Modular Automation Solutions for Smart Meter Manufacturing

Flexible, Scalable Production of Smart Electricity, Water, and Gas Meters

Smart meters are essential for the digitalization of energy and utility networks. Their production demands high precision, flexible automation, and reliable test procedures for long-term product quality. 

HAHN Automation Group provides modular systems covering everything from manual workstations to fully automated lines — including different testing technologies, e.g. flow, leakage, flashing, or high-voltage testing.

#Production #SmartManufacturing #Modular #Automation

 

  • Flexible Production Concepts
  • Integrated Test Technology
  • Scalable Automation Solutions

 

Challenge

Manufacturers in the metering industry face increasing complexity and market pressure. They must balance high throughput with strict quality and regulatory requirements and flexible variant handling across different product types and volumes. 

Integrating in-house injection-molding systems, manufacturing hybrid components, and ensuring testing within one unified setup demand a highly adaptable automation concept. Achieving this efficiency and consistency is key to maintaining competitiveness in a rapidly evolving market.

 

Developing a Solution

HAHN Automation Group delivers a modular automation platform that adapts to each customer’s specific requirements. From manual to fully automated systems, the solutions integrate flashing, testing, and assembly processes seamlessly. Existing injection-molding equipment can be incorporated and hybrid parts can be manufactured which allows different product variants to be managed flexibly. 

Each system ensures comprehensive quality control through integrated tests. With its scalable architecture, the platform supports efficient production for both pilot series and large-scale manufacturing — ensuring consistent quality, reliability, and process transparency.

 

Process Overview

  1. Component & Housing Preparation
    Integration of molded and hybrid components, with seamless connection to in-house injection-molding systems.
  2. Module Assembly & Firmware Flashing
    Automated installation of sensor and PCB modules, followed by firmware flashing for smart-meter functionality.
  3. Housing Assembly & Variant Handling
    Insertion of components & modules into housings and flexible setup for different meter variants and configurations.
  4. Functional Testing
    Inline or end-of-line test solutions, including flow, leak, or high-voltage testing to ensure full operational reliability.
  5. Final Quality Control & Packaging
    End-of-line inspection, serialization, and packaging for complete traceability and shipment readiness.

Flexibility. Scalability. Efficiency.

Results

With modular, scalable automation solutions, HAHN Automation Group enables efficient and reliable production of smart meters across all volumes and variants. 

Integrated test technologies and flexible system architecture ensure maximum quality and adaptability — turning complex manufacturing challenges into competitive advantages.