Retrofit for our DIAdem-based pneumatic test benches

They come in numerous configurations and are located all over the world – our test benches for end-of-line testing of pneumatic components. Continuously refined over almost 30 years, all systems have one thing in common: NI DIAdem as the central software component, which not only provides the user interface but, above all, controls the test sequences and analyses the test data. This is where the core expertise lies – and thus the result of decades of optimisation.

Some of these test benches have been in use for more than two decades with virtually no changes, are still running on Windows XP and therefore urgently need an update. Twenty years ago, our typical test bench system consisted of a 19-inch PC running DIAdem and one or two Goldammer Multichoice Light PCI cards, a signal connection unit from Bedo tailored to the application, and a separate small PLC from various manufacturers for controlling the clamping processes.

Times have changed. DIAdem remains a powerful analysis tool, but has lost its real-time capabilities for measurement and control. Industrial PCs have become smaller and more compact and now feature – if at all – only a few specialised interfaces. PC cards have proved cumbersome to use, particularly when it comes to setting up new systems quickly. Most of the PLCs previously supplied by our customers are no longer available in this form and must be replaced with current models. Our DIAdem real-time extension, based on TwinCAT, offers the solution to all these problems. It takes over the real-time measurement and control functions from DIAdem, carries out the PLC tasks and requires just a single Ethernet interface to connect all signals via EtherCAT and the corresponding bus terminals. DIAdem retains its function as a user interface, continues to control the test sequences and evaluates the data. All knowledge-intensive programme components therefore remain largely unchanged. Thanks to a generic connection to TwinCAT, the software adaptation effort is manageable. That leaves the hardware adaptation. As the Bedo signal connection units are virtually indestructible, we simply connect the EtherCAT terminals to the same connector that was previously used for the PCI cards. Just swap the connectors and the new hardware is up and running!