipped with semi-automatic calibration, dust-removal systems, aging benches, and MES integration; the design is based on your metering specifications, desired output, and communication protocol. A complete ROI analysis will also be included in the engineering deliverables.
WhatsApp: +86 150 5837 0007 | 이메일: xsb@benlongkj.cn | 영어 및 중국어 지원
Why Choose Benlong for Single‑Phase Meter Lines?
- 15년 이상 디자인 경력 meter production and test lines for the energy metering industry
- Proven semi‑auto calibration with 0.05% reference accuracy
- Integrated PCBA dust removal, hi‑pot (4kV), and insulation test stations
- Laboratory‑grade aging bench with real‑time monitoring
- Full MES traceability – barcode to test data, ready for utility audits
일반적인 맞춤 제작 라인에는 다음이 포함됩니다.
Base meters auto-feeders; manual assembly stations; PCBA dust-removal equipment; Semi-automatic calibration benches (0.05% accuracy); High-voltage (Hi-pot) & insulation resistance testers; Laser marking stations; Multi-position aging-test benches with 48 positions each; Conveyor systems; Programmable logic controllers (PLC) with human machine interfaces (HMI) all set for use; Barcode scanners provide communication between devices or between devices and their associated software; Information on installation and training will be provided; 1 Year Warranty is included.
자주 묻는 질문
Single-phase 2P DIN rail meters, which have a low current rating (typically 5-100A) as well as basic calibration requirements have been specially made to use this design. There is a smaller footprint and throughput is optimized for high volume residential meter production. Three-phase lines have an increased footprint to accommodate 3P/4P meters that have a higher current rating (120A) requiring more space.
There are two options available. For higher volume assembly lines, we offer an automatic torque checking station or an electric screwdriver with a torque sensor. If you are producing lower volumes and don’t need the extra features of the automatic torque hand tools, then you can use a manual torque wrench and barcode record the torque measurement. The choice of which option to use will have an impact on the cycle time and cost.
The aged bench has the ability to measure and record meters via RS485 (Modbus, DLMS/COSEM), an optical port (IEC 62056-21) and via PULSE outputs. Wireless modules (LoRa, NB-IoT) are an option but require additional integration work.
Indeed, a robotic load/unload module could be used in place of the semi-automated calibration booth (in keeping with the calibrated bench design). This is recommended for production volumes greater than 15,000 units per manufacturing run/one shift.
A company that builds 8,000 meters of product production (2 independent shifts) will typically realize a ROI in the 9 to14 month range due primarily to reduced labor (4 to 6 calibration / test operators removed) and an improved initial pass yield.
