benlong 
Linha de produção automática de medidores elétricos trifásicos
Custom three‑phase smart meter automatic production line with PCBA dust removal, hi‑pot testing (4kV), semi‑auto calibration (0.05% reference), automatic sealing cap installation, and integrated aging test bench. Full traceability, MES ready. Ideal for high‑volume meter manufacturing.
Fully Integrated Three‑Phase Smart Meter Production Line
Precision Climate-Controlled Reliability Test System for Energy Meters This Smart Meter Aging Test Bench serves as a vital piece of laboratory equipment for performing accelerated life-cycle and reliability testing (burn-in) on new and production batch energy meters. The system comprises a climate-controlled chamber capable of maintaining precise temperature (e.g., $-20^{circ}text{C}$ to $+85^{circ}text{C}$) and humidity settings, simulating extreme operating environments. Meters installed in the bench are subjected to continuous electrical loading (current and voltage) under these fluctuating environmental conditions. The bench’s advanced data logging system monitors key performance indicators, such as drift in accuracy, power consumption, and communication stability, identifying potential failures before deployment. It is indispensable for validating design robustness and ensuring compliance with utility reliability standardsEnergy meter assembly line.
Standard delivery: 60-90 days | Semi‑auto calibration | Integrated aging bench
What is a Three‑Phase Electric Meter Automatic Production Line?
Three-phase electrical meter production line refers to the automated assembly/calibration/testing of three-phase energy meters (active/reactive/smart). The line automates the critical aspects of the production process, PCBA cleaning (dust removal) that allows for insulation integrity; automatic sealing cap installation that meets the different IP protection ratings; semi or fully automated calibration of voltage/current accuracy; and hi-pot testing; as well as having an integrated aging test bench that gives accelerated life-cycle testing under power and environmental conditions, to validate the stability and reliability of the meter’s communication over time. The line is designed to accommodate direct connected, current transformer (CT) connected and voltage transformer (VT) connected meters, as well as a number of communication modules (RS-485, PLC, RF). Each meter is fully traceable via barcode, creating a link between each meter with its test results for utility compliance (IEC 62053-11 & 22; ANSI C12). As a custom non-standard solution, we will configure the line to fit your meter dimensions, accuracy class and production volume.
Operator‑assisted high‑precision calibration of active/reactive energy.
Dielectric strength (hi‑pot) up to 4kV AC, 100% in‑line verification.
Clean boards before assembly; automatic sealing cap installation for dust/water protection.
Accelerated life‑cycle test under electrical load and optional temperature/humidity.
Características e processo da linha de produção
Especificações técnicas
| Meter types supported | Three‑phase four‑wire, three‑phase three‑wire; direct or CT/VT; active/reactive |
|---|---|
| Calibration method | Semi‑automatic (operator assisted) with reference standard (accuracy class 0.05%) |
| Hi‑pot test voltage | Programmable up to 4,000V AC, 1‑99 seconds, automatic pass/fail |
| PCBA dust removal | Ionizing air blow or vacuum cleaning station, optional filtration– |
| Sealing cap installation | Automatic press‑fit or screw‑type cap placement, torque monitoring– |
| Aging test bench | Multi‑position chamber (up to 48 meters), programmable voltage/current cycles, real‑time accuracy monitoring– |
| Test coverage | Basic error, start/creep, influence quantities, communication (RS485, PLC), load profile– |
| Sistema de controle | PLC (Siemens/Mitsubishi) with HMI, recipe storage, MES interface (OPC UA)– |
| Rastreabilidade | Barcode per meter, test data stored in SQL database, exportable to CSV– |
| Fonte de energia | 380V ±10% 50Hz | Compressed air 0.6‑0.8MPa– |
Principais vantagens técnicas
Eliminates manual calibration errors
Semi‑automatic calibration uses a precision reference standard (0.05% class) and automated adjustment of meter gains. The operator simply connects the meter; the system applies test points, calculates corrections, and verifies results – reducing human error and calibration time by 70%.
Integrated dust removal for high‑voltage safety
PCBA dust removal (ionizing air or vacuum) prevents conductive dust buildup that could cause dielectric breakdown during hi‑pot testing. This step is critical for meters operating in humid or polluted environments.
Accelerated aging without external chamber
The dedicated aging test bench applies continuous voltage/current cycles (e.g., 8 hours at rated load) while monitoring drift in accuracy and communication stability. This simulates months of field use in a single shift, catching early failures before shipment.
Full traceability for utility acceptance
Each meter’s calibration data, hi‑pot result, aging profile, and final test report are linked via barcode. Exportable audit trail satisfies utility requirements and ISO/IEC 17025 lab accreditation.
Customer Success Story – Utility Meter Manufacturer
A leading manufacturer of electric meters had a demand for a large increase in production of three-phase smart meters (Class 1 Active – 8,000 units/month). The existing manufacturing process required high calibration time and also had an occasional high-pot failure due to contamination on the PCBAs. Benlong delivered a complete production line with dust removal, semi-automatic calibration and integrated aging bench; within 6 months resulted in:
The line recouped its expenses in just over a year (13 months) and met utility standards for accurate traceable (traceable to a standard) measurement.
Aplicações e Integração
Engenharia e entrega personalizadas
Request a Custom Three‑Phase Meter Production Line Quote
We would like to request your meter’s specifications, accuracy class, and target output so that our engineer team can start designing a custom line with features for dust removal; hi-pot testing; semi-auto calibration; sealing cap assembly; and aging bench -along with a complete ROI analysis.
WhatsApp: +86 150 5837 0007 | E-mail: xsb@benlongkj.cn | Suporte em inglês e chinês
Why Choose Benlong for Meter Automation?
- Mais de 15 anos de experiência em design. meter production and test lines for energy metering industry
- Proven semi‑auto calibration with 0.05% reference accuracy
- Integrated hi‑pot (up to 4kV) and aging test benches
- Full traceability – barcode to test data, MES ready
- Serviço global e suporte de peças de reposição
Uma linha personalizada típica inclui:
– Dust removal station for PCBA (Ionizing air and vacuum) – High-voltage (hi-pot) testing equipment – Calibration equipment (bench top) with standard reference – Automatic cap sealing equipment – Aging test equipment (multiple test locations, can accommodate up to 48 units) – Conveyor system/PLC and HMI (Siemens) – Barcode scanner and associated database – Equipment installation and associated training – 1-year parts and labor warranty on equipment
Perguntas frequentes
Operators manually connect the test leads and physically load/unload the meters when performing semi-automatic calibrations, while the calibration process itself is automated (calculating errors, checking for errors, adjusting gains, etc.). Fully automated calibration includes loading/unloading via robots and connecting to test leads automatically; this type of calibration is intended for companies that will be producing large numbers of meters (greater than 50,000 per month). Our current systems can be upgraded to mass produce meters later.
When dust is present on a PCBA, it can form conductive pathways and can produce an erroneous dielectric breakdown failure or reduce the insulation clearance. By cleaning away any dust (with ionizing air, a vacuum, etc.), the dielectric strength test results will only reflect true insulation issues rather than any related to the dust or other contaminants.
The ageing bench records communications stability and data integrity of meters communicating via RS485 (做Modbus, DLMS/COSEM)或光學介面的IEC62056-21 (or電波無線網絡的LoRa和 NB-IOT)在需求的場合。
Absolutely. The station has tri-change tooling for press-fit caps, screw caps or ultrasonic welding. Type of tooling changeovers takes under 30 minutes.
The range of standard aging cycles is 2 to 48 hours, according to customer specifications and meter requirements. The bench may be programmed for voltage/current ramping, load variation and temperature cycling (for an integrated environmental chamber) depending upon what is requested by the customer.
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