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Flexible data acquisition for development, test benches and condition monitoring
Data acquisition – commonly referred to as DAQ (Data Acquisition) – covers the acquisition, digitization, transmission and analysis of physical measured variables. DAQ systems form the interface between sensors and analysis software: they condition analog sensor signals, convert them into digital measurement values and transmit the data to a PC or higher-level system for visualization, storage and analysis.
Althen DAQ solutions enable the acquisition of a wide range of measured variables and sensor types. Depending on the device, voltage, current, temperature, resistance, strain, vibration or acceleration can be measured, for example. In addition to multifunctional USB data acquisition devices, specialized modules are available for strain gauge, IEPE and vibration sensors as well as acceleration measurements.
For larger or spatially distributed measurement systems, EtherCAT-based DAQ modules provide a particularly flexible solution. Multiple measurement modules can be interconnected using standard network cables and installed in a decentralized configuration close to the respective sensors. This makes it possible to implement even complex measurement tasks with many or widely distributed measuring points in a clear and efficient way.
Connection to powerful measurement software enables configuration of the measurement channels as well as visualization, recording and analysis of the acquired data.
Precise, versatile and scalable measurement
Althen DAQ systems combine flexible sensor connectivity with fast data acquisition and powerful digital signal processing. This makes them suitable for both individual measuring points and extensive distributed measurement systems.
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Versatile signal acquisitionVoltage, current, temperature, strain gauge, IEPE, resistance, acceleration and other sensor signals can be acquired and digitized directly, depending on the DAQ module.
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Precise and dynamic measurementsHigh-resolution A/D converters with up to 24-bit resolution and sampling rates of up to 50 kS/s enable both precise static and dynamic measurements.
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Modular and scalableEtherCAT-based DAQ modules can be easily interconnected and installed in decentralized configurations. This allows measurement systems to be flexibly expanded and adapted to changing requirements.
What to consider when selecting a DAQ system
1. Determine the measured variable and sensor type
The first step is to determine which physical variables need to be measured. Depending on the application, different input modules are required for voltage, current, temperature, strain gauges, IEPE sensors, acceleration or other signals.
2. Consider signal type and measurement range
Sensors provide different electrical output signals. The DAQ system must therefore match the respective signal level and measurement range. In addition to voltage inputs, current, thermocouple, strain gauge or IEPE inputs may be required.
3. Determine the number of measurement channels
For individual sensors, a compact single-channel or multifunction device is often sufficient. For larger measurement tasks, modular expandable systems should be selected so that additional measurement channels and sensor types can be added.
4. Determine the required sampling rate
The required measurement speed depends strongly on the application. Temperature or long-term measurements usually require significantly lower sampling rates than vibration, acceleration or dynamic strain measurements. For dynamic applications, devices with sampling rates of up to 40 or 50 kS/s are available.
5. Consider resolution and measurement accuracy
High A/D resolution makes it possible to detect small signal changes. Depending on the DAQ system, 16-bit or 24-bit A/D converters are available. For particularly demanding measurements, input accuracy, noise performance and dynamic range should also be considered.
6. Check sensor excitation and signal conditioning
Many sensors require suitable excitation or signal conditioning. Strain gauges, for example, require bridge excitation, while IEPE sensors require constant-current excitation. Specialized DAQ modules already integrate these functions, reducing the need for additional hardware.
7. Consider galvanic isolation
In industrial measurements, potential differences and electrical interference can affect signal quality. Galvanically isolated inputs or isolated front ends help decouple the measurement system from the PC and enable low-noise measurements.
8. Choose centralized or decentralized data acquisition
For spatially distributed sensors, it is often beneficial to place the measurement modules as close as possible to the measuring points. EtherCAT-based systems enable a decentralized architecture and therefore reduce long analog sensor cables.
9. Consider networking and expandability
If the measurement system is to be expanded later, a modular system architecture is particularly advantageous. IOLITE modules, for example, can be connected in series via EtherCAT. Distances of up to 50 metres between individual devices are possible.
10. Include measurement software and data analysis
In addition to the hardware, the software plays a crucial role. The measurement software should provide easy channel configuration as well as functions for visualization, storage, analysis and data export. MonoDAQ and IOLITE devices are supported by Dewesoft for this purpose.
Our technical expert team will be happy to help you optimally match sensors, signal conditioning, DAQ hardware and software to your measurement task. Contact our sales team
Typical applications for DAQ systems
DAQ systems are used wherever sensor signals need to be precisely acquired, synchronized, stored and analyzed.
Typical applications include:
- Test benches and test systems
- Research and development
- Machine and plant monitoring
- Condition monitoring
- Vibration measurements
- Condition monitoring of bearings and machinery
- Strain and load measurements with strain gauges
- Industrial quality control
- Structural and modal testing
- Structural Health Monitoring
- Temperature and climate measurements
- Current and voltage measurements
- Energy and power analysis
- Development of electronic systems
- IoT and IIoT applications
- Long-term monitoring of machinery and structures
By combining different input modules, complex measurement tasks can also include different physical variables within one system and evaluate them together.
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Frequently asked questions about Data acquisition (DAQ)
Answers to the most important technical Questions
What does DAQ mean?
DAQ stands for Data Acquisition. It refers to the process of measuring physical quantities with sensors and subsequently digitising, transmitting, storing and analysing the measurement data.
How does a DAQ system work?
A sensor first converts a physical quantity such as strain, temperature or acceleration into an electrical signal. The DAQ system conditions this signal and digitises it using an A/D converter. The digital measurement data is then transmitted to a PC or another system, where it can be visualised, stored and analysed.
Which sensors can be connected to a DAQ system?
This depends on the specific input module. Althen data acquisition systems support measurements with strain gauges, IEPE sensors and thermocouples, as well as the acquisition of voltage, current, resistance and acceleration signals. Multifunctional DAQ systems can acquire several signal types within a single system.
What sampling rate do I need for my DAQ system?
The required sampling rate depends on how quickly the measured process changes. Slowly changing quantities such as temperature can be measured at relatively low sampling rates. Vibration, acceleration and other dynamic processes require significantly higher sampling rates. Depending on the version, the DAQ devices in this product group achieve sampling rates of up to 40 or 50 kS/s.
What does the resolution of a DAQ system mean?
The resolution of the A/D converter determines how finely the analogue input signal can be divided into digital values. A higher bit depth generally makes it possible to distinguish smaller changes in the input signal. Depending on the device, Althen DAQ systems are available with 16-bit or 24-bit A/D converters.
What are the advantages of a modular DAQ system?
A modular data acquisition system can be adapted to the specific measurement task and expanded later if required. Different modules can, for example, be combined for strain-gauge, IEPE or other sensor signals. This means that a completely new data acquisition system does not have to be built for every new measurement task.
Why is EtherCAT suitable for data acquisition?
EtherCAT enables fast digital transmission of measurement data between multiple networked devices. With IOLITE systems, several DAQ modules can be daisy-chained using standard network cables. This also makes it possible to create distributed data acquisition systems with greater distances between individual measurement points.
How far apart can the data acquisition modules be installed?
With various IOLITE devices, the data acquisition modules can be connected via EtherCAT with a distance of up to 50 metres between two devices. This allows the modules to be installed close to the respective sensors.
What are the advantages of distributed data acquisition?
In a distributed data acquisition architecture, the DAQ module is installed close to the sensor. This means the analogue sensor signal only needs to travel over a short distance, while further data transmission takes place digitally over the network. This is particularly useful for measurement systems with widely separated measurement points.
Can strain gauges be connected directly to a DAQ system?
Yes. Dedicated strain gauge DAQ modules are designed for direct connection of strain gauges. The IOLITEi-1xSTG, for example, supports quarter-, half- and full-bridge configurations and provides internal bridge completion for 120 Ω and 350 Ω strain gauges. The multifunctional MonoDAQ-U-X also supports strain measurement and the connection of up to two full bridges.
Can a DAQ system measure different physical quantities simultaneously?
Yes, provided that the hardware supports the required input signals. Multifunctional DAQ devices such as the MonoDAQ-U-X can measure voltage, current, temperature, strain and resistance. Modular data acquisition systems also allow different specialised input modules to be combined within one measurement system.
What is the difference between a DAQ system and a data logger?
The distinction between a DAQ system and a data logger is not always clear-cut. A data logger is often designed for standalone and sometimes long-term storage of measurement data. A DAQ system generally focuses more on direct PC connectivity, high-speed data acquisition, signal conditioning, synchronisation of multiple measurement channels and advanced software analysis. The most suitable solution therefore depends on factors such as measurement speed, number of channels, sensor type, required data analysis and system architecture.
Which software is used for data acquisition?
MonoDAQ and IOLITE products support Dewesoft data acquisition software. The software can be used to configure measurement channels and to visualise, record and analyse measurement data. Depending on the version, EtherCAT-based IOLITE devices can also be used with standard EtherCAT masters.
Which applications is the MonoDAQ-U-X suitable for?
The compact USB DAQ system is particularly suitable for versatile measurement tasks involving different input signals. Typical applications include industrial testing and measurement, strain measurement in quality control, condition monitoring, and voltage, current and temperature measurement.
Which DAQ solution is suitable for condition monitoring?
For machine and condition monitoring, DAQ modules designed for IEPE and vibration sensors as well as acceleration measurement are particularly suitable. They can be used, for example, to monitor machine vibration, detect bearing faults or analyse structural vibration.