smart-energy-meter

Display:

Mechanical Design

• Mounted components inside a safe, insulated enclosure with dedicated areas for high-voltage and low-voltage circuitry

• Used AC-rated terminal blocks and cable strain relief to ensure secure and safe wiring

• Provided front access to the display for easy reading during operation

• Maintained physical separation between the mains sensing front-end and the low-voltage microcontroller section

• Added venting slots to prevent heat buildup around the power supply module

Sensors & Sensing

• Used a ZMPT101B AC voltage sensor to measure RMS mains voltage with proper scaling and filtering

• Integrated a current sensor (SCT-013 clamp or shunt + HLW8032/ADE7753 interface) for accurate AC current detection

• Employed an energy-metering IC (HLW8012 / ADE7753) to compute real-time parameters including:

  • RMS Voltage

  • RMS Current

  • Active Power

  • Apparent Power

  • Power Factor

  • Energy (Wh / kWh)

• Added hardware filtering networks to stabilize noisy AC waveforms and suppress high-frequency switching noise

Control System

• Powered by an Arduino/ESP32 microcontroller to read metering-IC outputs and drive the display

• Implemented continuous sampling loops to update:

  • Voltage and current

  • Real-time wattage

  • Running kWh accumulation

  • PF and frequency

• Included a TFT/OLED or 20x4 LCD for clear viewing of live electrical parameters

• Added calibration routines using known loads for improved measurement accuracy

• Optional serial or wireless telemetry for logging historical power usage

Electronics & PCB Design

• Designed a custom PCB integrating:

  • Voltage and current sensing front-end

  • Energy metering IC (HLW8012/ADE7753)

  • Microcontroller header

  • Display connector

  • Regulated low-voltage supply

• Followed creepage and clearance rules for high-voltage AC measurement circuits

• Added input protection: fuse, MOV surge protector, and filtering capacitors

• Implemented grounding strategy and filtering to isolate noisy AC sections from digital logic

• Created a compact, single-board layout that enables safe, accurate power measurement