International Journal of Applied Engineering Research ISSN 0973-4562 Volume 19, Number 2 (2024) pp.

197-201
https://dx.doi.org/10.37622/IJAER/19.2.2024.197-201

Design and Fabrication of Test Set-Up for Pcbs of Smart Energy Meters

Dr. Anagha Soman

Associate professor, Electrical Department, MMCOE, Pune,

Abstract necessary with the main focus on the PCB of these meters. To
optimize the energy production as per the demand is one way
At present the losses in transmission and distribution are 15%.
to conserve the energy. For the efficient utilization of energy,
This means that despite this 15% energy is delivered to the load,
the unnecessary consumption/ losses are to be minimised. To
since it is not recorded or documented, the revenue is not
design a smart energy meter is a herculean task due to issues
generated. This loss affects the overall system efficiency.
such as a temperature change which directly affects the
Energy meters are the devices that are used to measure and
performance of digital/ analogue meter, power theft,
record the electricity consumption. Traditional meters can only
malpractices as meter is placed at consumer premises. Basic
record and display the units consumed Conventional energy
problems with an Analog meters are the stability issues, varying
meters have flaws such as they are prone to tampering for
precision over a longer time period because of defects in the
malpractices (use of magnets to slower the speed of rotation of
manufacturing/ production and also the variation in the
disc), human intervention to note the reading once a month,
mechanical properties such as spring tension, strength and
prone to theft etc. In fast changing technology of this era, smart
mass. To address all these issues, new technology is required to
energy meter is the need of hour. Smart energy meters (SEM)
design and develop a smart meter. A System on chip (SoC)
have features such as safety, accuracy, less losses, privacy
needs to be included which can interface with all types of
which are the added advantages. This paper is an attempt to
sensors. The samples of voltage and current are received as
discuss the design and development of a customized test set-up
output from the voltage and current transducer [2]. The future
which will test the smart meters thus reducing the testing time
market, cost and the life of meter will be dependent on the
& hence the rise production rate without hampering the
Digital Signal Processing (DSP) technique and analog to
accuracy as human intervention is skipped. Owing to so many
Digital Conversion.
better features, the conventional energy meters are replaced by
the smart meters at a fast rate. Deployment of smart meters Smart energy meters can be wirelessly monitored, controlled
improves the revenue collection, reduce the losses (as any and also these meters can control the energy consumption of the
discrepancies or anomaly can be easily traced out). The revenue consumers as per the predefined value. The smart meters are
management can also be largely affected with the use of smart utility friendly and user friendly, too. GSM Modem can be used
meters. In case of manufacturing of smart meters, one of the to control the power supply without human intervention and
important factors is to ensure the quality & reliability of printed also malpractices can be detected remotely [3], [4], [5]. This
circuit boards (PCBs). The proposed test set-up will be used to paper discusses the ideation, design and execution of a test set
test different parameters on the PCBs of smart meters at up which will address all the issues and achieve all the expected
strategic points. This test set-up will streamline the testing outcomes. The ever-increasing demand of efficient smart
process and also improve the efficiency of process. meters which will be having fast response also is to be met by
designing & developing such test set up. Such test set up will
Keywords: SEM, PCB, Revenue management, human
assure good quality of smart meters in fast and reliable way.
intervention, Efficiency
The test set up will guarantee good functionality of the smart
meter.
Introduction
The conventional energy meters suffer from various flaws as Background
compared to the smart energy meters [1]. The smart meter
The smart energy meter is do designed that continuous
technology is improving day by day which greatly affects the
monitoring, control and shut down the supply (I case of failing
energy management as well as monitoring of electricity
to pay the amount of bill for consumption of electricity) is
consumption. For gathering accurate data, monitoring the
possible remotely and wirelessly. No human support is required
parameters from faraway place and improving the overall
in this whole process so not only the human error or
efficiency of the system, smart meters play a vital role.
malpractices are avoided but the maintenance cost is also
However, to ensure all these qualities and smooth-running
reduced. Accuracy and efficiency of smart energy meters is
operation of these meters, a well-defined testing procedure is
more. The system is transparent as the consumer as well as

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 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 19, Number 2 (2024) pp. 197-201
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supply utility can read or record the display of the meter to The basic layout of the PCB is as shown in fig.2 below.
check the consumption of electricity at any time [6].
[7]Proposes a system which is so developed that it is very
effective and eliminates all the drawbacks of serial
communication in Smart Energy Meter (SEM). This
development makes the SEM lesser prone to power theft,
accurate and efficient. These implementations make the
designed system unique and effective compared to the previous
proposals. The designing principles for the test set up are
discussed and the features of PCB design such as modularity,
scalability, and flexibility is discussed in detail in [8], [9], [10].
[11] discusses about case study on practical challenges faced in
the testing phase and the causes of most common failure are
elaborated. Similar architecture of PCB design for the testing Figure.2 Basic layout of PCB
of smart meters is elaborated by Wang et al. [12] with special
focus on using different PCB layouts and their testing
procedure. The application of Industry 4.0 & IoT in the PCB
SEM Hardware Details
testing is proposed by Yang [13]. Also, a real time monitor,
predictive and remote control over the Test Jig is discussed in The components used in PCB of SEM are as discussed below:
simple words. [14] and [15] investigate the application of AI &
1. Raspberry Pie: is the master mind/ decision maker on the
ML to optimize the test jig performance. The analysis in these
PCB for the test set-up. The input-output diagram for the
papers reconfirms the enhancement in efficiency of the test jig
same is as shown in fig. 3 below. The interfacing of various
resulting in longer life of the equipment. New policies are
components and the PCB is done through it.
introduced by Government of India for changing all the
conventional energy meters by SEM [18]-[20]. Researchers are
now working as per the amendment done in IS 16444 as per
BIS. An Indian company, Shete Advanced Technology (SAT)
is working on a SEM project wherein the software as well as
hardware design requirements for manufacturing of SEM for
mass production. The SEM manufacturing should be done as
per the guidelines in IS 16444. Despite all the good features of
SEM, the high sensitivity of these meters is a challenge for
researchers & designers. SEM should be so designed,
manufactured, calibrated and tested that the accuracy levels are
maintained and the electrical parameters and performance
parameters should be checked Smart meter being placed in
consumer are highly sensitive. Smart meters need to be
manufactured and calibrated as per the desired accuracy
standards. As per the IS 16444, a few check points are defined Figure.3 Input-output diagram
for PCB as in fig.1 below.
During the testing of PCBs, selection of check points on the Raspberry pie is so popular due to its features such as simpler
PCBs to monitor electrical parameters is crucial. These design, cheaper, smaller and an ease of configuring the
monitored values of electrical parameters will be the key approach. It operates like a micro-computer. There are few
indicators of operational performance of the PCBs. Check shortcomings such as limited application, slow rate of
point parameters: Input voltage, Battery current, Pulse check in operation, not designed for multi-tasking. Thus, for SEM, the
phase & neutral, RTC set in memory & deleting full memory. central control unit in the test set-up is Raspberry Pi. Raspberry
pi makes the PCB automated and also the device under test can
communicate with outside world. The data logging, analysis
and user interface are amongst the best features of Raspberry
pie [21], [22]. The designer also gets the flexibility as
Raspberry pie can be customized for a particular application.
2. Step down transformer: As the name itself suggests, it is
used to step down the input voltage (230 V) to 15 V for the
control circuitry.
3. Bridge rectifier: It is used for the conversion of AC input
supply to DC.
The circuit diagram for the test set-up is as shown in Fig.4
Figure.1 Check points on PCB of smart meter under test below

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 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 19, Number 2 (2024) pp. 197-201
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model platform. After placing the PCB on test set-up, the

bugs/faults in the PCB are checked by tapping the voltages and
currents at strategic points. The operational performance of
each of the components is tested. So, there can be two cases i.e.
healthy and faulty as depicted below in Fig 7, 8 and 9.
Case I: Healthy condition: When each component works in
healthy condition and the electrical parameters are satisfactory.

Figure.4 Circuit diagram of the test set-up

Actual photograph of the test set-up is as shown in fig.5 below

& working model of the test set-up is as shown below in fig.6 Figure.7 Case 1: Healthy condition
Case II: Faulty condition: When there is a faulty operation due
to maloperation of one or more components and the electrical
parameters are not satisfactory.

Figure. 8 Case II: Faulty condition

Figure.9 Case II: Faulty condition

Conclusion/ Summary
A systematic set up and testing procedure is developed for
testing of PCB of SEM which will increase the efficiency of the
Figure.5 Actual photograph of test set-up
testing procedure and definitely increase the production rate of
Figure.6.Working model of the test set-up for PCB of SEM SEM. The test set-up is specially customised for the testing of
PCBs of SEM as per the specific requirements of electrical
parameters such as voltage and current at specific check points
Result and discussion on the PCBs. This set-up will help the manufacturers to produce
accurate, efficient, dependable and flawless smart meters on a
The PCBs are to be tested by placing them on the working

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large scale. Output of this testing procedure will be good quality [11] Kumar, A., & Singh, B. (2023). "Enhanced Test Jig
and high-performance smart energy meters. Design for Comprehensive Testing of Smart Energy
Meter PCBs." International Journal of Engineering
Research & Technology, 12(4), 586-594
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