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Change The Way You Think
We are creatures of base 10 and the alphabet. It gives us comfort to know that the files our data acquisition programs create can be displayed, printed and interpreted as easily as reading the morning paper. Unfortunately, base 10 is not the number system of your PC and it doesn't know the difference between A and Z. To achieve high speed real time data acquisition, you have to accept the PC for what it is and work with it on its terms. That means a base 2 number system and binary-coded files. To learn why, lets look at a single sample acquired from a 12-bit data acquisition device.
Computers like to work in groups of bits that are a multiple of 8 (one byte). The 12-bit binary number representing the sample's value fits nicely into a 16-bit word (only 2 bytes) and it's efficient for the PC to write it to disk in this form. But you'd prefer the PC to convert the sample to its ASCII equivalent (one we can read) before writing the value to disk. This simple, seemingly logical request explodes the number of bytes written to disk by at least a factor of 2.5. The range of our 12-bit ADC is 0 to 4095 counts. Writing counts to disk in ASCII-readable form consumes one byte for each character, plus a delimiter (like a comma) for a total of 5 bytes. In the more likely case that you want data stored in meaningful units (like psi), multiplying by m and b scaling constants yields an even larger number of digits that must be written to disk. Your 2-byte binary representation of a single sample could easily explode to 10 or more ASCII characters (bytes). The resulting 5:1 burden will tax your PC and the hard drive and ultimately limit your maximum data acquisition rate.
Here's a hard and fast rule: Real time data acquisition programs that store data to disk as ASCII characters are not high speed solutions. Any well conceived program not only stores data to disk in a two's complement or other non-text, binary format, but will also provide the ability to convert any range of waveform data to ASCII after acquisition.
Detecting Relay Chatter in Delta Launch Vehicles
Imagine the vibrations you'd encounter as you were launched into space by a rocket. Now imagine how these vibrations can affect on-board control circuits. Since the failure of even one such component during launch can be both costly and tragic, engineers strive to simulate as much of the mission as possible on the ground. One area of particular concern was relay chatter caused by the tremendous vibrations of flight.
A simulation was carried out to determine whether on-board relay assemblies remained closed when subjected to a 70g, 100 Hz to 3 kHz random vibration. Engineers had defined a minimum sample interval of 5 µs with a total data acquisition time of 3 minutes. This translated to a 200,000 Hz sample rate and a data file size of about 72 megabytes. It also precluded use of an older data acquisition product that had a top sample rate of 50,000 Hz. Instead, a small DC current was injected into the relay circuit and connected to a DATAQ Instruments model DI-400 data acquisition card (now obsolete) running under WinDaq/Pro real time software. This combination is capable of sample rates to 500,000 Hz. Any break in the relay circuit caused by vibration would immediately show as a spike on WinDaq/Pro's real time display (Figure 3), thus allowing relay performance to be judged on-the-fly. Subsequent to the test, data files created by WinDaq/Pro can be further interpreted using WinDaq Waveform Browser software. The disk streaming capabilities of both software packages allows data acquisition and analysis independent of data file size.
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