Integrated IoT-Based Design and Manufacturing of Smart Energy Meters for Intelligent Grid Infrastructure

Abstract Although the recent advances in the development of smart metering technologies, it is still considered as a restricted devices regarding to their power consumption, increasing delays, Storage and processing overhead. For the other hand, the additional demands to perform reliable data transfer, and risk of data breaches. As a consequence, an integrated IoT-based design and manufacturing approach is considered as feasible and optimal solution. This paper introduces a novel metering system called GEMS—A Grid-Enabled Metering System for Sustainable Solutions in Intelligent Energy. The proposed metering system is an integrated IoT-based design and manufacturing approach for developing a low-cost, microcontroller-driven smart electricity meter centered on the ATmega32 microcontroller. By utilizing high-accuracy sensors and the microcontroller’s built-in 10-bit analog-to-digital converter, the suggested system allows for accurate, real-time monitoring of three crucial electrical parameters: voltage, current, and power. Data acquisition and component communication are efficiently managed through standardized serial protocols, including SPI and TWI (I²C), ensuring system modularity, scalability, and ease of integration with external modules. This integration enhances user interaction, supports data-driven energy consumption decisions, and lays a robust foundation for scalable deployment within intelligent grid infrastructures. The experimental results and lab testing in voltage/current sensing, zero-crossing detection confirming measurement accuracy with <3% error margin.