IOLITE - Data Acquisition and Real-time Control System

Data acquisition and real-time control front-end system with dual EtherCAT buses for industrial testing applications. All-in-one solution for real-time control and feedback monitoring. Watch the IOLITE presentation video.

Strain / Stress
Strain / Stress
Quarter Bridge
Quarter Bridge
Half Bridge
Half Bridge
Full Bridge
Full Bridge
Digital IO
Digital IO
DSI compatible
DSI compatible
TEDS compatible
TEDS compatible
-10°C to +50°C
-10°C to +50°C

Main Features

  • DUAL ETHERCAT BUS: IOLITE is equipped with two EtherCAT buses in parallel. The primary bus is used for full speed buffered data acquisition to a PC computer hard-drive. The secondary bus is mainly used for the real-time low-latency data feed to any 3rd party EtherCAT based control system.
  • GREAT SIGNAL CONDITIONING: IOLITE features high-quality analog amplifiers that offer excellent signal quality and up to 20 kHz sampling rate. 
  • REDUNDANT POWER SUPPLY: Integrated redundant power supply provides maximum system reliability. 
  • MULTIPLE CHASSIS OPTION: IOLITE I/O modules can be configured as a 19-inch cabinet compatible aluminum chassis or in rugged aluminum SIRIUS-like compatible chassis for field-use. 
  • GREAT PRICE/PERFORMANCE: IOLITE offers great price/performance ratio and is suitable for test bed integration and various industrial applications.
  • SOFTWARE INCLUDED WITH FREE LIFETIME UPGRADES: Easy to use, yet very robust in functionality, award-winning Dewesoft X data acquisition software is included. The software comes with lifetime free upgrades and no hidden costs, bringing you intuitive configuration, smart sensors, advanced storage, and analysis capabilities.


Redundant EtherCAT Bus Systems

Each IOLITE data acquisition system is equipped with two fully independent EtherCAT bus systems that work in parallel. 

The Primary Bus

The primary bus is used for perfectly timed and synchronized data acquisition via Dewesoft X data acquisition software. The IOLITE connects via any EtherCAT RJ45 cable to the PC running Dewesoft X DAQ software and streams any number of input and output channels in high-speed to the PC's the hard drive. 

The Secondary Bus

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

  1. Low latency front-end interface for any 3rd party EtherCAT compatible real-time controllers
  2. Redundant data acquisition system bus for critical DAQ applications

Perfect Signal Conditioning

IOLITE offers great signal conditioning. With its range of input and output slots, you can measure voltage, current, strain, stress, vibration, sound, temperature, digital, counters and so much more.

Proven high-quality data acquisition hardware combined with award-winning Dewesoft X data acquisition software performs data collection without losing even a single sample. It also provides great data visualization and processing capabilities.

Data can be stored in a time-series database, and served to SCADA systems using standard interfaces such as OPC UA or XCP to truly support Industry 4.0 applications.

Off-the-shelf Dewesoft X data acquisition software with a series of supported industry-standard interfaces makes IOLITE the perfect choice for even the most price-sensitive measurement and control tasks.

Merging Data Acquisition and Real-time Control

Until the IOLITE, the worlds of data acquisition and control were completely disconnected. Controller / PLC systems are dedicated to reacting to events as fast as possible, and recording data is a secondary concern. On the other hand, the data acquisition systems are made to acquire data as fast as possible, and doing real-time control is secondary or simply unavailable in many of them.

Very often test benches require both precise signal conditioning and processing, and real-time control. In the past, DAQ and PLCs were often connected by using analog connection - one cable for each signal.

This is where the IOLITE system shines with its dual independent EtherCAT buses. There is only one EtherCAT line between the PLC and DAQ. 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.

The Endless Possibilities

IOLITE - a perfect solution for your data acquisition and control applications. And this is just the start.

With its outputs, the IOLITE data acquisition and control system totally eliminates the need for the PLC hardware! Any PLC software can fully control the outputs of IOLITE.

Only your preferred EtherCAT based real-time controller software is needed, and the IOLITE system can drive the actuators.

There is no longer a need for two systems, one system can perform everything - Dewesoft IOLITE.

IOLITE Input and Output DAQ Modules

IOLITEs chassis can be configured with 12 IOLITE slots (IOLITEr) or 8 IOLITE slots (IOLITEs) each featuring high-quality input and output amplifiers. Currently, the following amplifiers are available:

  • 6xSTG: Universal analog and strain gage amplifiers. Compatible with Dewesoft smart interface DSI adapters for expansion to Thermocouple, RTD, LVDT, current, and IEPE measurements.
  • 8xLV: Isolated 8-channel low voltage module. This module is a perfect choice for a general-purpose voltage input data acquisition module due to high accuracy and high channel-to-channel and channel-to-ground isolation.
  • 8xTH: Isolated universal thermocouple amplifier. Supports any thermocouple type sensors.
  • 8xRTD: Isolated universal PTx temperature, resistance, and voltage.
  • 32xDI: 32 channel digital input module.
  • 32xDO: 32 channel digital output module with the watchdog functionality.
  • 8xDI 4xDO: 8 digital input and 4 digital output channels.
  • 4xCNT: 4 channel digital counter input with SuperCounter® technology.

All IOLITE DAQ modules are equipped with two independent EtherCAT buses in parallel for both DAQ and real-time control. All DAQ modules can be mounted either in IOLITEr or IOLITEs chassis.

See the tech specs page for the full technical specifications of the IOLITE DAQ modules.

6xSTG - Universal Strain Gage Amplifier

Six-channel universal differential analog with 20 kS/sec per channel sampling rate. This module can acquire:

  • Analog voltage up to 50 V
  • Full, half and quarter bridge strain gage channels
  • Potentiometer
  • IEPE, Thermocouple, RTD, Current and LVDT channels (using DSI adapters)

It also features channel independent programmable power supply to power sensors.

8xLV - Isolated Low Voltage Module

Isolated 8-channel low voltage module. IOLITEi-8xLV is the perfect choice for a general-purpose voltage input data acquisition due to high accuracy and high channel-to-channel and channel-to-ground galvanic isolation.

Main highlights of IOLITE-8xLV DAQ module:

  • Two input ranges: ±100 V and ±10 V. Optionally it is also available with the input ranges of ±10 V and ±1 V.
  • Data is acquired simultaneously from all 8 channels with a sampling rate of up to 20 kS/sec.
  • It includes analog anti-aliasing filter with 26 kHz cut-off frequency (3rd order, Butterworth).
  • There are two different input connector types available: BNC or Terminal block.

8xTH - Universal Thermocouple Module

Isolated universal thermocouple module can acquire data from any kind of thermocouple type - Type K, J, T, R, S, N, E, C, U, B.

It offers software sensor break detection as well as using a hardware LED indicator.

8xRTD - Universal Resistance Thermometer (PTx) Module

8 isolated universal PTx temperature, resistance, and voltage input channels for PT-types

  • PT100,
  • PT200,
  • PT500,
  • PT1000,
  • PT2000

It offers software sensor break detection as well as using hardware LED indicator.

32xDI - Digital Input Module

Digital input module with screw terminal and power supply is perfect for high channel count  data acquisition and control applications.

32xDO - Digital Output Module

Digital output module with screw terminal and power supply is great for control application with feedback monitoring. The module also includes watchdog function.

Digital Input/Output DAQ Module

IOLITE-8xDI-4xDO is a perfect digital input/output combo module for industrial applications.

The module offers 8 digital input and 4 digital output channels. Digital IN and OUT banks are isolated from each other and can be powered by separate external power supplies.

Additionally, non-isolated supply voltage with a current limit 2 A can be used from PWR OUT pins.

The input connector of IOLITE-8xDI-4xDO is a terminal block OMNIMATE Signal SL Series.

IOLITE-8xDI-4xDO is your choice for more demanding industrial applications such as valve control, with a maximum sink current 0.5 A and maximum switching voltage 50 V.

4 Channel SuperCounter DAQ Module

IOLITE-4xCNT is a 4-channel counter module.

Each channel is capable of 3x digital inputs, 1x event counter, encoder, period, pulse-width, duty-cycle, and precise frequency and angle measurement using patented SuperCounter® technology

Supported counter modes are counting, waveform timing, encoder, and gear-tooth sensor.

Additionally, IOLITE-4xCNT also offers a sensor supply (+5 V/100 mA, +12 V/50 mA).

The input connector of IOLITE-4xCNT is a Lemo 1B 7-pin (EEG.1B.307.CLNY) or optionally terminal block input connector (OMNIMATE Signal SL Series SL 2.50/09/90G).

Counter inputs are a perfect choice for applications like balancing, order tracking, and torsional vibrations.

Redundant Power Supply

Every IOLITE data acquisition system is equipped with a redundant power supply completing the feature set for the ideal and reliable front-end system. 

If the primary power supply fails, the system will be powered by a secondary power supply without any interruption or system shutdown/restart.

Feedback Monitoring

What is really amazing is that IOLITE DAQ system gives the operator the capability to acquire and monitor the data in daily operation as well as while tuning the control systems.

Apart from monitoring the input channels on the data acquisition bus, the system can also monitor the outputs from the controller. Let's say we regulate the switch-off valve by monitoring the pressure. DEWESoft can show the pressure signal as well as digital output signal coming from the controller, all fully synchronized.

This allows the operator to prove that the control system is operating correctly every time.

IOLITEr - 19-inch Rack Cabinet Mount Chassis

Standard IOLITE aluminum chassis is compatible and can be mounted in any 19-inch rack cabinet. This is perfect for the test-bed installations.

The IOLITEr chassis height is 4U and can host up to 12 IOLITE I/O modules.


IOLITEs - Rugged Boxed Chassis

In addition to 19-inch rack cabinet compatible chassis, the IOLITE DAQ system is also available in standalone rugged aluminum chassis compatible with SIRIUS data acquisition instruments. 

The IOLITEs chassis provides 8 slots for IOLITE input and output slices to be installed.

Real-life Example - Durability Tests

Let’s look at a real-life example for IOLITE use.

Automotive durability test benches require hundreds of input channels for very precise data acquisition. They need to record force, torque, linear or angular motion, and more - and everything must be acquired with high precision and fast sample rates. 

Typically, the data acquisition devices are connected to PLCs which control the tests via analog outputs. So each analog output from signal conditioning is connected to inputs of PLC. Hundreds of signals … hundreds of cables … long set-up times and lots of work to connect everything.

But with IOLITE, only a single Ethernet digital interface is required to capture all of this data in real-time and then perform actions via IOLITE analog, digital or CAN outputs.

As a final touch, Dewesoft software monitors the performance of the controller, making sure that the controller and actuators are working flawlessly.

IOLITE is perfect for Industry 4.0 automation, automotive test benches, aerospace component testing, structural monitoring and alarming - just to name a few applications.

We are very happy that this dual bus technology is recognized and used already in the testing of the most advanced systems in the world, including testing a new engine for the most powerful European rocket ever built.

Data Acquisition Software Included for Free

All Dewesoft data acquisition systems are bundled with award-winning Dewesoft X Professional DAQ software. Dewesoft X is the world's most advanced and easy-to-use data acquisition and analysis software. Dewesoft X's flexibility and power will help you unleash the DAQ system to its full potentials and gives you many advantages over other DAQ systems. Functionalities like plug-and-play, hardware auto-detection, smart TEDS sensors, advanced storing and data analysis features will take your measurement and analysis needs to a whole new level.


Plug and Play

Connecting the DAQ system and sensors could not be faster or easier. DEWESoft X will automatically detect the connected DAQ systems and TEDS equipped sensors and will configure the entire channel configuration for you. Features like:

  • hardware auto-detection,
  • smart sensors,
  • sensor database,
  • advanced TEDS support,
  • automatic unit conversion,
  • real-time signal preview,
  • store setup files

will make you ready for measurement in seconds. Spend less time configuring your DAQ systems and be more productive. Time is money!

Measure and Store

Powerful storing capabilities with more than 500 MB/s sustained stream rates means you can always store data at full speed and never again worry about losing data that could compromise your tests. DEWESoft X features:

  • real-time data acquisition,
  • synchronized acquisition of analogue, counter, video, GPS, CAN bus, and many other sources,
  • advanced triggering and alarms,
  • single or multi-file storage,
  • remote and distributed network storing,
  • automated test sequences.

Even if you store gigabytes of data, our innovative data file format will ensure you can load and analyze your data as fast as a blink of an eye.

Analyse and Publish

From Vehicle Dynamics, NVH to Power analysis and much more. Forget about using several and complex software solutions just to analyze and visualize your data. DEWESoft X offers advanced data visualization, analysis, and reporting tools:

  • online and offline mathematics,
  • flexible real-time visual displays,
  • synchronized video support,
  • PDF reporting tools,
  • data export to many standard file formats,
  • unlimited FREE licenses to view and analyze stored data files.

DEWESoft X is designed with the mindset of a test engineer and offers a complete solution in a single software package that is a joy to use.

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