Written by Grant Maloy Smith, the data acquisition expert

In this article we will discuss how it is possible to integrate a fully-featured data acquisition system with a real-time control system, getting the best of both worlds. At the end of this article you will:

  • See how DAQ and real-time control can work together seamlessly
  • Learn more about the IOLITE and RT series systems from Dewesoft
  • Understand the benefits of combining DAQ with real-time control

Are you ready to get started? Let’s go!

Introduction Into Data Acquisition and Real-Time Control

Until recently, there were two types of separate systems:

  • Real-time Control systems - designed to react to events as fast as possible and with highly deterministic data. Recording high speed data was a secondary concern. 
  • Data acquisition systems (DAQ systems) - designed to acquire data as fast as possible. Providing real-time data to a control system was largely or completely unavailable.

Now, we have entered a new era, where both systems can be merged together. These systems provide the best of both worlds. A highly deterministic data for control purposes and high-speed and high accuracy data for detailed online or offline analysis.

Both are achieved using the same front end with inputs and outputs used for both purposes. 

This greatly reduces the complexity and the price of the whole system since there is no longer a need for installing two sensors going to two different input channels while acquiring the same data in the same place. It also introduces a much simpler configuration, since the input channels only need to be configured once to serve both parts of the system.

For Dewesoft’s DAQ and control systems these features come included by default. There is no longer a case where data is shared over analog lines. Our systems include a dedicated EtherCAT bus for direct connection to the real-time control system. EtherCAT connection replaces dozens of analog cables with a single digital one, eliminating the redundant analog-to-digital conversion of the signals and at the same time taking noise and interference out of the equation.

The use of od EtherCAT technology in data acquisition and test bench controller has removed the need for an additional analog input stage at the controller side

The use of EtherCAT technology in data acquisition and test bench controller has removed the need for an additional analog input stage at the controller side

Data Acquisition and Real-Time Control Applications

Here are some of the real-world applications where data acquisition and real-time control are tightly integrated:

  • Vehicle structural durability testbench testing (Road load data simulation)
  • Rocket engine testing
  • Factory automation / PLC networks
  • Motion Control and Machine control platforms
  • Robotics research and development
  • Material and baggage handling systems
  • Weighing Systems
  • Semiconductor manufacturing
  • Metals manufacturing (e.g., steel, aluminum mills)
  • Pulp & Paper manufacturing
  • Power plants
  • Wind turbines
  • Milling machines
  • Wind-Tunnel control systems
  • And hundreds more

Dewesoft Data Acquisition and Control Solutions

Dewesoft recently introduced a game-changing step forward in bringing the worlds of data acquisition and control closer. Data acquisition systems are equipped with two data buses that run in parallel.

The primary data bus (EtherCAT or USB) is used for full-speed buffered data acquisition to a computer’s hard drive. The secondary data bus (always EtherCAT) is used for the real-time low-latency data feed to any third-party EtherCAT-based control system.

This is a huge step in bridging the worlds of high-speed data acquisition and streaming low-latency data to a PLC controller. But the Dewesoft systems go even farther. While most data acquisition systems focus 100% on handling a variety of analog input types, Dewesoft DAQs add multi-channel digital and analog outputs, so that they can directly drive actuators.

With these digital and analog outputs, Dewesoft DAQ systems can eliminate the need for PLC hardware. The EtherCAT master be implemented in the software on a computer. This master can fully control the outputs of the data acquisition system. 

Amazingly, there is only one EtherCAT line between the PLC and DAQ established by connecting a single cable. This greatly reduces cabling and eliminates redundant analog-to-digital conversion of the same signals. Finally, the different worlds of control and data acquisition are combined in one elegant system.

This secondary EtherCAT data bus on Dewesoft DAQ systems can therfor be used in two ways:

  • As a low-latency front-end interface for any third-party EtherCAT real-time controller.
  • Redundant data acquisition system bus for critical DAQ applications.

Dewesoft provides two product families that implement dual bus technology for integration into real-time controllers:

  • IOLITE DAQ systems: IOLITE systems feature dual EtherCAT buses, one dedicated for high-speed buffered data acquisition and the other for real-time feed to controllers.
  • SIRIUS RT DAQ systems: the RT systems feature a data bus that is used for very high-speed buffered acquisition (up to 1MS/s) and a dedicated EtherCAT control bus for the real-time data feed.

Both IOLITE and SIRIUS RT DAQ systems like the R2rt, R4rt, and R8rt are designed for control and data acquisition applications. All IOLITE and SIRIUS RT systems replace unnecessary equipment and simplify configuration and workflows.

In order to understand how seamlessly these models work within an EtherCAT system, we have to know what EtherCAT is and how it works.

What Is EtherCAT?

EtherCAT stands for “Ethernet for Control Automation Technology.” It’s a protocol that brings the power and flexibility of Ethernet to the world of industrial automation, motion control, real-time control systems, and DAQ systems. 

EtherCAT logo

You might be wondering why we can’t simply use Ethernet to interconnect DAQ and control systems? Ethernet is fast. It’s inexpensive. And it’s easy to implement in today’s computer-based instruments. So what is missing? 

The answer lies mostly in determinism or TIME ACCURACY

Factory automation control systems are by definition Real-time systems. Motion control, robotics, factory automation, safety protocols - all of these things require very low latency. 

Unfortunately, in a conventional Ethernet network, this isn’t possible. All data is essentially “equal.” This works fine with your office computers sharing network bandwidth to access servers and printers, but not so well with real-time applications.

Typical industrial PLC control systemTypical Industrial control system
Image by Bruno /Germany from Pixabay

EtherCAT Time-Stamped Data

One of the most important aspects of EtherCAT is the distributed clock. Each node timestamps the data when it is received, and then stamps it again when it sends it on to the next node. So when the master receives back the data from the nodes, it can easily determine the latency of each node. Every data transmission from the master gets an I/O time-stamp from every node, making EtherCAT far more deterministic and accurate on the T axis than Ethernet can be.

EtherCAT network with ring topologyEtherCAT network with ring topology

Even before the EtherCAT goes to work, however, the master sends out a broadcast to all of the slave nodes on the network, who latch it when they receive it and when they send it back. The master will automatically do this as many times as necessary to reduce jitter and keep the slave nodes synchronized with each other. 

This timing accuracy is extremely important in real-time control and factory automation applications. It further allows DAQ systems such as the ones available from Dewesoft to be integrated so easily into control systems.

EtherCAT’s built-in distributed clock provides excellent “jitter” performance far smaller than one microsecond (1 µs), which is equivalent to IEEE 1588 PTP (Precision Time Protocol), without the need for any additional hardware.

Connecting a DAQ System to a Real-Time Controller

Over the years, engineers have turned to high-end data acquisition systems when the acquisition devices available for their real-time systems were not fast or accurate enough to sample an object under test. But the problem was always the same. Data acquisition systems were simply not made to connect to a PLC controller.

But engineers still found ways to do it. In general, we know three different phases of integrating DAQ systems with a real-time control system. Let’s look at each one in more detail.

Phase 1 Integration With a Real-Time Control System 

In so-called Phase 1 engineer used data acquisition systems as a front-end, feeding their analog outputs into analog inputs on their network. This is referred to as a Phase 1 integration of a DAQ system with a real-time control system.

Phase 1 integration of a DAQ system and a real-time control systemPhase 1 integration of a DAQ system and a real-time control system

This was cumbersome, and resulted in data being converted from analog to digital twice. Not a very efficient approach that resulted in a lot of cabling, configuration, and also big cost.

Phase 2 Integration With a Real-Time Control System 

Later, some DAQ systems were designed with the ability to output data to the PLC digitally, via Ethernet. This was a step forward, but still not deterministic. In other words, the time accuracy was sufficient for data archiving or as a reference, but not for real-time control.

Phase 2 integration of DAQ with Real-time Control system using ethernetPhase 2 integration of DAQ with Real-time Control system using Ethernet

However, it did eliminate redundant A/D and D/A processes, so it can be referred to as a Phase 2 integration of a DAQ system with a real-time control system.

Phase 3 Integration With a Real-Time Control System 

So how can we get to a phase 3 integration, where the DAQ system has a deterministic integration with the real-time control system?

In fact, the DAQ system needs to become part of the network, not just an asynchronous peripheral. Instruments using EtherCAT are divided into two groups: 

  • Control systems and
  • Measurement systems. 

Control devices such as PLCs are masters on the EtherCAT network, whereas measurement devices like data acquisition systems are slaves.

By installing an EtherCAT slave port into their DAQ systems, Dewesoft eliminates the limitations of Phase 1 and Phase 2 integrations, and brings the DAQ system directly into the real-time control system:

Dewesoft DAQ system sending real-time data via EtherCATDewesoft DAQ system sending real-time data via EtherCAT

This truly is a Phase 3 implementation, because the DAQ system is a true slave node on the EtherCAT network, sending time-stamped (deterministic) data at the direction of the host. There is no more redundant A/D conversion or non-deterministic Ethernet data.

Problem solved? Yes, but this is actually just the beginning. Dewesoft DAQ systems like the SIRIUS RT and IOLITE models can also stream much higher speed data in parallel via USB (or Ethernet) to a secondary computer.

There are applications where it is desired that the DAQ system should provide BOTH the deterministic data requested by the EtherCAT master AND high-speed data to a second computer for high-end analysis. 

This is exactly what Dewesoft RT systems provide in the real-world example below.

Real-World Application: Implementation of Dewesoft R8rt Systems With an MTS Real-Time Master

Implementation of Dewesoft R8rt systems with an MTS real-time MasterImplementation of Dewesoft R8rt systems with an MTS Flextest Real-Time Master 

In the system shown above, R8rt DAQ systems are used with an MTS road simulator test bench for testing the durability of car and truck suspension systems. It consists of four corners, each having 6 degrees of freedom. Over a hundred analog input and output channels were used by the MTS FlexTest controller for actuator control.

There are two master computers used: 

  • The MTS real-time master using EtherCAT to control the road simulator in real-time. The Dewesoft R8rt DAQ slaves provided deterministic measurement data from the accelerometers to the test-bench controller via EtherCAT.
  • The Dewesoft master, recording the streams of higher speed data from the Dewesoft R8rt for advanced post-mission analysis.

It is interesting to note that the Dewesoft RT models can provide extremely high-speed data via USB in parallel with the deterministic data across EtherCAT at the usually lower speeds requested by the EtherCAT master. 

It is also possible to send the high-speed data across Ethernet to a master PC running DewesoftX NET add-on when USB is not practical due to distance. In this case, the data can also be safely stored on the Dewesoft hardware to guard against network data interruptions.

Just one of the four corners where the test car will be mounted, rigged with accelerometersJust one of the four corners where the test car will be mounted, rigged with accelerometers

An additional 96 channels were used for measuring the response of the specimen to correlate the loads on the test bench to the real road load data. Signals from those channels were acquired by two Dewesoft R8rt data acquisition systems. Each of the R8rt systems includes 6 SIRIUS strain gauge amplifier slices and streamed over EtherCAT to the MTS FlexTest controller.

But the Dewesoft systems were not only used to test vehicles on the road load simulator! They were also used as the fully-featured DAQ systems that were installed in the car and collected the raw data on the test track in the first place! 

The fact that they serve this double duty is a huge money saver for the customer, both in terms of eliminating the need to buy two separate systems, but also in the savings of user training, configuration management, and spares.

And by sending data digitally instead of by analog cables, the customer could eliminate kilometers of analog cables. 

The actual amount of cabling that the customer eliminated after installing the Dewesoft RT solutionThe actual amount of cabling that the customer eliminated after installing the Dewesoft RT solution

Dewesoft logo

Read full Dewesoft case studies on data acquisition and control integration:

Road load data logger and signal conditioner for MTS test bench

ESA’s Ariane rocket booster test

Arianne V rocket engine test

Software EtherCAT Masters

It is possible to connect Dewesoft DAQ and Control systems to a computer host running a 3rd party real-time PLC software. Dewesoft DAQ and control system are currently compatible with the following 3rd party masters:

Furthermore, Dewesoft systems can even drive the actuators, providing the real-time hardware control needed for the system.

IOLITE can serve as the hardware backbone of a Control/DAQ system via EtherCATIOLITE can serve as the hardware backbone of a Control/DAQ system via EtherCAT

Channel Expansion via EtherCAT Master Port

IOLITE has dual redundant EtherCAT ports, meaning that it can also receive synchronized data from other EtherCAT-equipped DAQ systems, like the SIRIUS EtherCAT and KRYPTON models.

Channel expansion via additional EtherCAT equipped DAQ systemsChannel expansion via additional EtherCAT equipped DAQ systems

Dewesoft Data Acquisition and Control Systems

Dewesoft provides two product families that implement dual bus technology for integration into real-time controllers:

  • IOLITE industrial data acquisition and control systems with dual, redundant EtherCAT buses.
  • SIRIUS RT high-end signal conditioning data acquisition systems feature a USB data bus that is used for very high-speed buffered acquisition (up to 1MS/s) and a dedicated EtherCAT control bus for the real-time data feed.
  • KRYPTON rugged IP67 distributed DAQ modules compatible with 3rd party EtherCAT masters.

IOLITE Rack DAQ and Control Systems

IOLITE is a data acquisition and real-time control system for industrial applications. They can provide both real-time control and feedback monitoring systems. IOLITE systems are equipped with two fully independent EtherCAT busses that run in parallel.

IOLITE has dual EtherCAT busses, plus sync I/O for connecting expansion DAQ devices like SIRIUS and KRYPTON
IOLITE has dual EtherCAT busses, plus sync I/O for connecting expansion DAQ devices like SIRIUS and KRYPTON

The primary EtherCAT bus provides perfectly synchronized and full-speed data acquisition via DewesoftX software. IOLITE can stream any number of input and output channels at high speeds to the computer's internal hard drive.

IOLITE's secondary EtherCAT bus can be used in two ways: 

  • A low-latency front-end interface for any third party EtherCAT compatible real-time controller
  • A redundant data acquisition system bus for critical DAQ applications

To summarize, IOLITE is unique among DAQ systems in that it can be used both for high-speed DAQ and real-time control via either a hardware or software real-time PLC.


IOLITE data acquisition and control systems introduction video

The IOLITE systems are available in two chassis configurations:

  • IOLITE R12 is a 19-inch rack-mounting system with 12 slots for multi-channel input modules. Using 8 channel modules you can achieve up to 96 channels per chassis.
  • IOLITE R8 is a desk-top system with 8 slots for multi-channel input modules. Using 8 channel modules you can achieve up to 64 channels per chassis.

IOLITE rack data acquisition and control system (IOLITE R8 and IOLITE R12)Left: IOLITE R8 benchtop system
Right: IOLITE R12 rack-mounting DAQ system

IOLITE I/O Modules

These multi-channel modules are available for the IOLITE system and are compatible with both IOLITE R8 and IOLITE R12 chassis:

Module Type Channels ADC Isolation Note
IOLITEr-6xSTG Universal and strain gage input 6 24-bit delta-sigma ADC @ 20 kS/s Differential Compatible with all DSI adapters for multiple sensor types
IOLITEir-8xTH Universal thermocouple input 8 24-bit delta-sigma ADC @ 100 S/s 1000 V Supports K, J, T, R, S, N, E, C, U, B types
IOLITEir-8xRTD Universal PTx temperature, resistance, and voltage input 8 24-bit delta-sigma ADC @ 100 S/s 1000 V Supports PT100, PT200, PT500, PT1000, PT2000
IOLITEir-8xLV Isolated low voltage inputs 8 24-bit oversampled SAR ADC @ 20 kS/s 450 V Ranges: ±100 V, ±10 V
IOLITEr-16xLV General-purpose voltage module 16 24-bit delta-sigma ADC @ 20 kS/s / Ranges: ±200 V, ±10 V
IOLITEir-8xLA Current input module 8 24-bit oversampled SAR ADC @ 20 kS/s 450 V Ranges: ±20 mA, ±2 mA
IOLITE-16xAO Analog output module 16 / / Output voltage ±10 V
IOLITEr-32xDI Digital input module 32 20 kS/s 1000 V  
IOLITEr-32xDO Digital output module 32 / 1000 V Maximum switching voltage 50 V
IOLITEr-8xDI-4xDO Digital Input and Output Module 8 input
4 output
40 kS/s 1000 V  
IOLITEr-4xCNT Digital Counter Module 4 Timebase 100 Mhz ±25 V continuous Bandwidth 10 MHz

SIRIUS RT Data Acquisition Systems

SIRIUS is the flagship of the Dewesoft product line. They combine state-of-the-art data acquisition technology with unmatched signal conditioning and A/D conversion. SIRIUS modules are available to handle virtually all signals and sensors, from strain gages to low and high voltages, thermocouples, RTDs, charge and IEPE accelerometers, microphones, current, LVDTs, counters and encoders, and many more. 

Patented DualCoreADC® technology provides a dynamic range up to a remarkable 160 dB. Connects to your computer via USB or EtherCAT®. Adding the ruggedized SBOX computer provides a local host with removable storage, a display interface, and more.

Dewesoft’s SIRIUS RT systems are equipped with so-called DualMode functionality. DualMode means that they can simultaneously stream data at the highest possible rates (up to 1 MS/s) into the computer (either integrated or external via USB) running DewesoftX software and in parallel stream data across EtherCAT at reduced rates with extremely low latency.

Dewesoft RT systems come in several chassis variations: 

  • R2rt
  • R2rt-HUB
  • R4rt
  • R4rt-HUB
  • R8rt
  • R8Rrt
  • SIRIUS EtherCAT modular

Even the SIRIUS EtherCAT modular slices can be used with DualMode functionality by adding the SBOX computer. SBOX not only provides a built-in ruggedized computer with SSD storage to a single or stack of SIRIUS modular slices, but it also provides dual EtherCAT ports.

SIRIUS R2rt and R2rt-HUB

The SIRIUS R2rt is a compact data acquisition system with a built-in data logger and powerful data processing computer called SBOX. The R2rt systems can be configured with up to two SIRIUS amplifier slices, for either:

  • 16 DualCoreADC input channels
  • 16 HS (high-speed) channels
  • 32 HD (high-density) channels

SIRIUS R2rt DAQ and control systmR2rt DAQ and control system with integrated SBOX computer

The R2rt-HUB system offers the same chassis for 2 amplifier slices, but replaces the integrated SBOX computer with a USB hub for a connection to an external PC computer via USB. 

SIRIUS R4rt and R4rt-HUB

The SIRIUS R4rt is a compact data acquisition system with a built-in data logger and powerful data processing computer. It can be configured with up to four SIRIUS slices, for either:

  • 32 DualCoreADC channels
  • 32 HS (high speed) channels
  • 64 HD (high density) channels. 

The R4rt benchtop DAQ systemThe R4rt benchtop DAQ system

The 42rt-HUB system offers the same chassis for 4 amplifier slices, but replaces the integrated SBOX computer with a USB hub for a connection to an external PC computer via USB. 

SIRIUS R8rt and R8Rrt

The SIRIUS R8rt and R8Rrt are powerful benchtop data acquisition systems with a built-in data logger and powerful data processing computer. The R8rt chassis offers maximum channel count configurations in single compact chassis.

SIRIUS R8rt data acquisition and control systems
SIRIUS R8rt data acquisition and control systems offer the highest channel count in a single box chassis

SIRIUS R8rt systems can be configured with up to eight SIRIUS amplifiers slices, for either:

  • 64 DualCoreADC channels
  • 64 HS (high speed) channels
  • 128 HD (high density) channels

The R8Rrt chassis is additionally upgraded to withstand high shocks and 3 gRMS random vibrations for 10 minutes in each direction.

SIRIUS EtherCAT Modular DAQ Systems

SIRIUS modular DAQ systems offer both high-speed USB and EtherCAT outputs. They can provide the data to the EtherCAT master and in parallel, record much higher speed data to a separate computer running DewesoftX data acquisition software. 

SIRIUS system running fault-tolerant dual-mode data to an EtherCAT master and to a computer hostSIRIUS system running fault-tolerant dual-mode data to an EtherCAT master and to a computer host

SIRIUS can also be connected to the IOLITE or SIRIUS RT systems, for channel expansion. The DualMode operation allows serving data to the EtherCAT master and to a separate computer running DewesoftX software. This runs in parallel and is also fault-tolerant. If the computer with Windows operating system running DewesoftX were to completely fail, SIRIUS would continue sending data to EtherCAT master via the secondary EtherCAT data bus.

SIRIUS Amplifier Modules

Module Type Channels ADC Isolation Available connectors
DualCoreADC Amplifiers
ACC IEPE and voltage input 8 Dual 24-bit delta-sigma anti-aliasing filter @ 200 KS/s 1000 V BNC, TNC
CHG Charge, IEPE, and voltage input 8 Dual 24-bit delta-sigma anti-aliasing filter @ 200 KS/s 1000 V BNC, TNC
STG Universal and strain input 8 Dual 24-bit delta-sigma anti-aliasing filter @ 200 KS/s 1000 V DSUB-9, L2B7f, L2B10f
STGM Universal and strain input 8 Dual 24-bit delta-sigma anti-aliasing filter @ 200 KS/s 1000 V DSUB-9, L2B7f, L2B10f
LV General low voltage input 8 Dual 24-bit delta-sigma anti-aliasing filter @ 200 KS/s 1000 V DSUB-9, BNC, BANANA
HV High-voltage input 8 Dual 24-bit delta-sigma anti-aliasing filter @ 200 KS/s CAT II 1000 V BANANA
High-Density Amplifiers
HD-ACC IEPE and voltage input 16 24-bit delta-sigma with anti-aliasing filter @ 200 KS/s 1000 V BNC
HD-STGS Universal and strain input 16 24-bit delta-sigma with anti-aliasing filter @ 200 KS/s 1000 V DSUB-9, L1B10f
HD-LV General low voltage input 16 24-bit delta-sigma with anti-aliasing filter @ 200 KS/s 1000 V DSUB-9, BNC
High-Speed Amplifiers
HS-ACC IEPE and voltage input 8 16-bit SAR @ 1 MS/s 1000 V BNC
HS-CHG Charge, IEPE, and voltage input 8 16-bit SAR @ 1 MS/s 1000 V BNC, TNC
HS-STG Universal and strain input 8 16-bit SAR @ 1 MS/s 1000 V DSUB-9
HS-LV General low voltage input 8 16-bit SAR @ 1 MS/s 1000 V DSUB-9, BNC, BANANA
HS-HV High-voltage input 8 16-bit SAR @ 1 MS/s CAT II 1000 V BANANA

KRYPTON EtherCAT DAQ Modules for Harsh Environments

KRYPTON EtherCAT rugged DAQ modulesKRYPTON modules for harsh environments

Most DAQ hardware on the market is designed for office or light industrial use. But there are applications where the DAQ equipment must be located in harsh environments. For example:

  • High temperatures up to 85°C (185° F)
  • Cryogenic temperatures down to -40° C/F
  • High shock and vibration up to 100 g
  • Water spray or immersion
  • High dust concentration

Most DAQ instruments are not designed to withstand even one or two of those extreme environmental conditions. Based on these requirements, Dewesoft developed the KRYPTON series of DAQ instruments.

KRYPTON systems meet IP67 standards for water and dust, meaning that they can withstand not only water spray but total immersion in 1 meter (39 inches) of water for 30 minutes. They are completely sealed against dust and other small particles.

Being filled with a thermally insulating rubber, KRYPTON modules can withstand a wide range of temperatures from -40° to 85° C (-40° to 185° F). KRYPTON modules are found in hot and cold weather automotive tests, on rocket engine test stands, and in factories where ice cream and another cold (or hot) foods are made. 

KRYPTON modules are also designed to handle 100g shock and high vibration environments. This can be a serious requirement in many applications where large vibrating machinery is found, or testing rockets and other large force-producing machines.

KRYPTON shock testing in the labKRYPTON module undergoing a high g shock test in a testing laboratory

KRYPTON modules are interconnected via a single rugged EtherCAT cable that carries data, power, and synchronization. The cables can be up to 100 m (328 feet) long so that engineers can distribute the modules where the signals are. This might be across a bridge or a large factory floor.

Distributed KRYPTON modules interconnect via EtherCATDistributed KRYPTON modules interconnect via EtherCAT

Many modules can be connected this way. KRYPTON is available in multi-channel modules as well as single-channel KRYPTON ONE modules for the ultimate flexibility.

KRYPTON Multi-Channel DAQ Modules

These multi-channel modules are available for the KRYPTON system:

Module Type Channels ADC Isolation Note
STG Universal and strain gage input 3 and 6 24-bit oversampled SAR @ 20 kS/s Differential Compatible with all DSI adapters for multiple sensor types
TH Universal thermocouple input 8 and 16 24-bit delta-sigma ADC @ 100 S/s 1000 V Supports K, J, T, R, S, N, E, C, U, B types
RTD Universal PTx temperature, resistance, and voltage input 8 24-bit delta-sigma ADC @ 100 S/s 1000 V Supports PT100, PT200, PT500, PT1000, PT2000
ACC Voltage and IEPE piezoelectric input 4 and 8 24-bit 24-bit delta-sigma with anti-aliasing filter @ 20 kS/s / Supports TEDS sensors
LV General-purpose voltage module 4 and 8 24-bit oversampled SAR @ 20 kS/s 1000 V ±50 V and DC coupling
LA Current input module 8 24-bit oversampled SAR @ 20 kS/s 1000 V ±20 mA and 4-20 mA current loop
DIO Digital I/O module 8 and 16 20 kS/s 1000 V Available with either 8 ins + 8 outs, or 16 ins + 16 outs

KRYPTON Single-Channel Modules

For the ultimate in modularity, single-channel KRYPTON modules allow you to place your signal conditioners anywhere needed, right at the signal source. KRYPTON ONE modules are interconnected exactly like multi-channel KRYPTON modules and on the same EtherCAT network.

KRYPTONE ONE single channel EtherCAT modulesKRYPTON ONE single-channel modules are also rated from -40 to 85° C (-40 to 185° F)

Available single-channel KRYPTON modules:

Module Type Channels ADC Isolation Note
STG Universal and strain gage input 1 24-bit SAR with anti-aliasing filter @ 40 kS/s Differential Compatible with all DSI adapters for multiple sensor types
ACC Voltage and IEPE piezoelectric input 1 24-bit SAR with anti-aliasing filter @ 40 kS/s / Supports TEDS sensors
HV Universal thermocouple input 1 24-bit SAR with anti-aliasing filter @ 40 kS/s CAT III 600 V, CAT II 1000 V  
LV General-purpose voltage module 1 24-bit oversampled SAR @ 20 kS/s 1000 V ±50 V and DC coupling
LA Current input module 1 24-bit oversampled SAR @ 20 kS/s 1000 V ±20 mA and 4-20 mA current loop
TH-HV Universal PTx temperature, resistance, and voltage input  1 24-bit delta-sigma ADC @ 100 S/s CAT III 600 V, CAT II 1000 V  
DI Digital input module 4 40 kS/s Galvanic isolation CH, GND TTL / CMOS Voltage Levels
DO Digital output module 4 / Galvanic isolation CH, GND  
AO Analog output module 1 / / Full Scale Output Range ±10 V

EtherCAT Cables for Harsh Environments

Well, if the DAQ hardware is waterproof, dustproof, and can withstand -40° temperatures, the cables must also be able to withstand these environmental extremes, too. Otherwise, the system will fail simply because of the cables.

Accordingly, Dewesoft has developed EtherCAT cables that are used to interconnect their KRYPTON series of harsh environment DAQ systems. In the video below we show the cables being frozen to -40°C and how they maintain their flexibility.

Summary

We hope that you now understand the benefits of Dewesoft’s Phase 3 integration of DAQ systems with a real-time controller. High-speed DAQ systems such as the Dewesoft IOLITE, SIRUS RT systems, and expansion modules like KRYPTON and SIRIUS modular have completely changed the landscape for providing deterministic data to a control system. 

This final step was a big one. With Dewesoft’s unique implementation of EtherCAT into high-end DAQ technology, engineers can now realize these distinct advantages when designing their systems:

  • High performance: EtherCAT is 100 Mb/s
  • Deterministic: real-time operation with synchronization ~ 1 ns
  • Flexible: Dewesoft slave DAQs can also stream at an even higher speed to a separate host, far above the EtherCAT maximum speed
  • Affordable: direct connection of IOLITE to EtherCAT system eliminates go-between hardware. IOLITE can also eliminate hardware master controllers and connect to software PLCs.