Cal-Bay Systems

Data Acquisition Systems

In 1993, the year our company was incorporated, the concept of using a PC for data acquisition and automation was still fairly new. Cal-Bay Systems was one of the early pioneers of the use of PC-based data acquisition card systems to replace PLC-based (programmable logic controller) systems, pushing the envelope of what was possible in the automation world.

Integrated Systems Create Value

Since then, data acquisition has remained one of our core areas of expertise. In a range of applications from process monitoring and control to device calibration to Supervisory Control and Data Acquisition (SCADA), we have helped our customers realize the value of an integrated system where data from multiple sources and sensors can be viewed, stored, controlled and analyzed. Examples of the savings and value created include:

Reduce costs for system metrology, calibration tracking and documentation.
Precise timing and synchronization between multiple measurements that permit more complex measurements to be extracted.
Implementation of scripting and macros that allow data acquisition systems to be easily adapted to changing requirements.
Display and conversion of data between domains – such as between time series and via length for a web coating process or between time series and angular domain for rotating equipment.
Integrating advanced closed loop control into plain-vanilla data acquisition and logging systems. Cal-Bay has developed architectures for flexible control such as a plug-in fuzzy logic controller for a vacuum coating process and PID controllers for a thermal vacuum test.

Reduce costs for metrology and calibration tracking

End-to-end calibration with a database to allow tracking of calibration drift ensures traceable metrology. We offer this functionality with all data acquisition systems we supply. The payback from this feature is especially quick in high channel count applications, an example involving test of aircraft environmental controls is here.

Precise Timing and Synchronization

Low cost DAQ cards like the National Instruments M-series cards have timing features which can be exploited to increase their value. For flow calibration applications, we have used the PXI-6608 counter card to create a time base for acquisition scans. The oven-controlled oscillator on the 6608 improves precision and absolute accuracy when measuring small slew rates.

Scripting and macros

Changing requirements is challenge in many fields, not just data acquisition. Scripting and macros lower the cost of adapting to new requirements. Scripting and macros may be implemented with a number of tools, including TestStand, Perl or in an Excel spreadsheet with a small command list. We offer an Excel macro that uses the LabVIEW VI Server to set values for any Boolean or numeric control on the Front Panel. No programming changes are required as Front Pane controls and indicators are added or deleted.

Domain Conversion

For slower web processes, any section of roll is in the process for several minutes and the length of the roll in process is many meters long. The effect of changes in actuator settings is seen at different delay times for “down-roll” sensors. For a customer with a vacuum deposition process we created a trending database that allows process data to be displayed as function of time or of roll position.

Vibration monitoring for rotating equipment requires conversion from time-series to angular domain. Cal-Bay Systems is a leader in using National Instrument tools to provide solutions for rotating equipment vibration monitoring. We are pioneers in the use of LabVIEW FPGA to provide configurable tachometer signal conditioning for rotating equipment monitoring.

Closed Loop Control

Certain processes and monitoring applications require closed loop control in addition to data acquisition and logging

Using custom developed software, Cal-Bay can integrate third party control equipment into a data acquisition and control system using a necessary control techniques like:

On-off control
PID control
Fuzzy logic control for non-linear and complex processes
Motion control on single and multiple axes

For a customer with a vacuum deposition process we created real-time fuzzy logic controller using LabVIEW Real-Time and a plug-in PID controller for a thermal vacuum test.

Leverage Cal-Bay's data acquisition experience and capability for your demanding data acquisition system

As a result of 13+ years of experience in developing data acquisition systems, Cal-Bay has the advantage of leveraging off standard routines from our reusable code libraries. This saves your time and money.

We have experience integrating all kinds of equipment into data acquisition systems. Examples of communications and media we have experience with:

RS232
RS485
GPIB/IEEE488
USB
DeviceNet
Ethernet
Profibus

Some of the equipment Cal-Bay has extensive experience with . This list excludes instruments.

Data Acquisition Devices :

National Instruments E-series
National Instruments M-series
National Instruments CompactDAQ
National Instruments FieldPoint & Compact FieldPoint
Agilent 34970
Scanivalve

Semiconductor Process Equipment :

Unit Mass Flow Controllers
STEC Mass Flow Controllers
Kepco Power Supplies
Advanced Energy Power Supplies
Granville Phillips Vacuum Gauges
Huettinger Power Supplies
Ruska pressure controller

Gas Analyzers

Thermo Environmental
California Analytical
Teledyne API

Our vibration monitoring, remote monitoring, tachometer acquisition products are examples of data acquisition systems that we've developed and perfected over the years. These are now offered off-the-shelf or customized easily and quickly if necessary.

REMS-100 - Rotating Equipment Monitoring System - a vibration monitoring and analysis system for turbine and engine testing.

HCD-4100 - High-Channel-Count Data Acquisition System - a remote monitoring solution for high-channel-count, industrial data acquisition systems.

TAQ - Tachometer Signal Acquisition System - directly measure tachometer signals without expensive signal conditioning.

PC Based Data Acquisition cards