ICP DAS USA was contacted by a systems integrator seeking high-precision data acquisition (DAQ) modules capable of serial communication and DeviceNet networking. The end application was developed for an aerospace hardware manufacturer working directly with Boeing on the 7E7 Dreamliner (Boeing 787) program. The integrator was searching for a scalable, reliable data acquisition system capable of handling hundreds of analog input channels with exceptional accuracy and stability.
The scope of the project involved monitoring vacuum levels across a large CNC machining surface, where aircraft wing panels are mounted for precision fabrication. Using flush-mount inductive eddy current sensors, the customer needed to measure the air gap between the vacuum table and the aluminum sheet metal surface. This measurement ensured proper suction and uniform tension during machining, preventing warping or deformation of the wing panels. The production version of the setup would implement over 700 eddy current sensors, each outputting a 4–20 mA analog signal corresponding to the detected air gap. These signals would represent real-time variations in vacuum pressure and material position across the entire surface, requiring a DAQ system capable of capturing and transmitting a large amount of data quickly and accurately.
The primary challenge was the customer’s requirement to use DeviceNet not only as the main communication protocol but also as the backbone network for the entire data acquisition infrastructure. The system needed to handle hundreds of analog inputs while maintaining consistent data throughput and precise synchronization across all connected devices. To meet this challenge, ICP DAS USA recommended the I-7017C, an 8-channel analog current input module specifically designed for 4–20 mA signal measurement. The I-7017C features 16-bit resolution, a sampling rate of 10 samples per second, and independent channel configuration, allowing engineers to tailor each input to specific sensor parameters. By implementing approximately 89 I-7017C modules, the integrator could collect all 700+ sensor inputs efficiently while maintaining data integrity. These modules were networked together via RS-485, forming a stable, noise-resistant communication chain ideally suited for industrial environments. To bridge the RS-485 DAQ network with the DeviceNet communication protocol, ICP DAS USA supplied the GW-7243D DeviceNet gateway. The GW-7243D allowed all 89 modules to be daisy-chained and connected to the plant’s DeviceNet network, enabling synchronized data collection and real-time monitoring through the customer’s centralized data logging system.
After installation and initial system testing, the aerospace fabricator was highly impressed by the ease of integration, reliability, and scalability of ICP DAS USA’s solution. The modular nature of the I-7017C and the seamless DeviceNet connectivity offered by the GW-7243D gateway allowed the integrator to build a cost-effective, high-performance data acquisition network that met Boeing’s stringent aerospace manufacturing standards. The system successfully enabled continuous monitoring of the vacuum table’s performance, providing precise data for process control and quality assurance. The fabricator expressed strong confidence in the ICP DAS USA hardware and indicated their intention to standardize on the same product line for future expansions.
This application demonstrates how ICP DAS USA’s DeviceNet-compatible data acquisition modules can meet the rigorous demands of aerospace manufacturing environments, where precision, scalability, and reliability are critical. By combining the I-7017C analog input modules with the GW-7243D DeviceNet gateway, engineers achieved real-time, high-resolution data monitoring across hundreds of input channels with minimal latency and maximum stability. ICP DAS USA continues to provide robust, flexible, and cost-effective industrial automation and data acquisition solutions for system integrators and OEMs in the aerospace, automotive, and advanced manufacturing sectors throughout North America.
