Every automotive production line generates valuable information. Pressure, temperature, vibration, force, displacement and machine status can reveal whether a process is running correctly, whether a component meets its requirements, and whether equipment needs attention.

SUNDAR TECHNO SOLUTIONS, Bangalore, offers fanless industrial computer platforms for integration into sensor data acquisition, monitoring and storage systems.

The application illustrated in our poster brings together an STS fanless box PC, EtherCAT acquisition modules, industrial sensors and Beckhoff TwinCAT software in an automotive manufacturing environment.

WHAT IS EtherCAT?

EtherCAT stands for “Ethernet for Control Automation Technology”. It is an industrial Ethernet technology designed for fast, predictable communication between an automation controller and connected devices such as I/O modules, measurement terminals and drives.

EtherCAT devices read and insert their data as an Ethernet frame passes through them. This efficient communication approach makes EtherCAT useful for industrial control and measurement systems.

For data acquisition, it provides a communication path between sensor-connected measurement modules and the computer collecting their readings. Actual acquisition speed and timing depend on the complete hardware, software and measurement configuration.

HOW DOES THE APPLICATION SHOWN IN OUR POSTER WORK?

SENSORS MEASURE THE PROCESS

Sensors measure physical conditions such as pressure, temperature, vibration and force.

ACQUISITION MODULES READ THE SIGNALS

Suitable EtherCAT I/O or measurement modules accept the sensor signals and convert them into usable digital measurements. The module must match the sensor type—for example, thermocouple, RTD, voltage, current or strain-gauge input.

THE STS COMPUTER COMMUNICATES THROUGH EtherCAT

With the appropriate master runtime installed and configured, the STS box PC acts as the EtherCAT master, exchanging data with the connected modules through its selected Ethernet interface.

SOFTWARE PROCESSES AND DISPLAYS THE READINGS

The configured application scales measurements into engineering units, checks limits and presents the information to the operator.

THE SYSTEM STORES MEASUREMENT RECORDS

A configured logging application saves readings, timestamps and relevant production information for later review. Depending on the project, records can be retained locally or transferred to a plant database.

Ordinary sensors connect to appropriate acquisition modules. They do not plug directly into the computer’s Ethernet port.

WHERE CAN THIS BE USED IN AUTOMOTIVE MANUFACTURING?

COMPONENT AND END-OF-LINE TESTING

Collect measurements during component or assembly testing and record results against configured acceptance limits.

PRESS-FITTING AND ASSEMBLY MONITORING

Record force and displacement during operations such as bearing insertion, bush fitting and component pressing.

PRESSURE AND LEAK-TEST MONITORING

Acquire pressure, vacuum and flow readings from suitable test equipment.

MOTOR, PUMP AND GEARBOX TESTING

Monitor relevant temperature, vibration, speed and torque signals using appropriate sensors and measurement modules.

MACHINE CONDITION MONITORING

Track changes in equipment behaviour to support maintenance investigation and planning.

PROCESS MONITORING

Record operating conditions during manufacturing to help engineers identify variations and investigate production problems.

These are example applications; the final system is configured for the particular machine, sensors and testing requirements.

WHY IS DATA ACQUISITION IMPORTANT?

A displayed reading tells an operator what is happening at that moment. Data acquisition makes those measurements available to software for continuous monitoring, comparison and analysis.

It helps manufacturers:

• Identify readings outside the permitted process limits.

• Compare performance between production cycles.

• Detect gradual changes in equipment behaviour.

• Investigate process inconsistencies.

• Support repeatable testing.

• Make decisions using recorded measurements.

WHY IS DATA STORAGE EQUALLY IMPORTANT?

Without stored records, useful evidence disappears after the reading changes.

Properly configured storage makes it possible to:

• Review the history of a tested component.

• Link measurements to a serial number or batch.

• Compare results across shifts or production periods.

• Investigate a rejected component or customer complaint.

• Review conditions before an equipment fault.

• Support internal quality reviews and customer documentation.

Traceability requires the application to associate the correct part identity, timestamp, test settings and result with each record. Storage capacity, backup and retention periods should be planned around the actual data volume.

WHY AN STS FANLESS EMBEDDED COMPUTER?

FANLESS COOLING

The finned metal enclosure dissipates heat without an internal cooling fan, eliminating fan-related servicing and helping reduce maintenance requirements.

COMPACT INSTALLATION

A compact box PC can be integrated into a suitable control cabinet, machine workstation or test bench.

LOCAL PROCESSING AND STORAGE

The computer provides a platform for the acquisition runtime, operator application and local data logging, according to the selected configuration.

INDUSTRIAL CONNECTIVITY

Multiple interfaces help connect the computer to acquisition equipment, displays and supporting devices.

COST-CONSCIOUS SYSTEM DESIGN

An STS platform can help integrators optimise hardware cost while retaining the functionality required by their application, subject to validation of the complete system.

HARDWARE HIGHLIGHTS OF THE FEATURED STS BOX PC

• Fanless metal enclosure with external cooling fins.

• Intel® I219-V Ethernet controller on the port selected for the demonstrated EtherCAT setup.

• Two Ethernet ports on the featured unit.

• Six DB9 COM connectors; electrical interface modes depend on configuration.

• USB connectivity.

• HDMI and VGA display connections.

• Audio connections.

• 12 V DC input marking on the pictured unit.

• Processor, RAM, SSD capacity and operating system selected according to the project.

For a quotation, please share your required channel count, sampling rate, storage duration, software requirements and installation conditions.

WHY DOES THE LAN CONTROLLER MATTER?

For TwinCAT-based EtherCAT applications, selecting a suitable Ethernet controller and driver is an important part of system integration.

In the customer’s engineering screenshot, the Intel® I219-V appeared under “Compatible devices” in the TwinCAT RT-Ethernet adapter setup.

The second interface, shown as a Realtek PCIe GbE Family Controller, appeared under “Incompatible devices” in that particular setup. It may still serve ordinary networking purposes with the appropriate standard driver.

Compatibility must be checked for the exact PC, controller revision, operating system, TwinCAT version and required timing. A controller model alone does not guarantee every EtherCAT application or sampling rate.

WHAT IS THE BECKHOFF SOFTWARE SHOWN?

The application is TwinCAT 3 Engineering, running in the TcXaeShell environment.

XAE means “eXtended Automation Engineering”. Engineers use it to configure devices, develop programs, inspect variables and diagnose the system.

TwinCAT Runtime, or XAR, executes the configured automation application on the target computer. Data logging and storage require the relevant application logic or additional software components.

Software licences, measurement modules, sensors and system integration are specified separately according to the project scope.

WHY SUNDAR TECHNO SOLUTIONS?

STS works with automation integrators, machine builders and industrial users to select computing hardware around their actual application.

Discuss your requirements with us for:

• Fanless embedded and industrial box PCs.

• Required LAN controllers and peripheral interfaces.

• Processor, memory and storage configuration.

• Evaluation with your acquisition software.

• Hardware supply and technical coordination from Bangalore.

CITIES & INDUSTRIAL REGIONS

STS welcomes requirements from Bangalore/Bengaluru, Pune, Pimpri-Chinchwad, Chakan, Talegaon, Mumbai, Nashik, Chhatrapati Sambhajinagar, Chennai, Sriperumbudur, Oragadam, Hosur, Coimbatore, Hyderabad, Ahmedabad, Sanand, Vadodara, Rajkot, Delhi NCR, Gurugram, Manesar, Faridabad, Noida, Greater Noida, Pithampur, Indore, Jamshedpur and other industrial locations across India.

Contact us to confirm delivery and support arrangements for your location.

DISCUSS YOUR AUTOMOTIVE DATA ACQUISITION PROJECT

SUNDAR TECHNO SOLUTIONS

Bangalore, India

Email: [sales@sundartechno.com](mailto:sales@sundartechno.com)

Share your sensor types, EtherCAT module details, channel count, acquisition rate and storage requirement. Let us help you select the STS computing platform for your system.

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EtherCAT® is a registered trademark, licensed by Beckhoff Automation GmbH, Germany. TwinCAT is a Beckhoff software product. Application illustration; final capabilities depend on the selected and validated system configuration.