An AI-driven framework for efficient and accurate calibration of electricity meters using extreme gradient boosting

Abstract

Calibration testing plays a vital role in electricity meter manufacturing to guarantee measurement accuracy and compliance with industry standards. In practice, however, conventional calibration methods are often hindered by lengthy test cycles and the high cost of expanding test bench capacity. This study proposes a data-driven approach to address these limitations by applying machine learning techniques to optimize calibration testing. An extreme gradient boosting (XGBoost) regression model, enhanced through systematic hyperparameter tuning and feature engineering, was developed to predict calibration outcomes using data obtained from existing production test benches. When evaluated under real manufacturing line conditions, the proposed method shortened calibration runtime by about 55% compared with manual procedures relying on power supply units (PSU) and standard meter calculations, while maintaining reliable measurement accuracy. The framework also achieved lower root mean square error (RMSE), demonstrating improved predictive performance. In addition to reporting these results, the study describes the preprocessing pipeline, model selection process, and optimization strategy, providing a practical and replicable framework for integrating artificial intelligence (AI) into industrial calibration processes.