Beyond Conventional Data Loggers: A Superior Solution for PLC Data Acquisition

This article explains various PLC data‑logging solutions and introduces a streamlined alternative that eliminates the need for extra hardware or software.

What Is Data Acquisition (DAQ)?

Data acquisition, or DAQ, digitises signals from industrial equipment—ranging from sensors to building systems—so they can be visualised, analysed and stored in a computer, PLC, server or cloud environment.

A PLC, or Programmable Logic Controller, is the industrial computer that drives motors, robots and sensors on production lines. PLC data logging captures machine‑generated values, tags them with timestamps, and makes them available for condition monitoring, performance optimisation and maintenance planning.

Typical DAQ software can collect a wide range of parameters: vibration, temperature, pressure, voltage, current, sound levels, and more. The volume of data can be significant, yet the insights it provides are essential for proactive service and continuous improvement.

Components of a Data Acquisition System

All DAQ systems share three core components:

1. Sensors
2. Signal conditioning circuitry
3. Analog‑to‑Digital Converters (ADC)

Modern setups often add data‑analysis tools, reporting software, network connectivity, and live dashboards. These features allow operators to view equipment status in real time, log data for trend analysis, and trigger alerts via email or other notification channels.

Building a custom DAQ from scratch is complex; turnkey solutions typically deliver faster deployment and reliable performance.

Different Types of Data Acquisition Systems

Industrial environments employ several methods to capture, store and analyse data:

• Data‑collection software
• Integrated DAQ systems
• Standalone acquisition devices
• Hardware data loggers
• Remote Terminal Units (RTUs)

Data‑Collection Software

Software running on existing control systems or PCs can ingest data from remote acquisition modules. It is suitable for everything from simple automation to large‑scale factory monitoring. However, such solutions are typically confined to the plant network and may lack remote accessibility.

Integrated DAQ Systems

An integrated DAQ combines hardware, sensors, signal‑conditioning modules and control software. Modular variants accommodate high‑channel counts and multiple sensor types, offering flexibility at a higher cost and integration effort.

Acquisition Devices

USB, Ethernet or PCI cards provide signal conditioning and ADC functionality. They are versatile but require a host computer to operate.

Hardware Data Loggers

Data loggers are self‑contained units with embedded processors and firmware. They record and store data locally, which can later be retrieved or uploaded to a cloud platform. Their main limitation is that they perform little to no on‑the‑fly processing.

Remote Terminal Units (RTUs)

RTUs are microprocessor‑based devices that monitor field equipment and forward data to SCADA or plant control systems. They are ideal for wide‑area telemetry but demand specialised programming skills.

An Alternative Data Acquisition Solution for PLCs

PLCs sit at the heart of modern industrial control systems. To unlock the value of the data they generate, you need a solution that is easy to deploy, offers remote visibility, and provides secure, redundant storage.

IXON Cloud delivers exactly that: a web‑based platform that gathers PLC variables without extra hardware, programming, or third‑party software.

IXON Cloud: Data Collection, Acquisition & Web‑Based Monitoring

IXON Cloud captures PLC variables directly from Ethernet‑enabled devices—such as PLCs, HMIs, IPCs, drives, and smart meters—using a single, user‑friendly web interface.

Configuration is done through the web console, where you specify which PLC tags to collect. The IXrouter, a multifunctional VPN gateway, establishes secure connections, forwards data via MQTT, and provides edge‑computing capabilities.

The IXrouter monitors real‑time PLC variables through industrial protocols (OPC‑UA, Modbus, Siemens ISO, Ethernet/IP, BACnet). You can configure logging triggers (change, interval, or specific events) and define aggregation functions (min, max, average). Data is buffered on the IXrouter to survive internet outages, then transmitted to a secure cloud database cluster once connectivity is restored.

Collected data can be visualised in drag‑and‑drop dashboards, leveraged for remote condition monitoring, and enriched with cloud‑based alarms. Exporting to external SaaS tools is also possible via a robust API.

• No additional software, hardware, or programming required.
• Sub‑5 ms sample rate.
• Flexible acquisition intervals (200 ms to 1 h) or event‑driven triggers.
• Full support for OPC‑UA, Modbus TCP/IP, Siemens ISO, Ethernet/IP, and BACnet.
• Unlimited, redundant, and backup‑protected cloud storage.
• 24/7 monitoring and security oversight by experts.
• Edge processing to pre‑calculate data and minimise bandwidth.
• Customisable dashboards and alarm configuration in the browser.
• Remote access to PLCs, HMIs, and web servers for faster troubleshooting.
• No ongoing maintenance, power, or server costs.

Try a full scenario with our free starter kit and IXON Cloud platform account. Request yours here or reach out with questions.

[[Request IXrouter starter kit]]

Customer Success Stories

• How Better Origin monitors modular insect farms from the cloud
• Dorset Group: Turning raw data into optimal processes

Related Resources

• IXON Data Logging feature
• How to make your machine data more valuable
• 23 key metrics for your manufacturing dashboard
• Transform field‑level data into management information