Case Study: Data Acquisition Boxes


  • Custom wire DAQ boxes
    • 32 5-pin signals
    • 32 Thermocouples
      • Very stiff wires
    • Box hinged
    • Limited space
    • Need easy access to cDAQ chassis
    • Partial prototype (built by someone else) shown




  • Bundles wires in spiral wrap
    • Routed so stiff wires are parallel with hinge
      • Hinge moves freely
      • Minimize stress on wires
    • Chassis clipped on din rail for easy removal
      • Long runs to allow chassis to be removed for detailed probing
    • Wires grouped to approach cDAQ modules from two sides



  • Years of experience with wire harnesses complex cabling, etc
  • Extensive experience with NI’s cDAQ hardware
  • Significant Industrial Engineering Expertise





  • Seven boxes built
    • On schedule
    • Over 1600 wires with zero wiring mistakes
  • Customer impressed
    • Unanimous approval
  • Requested two more sets of boxes for additional systems

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