Ethernet network real-time automation controller (RTAC)

with integrated I/O

Overview
Measurement and control electronics are at the heart of STEP Lab testing systems. Optimised for deterministic control and high-resolution acquisition, they provide the precision required for dynamic and fatigue testing across laboratories, R&D departments and production lines.

Key solutions

• Test Manager: the controller for STEP Lab machines.
• Test Centre: software for system configuration, monitoring and data management.

Test Controller
STEP Lab’s Test Controller is a next-generation control platform combining precise real-time control, flexible I/O and cost-effective scalability. Its architecture supports integration with test benches, sensors and actuators while maintaining deterministic performance for closed-loop testing.

Scalable and modular design

• Available in configurations based on five platform variants to match capacity and channel requirements.
• Selection criteria include maximum controlled axes, control/acquisition loop frequency and required I/O channels.
• Modular modules allow adding channels or functions without replacing the base system.

Industry-grade performance

• Control frequency: up to 16 kHz for high-bandwidth control loops.
• Communication: fully digital Real-Time EtherCAT for deterministic networked control.
• Resolution: 24-bit control and acquisition channels for high-precision measurements.
• Rugged design: control units and I/O cards built for industrial test environments.

Applications

• Aerospace & Automotive: fatigue, durability and performance simulations.
• Biomedical: materials, implants and device testing.
• Manufacturing: structural validation and end-of-line (EOL) testing.

Integrated safety and reliability

• Automatic system monitoring and diagnostics.
• Protection functions for high-force or high-speed test sequences.
• Fail-safe architecture to preserve samples and ensure continuous operation.

Adaptability and lifecycle support

• Flexible to accommodate different test standards and methods.
• Expandable hardware and software to follow evolving test requirements.
• Serviceable components for reduced downtime and predictable maintenance.

Technical specifications

• Platform options: five configurable platforms to match laboratory requirements.
• Control frequency: up to 16 kHz.
• Communication protocol: Real-Time EtherCAT (fully digital).
• Measurement/control resolution: 24-bit channels.
• Scalability: modular architecture for channel expansion and reconfiguration.
• I/O: configurable additional inputs/outputs for system integration.
• Target applications: aerospace, automotive, biomedical and manufacturing testing.
• Safety: integrated automatic monitoring and fail-safe design.