Residential Energy Meter OEM for Accurate Home Energy Billing
End-to-end OEM manufacturing delivering precise metering accuracy, clean assembly, and reliable performance for large-scale residential deployment.
The customer is a metering solutions company that focuses on residential billing applications. They have finished the electronic design and developed their token-based billing software but needed a manufacturing partner who could convert it into a quality, reliable hardware product. They were seeking an OEM partner that could:
- Conduct stable PCBA manufacturing
- Install clean wiring andhousing assembly
- Carry out billing accuracy testing
- Ensureconsistent quality of product batches.
The project aimed to convert their meter design into a reliable, scalable residential energy billing product. The end product required stable measurement accuracy, clean and maintainable wiring, batch-to-batch consistency, and scalability for large-scale deployment across multiple residential settings.
Project Challenges
- The application demanded an architecture that has an independent metering unit and display module.
- The system had to offer highly accurate measurement that was suitable for residential housing.
- It was required to be Class 1.0 compliant with billing applications.
- The design required stable installation with a compact enclosure.
- MOKO performed PCBA, finished-unit assembly, wiring, and calibration.
- The client needed extensive functional testing, professional labeling and deployment ready packaging.
MOKO’s Energy Meter OEM Manufacturing Solution
Engineering Support
Provided DFM recommendations to improve PCB layout manufacturability, terminal alignment, and enclosure mating. Recommendations on how to improve the wiring layout and the positioning of the connector to improve installation stability and assembly efficiency.
Energy Meter PCBA Manufacturing
We used both SMT and THT for electricity meter PCB assembly. The former was used to assemble passive components such as 0402 and 0603 packages, while the latter was used to assemble terminal blocks and connector interfaces. Then, AOI inspection and in-circuit testing were performed to ensure the reliability of the PCBA
Final Product Assembly
MOKO integrated the PCBA, terminal connectors, wiring harness, and display modules into a fully functional unit. Our team assembled the housing using precise mechanical fastening methods to ensure stable and secure mounting. The final assembly process also involved labeling, sealing, and accessory preparation.
Calibration and Functional Testing
We calibrated billing accuracy by performing load-based calibration and functional testing, including token input, data display, wiring continuity, and relay switching. Burn-in testing was performed on each unit under varying temperature and humidity conditions to simulate real-life usage.
Results
- Achieved a very low error rate of 0.18%, which guaranteed consistency in the quality of products in all production batches and reduced the maintenance requirements.
- The full validation of billing accuracy was up to the Class 1.0 standard, making sure the electricity meters would work well in residential billing conditions.
- The efficiency of installations was increased by 22 percent due to enhanced wiring alignment and connector positioning.
- The manufacturing reliability and the consistent performance assisted the client to acquire more utility contracts, which reinforce their position and enable wider deployment of their metering solution.
Client Feedback
“MOKO enabled us to transform our concept into a product that is ready to deploy. The consistency in assembly, calibration and manufacturing helped us enhance the field performance in residential applications. Their dependable execution accelerated our time-to-market and allowed us to meet the growing demand of our customers. ”
