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SuperIOr® Controllers - The Future of I/O Control

MCM & RIM
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MCM & RIM

Digital Dynamics has developed a new generation of advanced-technology I/O controllers for the process control industry today. The SuperIOr Controller family is designed for applications that require high speed distributed I/O that simultaneously manage over 1000 inputs and 1000 outputs with sub-millisecond response times.

Each system is comprised of a Master Control Module (MCM) networked to multiple Remote Interface Modules (RIM). The system typically operates under control of a customer supplied supervisory host computer or can operate autonomously as the system computer for the entire machine or tool.

The SuperIOr MCM provides precise timing between as many as 16 Remote configurable I/O Modules (RIMs) distributed throughout a tool. I/O assignment and safety interlocks are easy to specify using a simple spreadsheet tool. Interlocks are electrically programmed into dual-redundant configuration PROMs providing the ultimate in configurable safety interlock integrity. Any number of I/O points in any combination of RIMs can be interlocked.  All interlocks are acted upon within each update frame. Interlocks can also be reconfigured electronically, substantially reducing hardware design spins needed to accommodate process changes.

SuperIOr RIMs are fast I/O subsystems configured to support sensors and actuators throughout the controlled equipment. RIMs are available in various sizes. Each RIM can be configured with multiple plug-in I/O cards specifically designed for machine control applications. The cards support high-resolution analog and fast digital I/O as well as precision temperature measurement and serial bus communications to smart devices.

Configured RIMs may be located up to 250 cable feet from the MCM allowing close-proximity installation to distant components. Flexible low-cost CAT6 cables provide dual-redundant communication paths between the MCM and the distributed RIMs. The SuperIOr Controller system significantly reduces the need for complex and costly custom cables usually required to reach I/O points in conventional control systems.

The SuperIOr Controllers are indeed superior in terms of size and performance. They are designed to meet SEMI-S2 and IEC 61508 safety standards, and offer latest technology dual-redundant safety interlocks that are fully configurable. Reconfiguration substantially reduces the need to redesign interlock boards for process changes. The SuperIOr Controller series also offers the best timing controls in the industry. It integrates easily into existing systems and is simple to upgrade as your processing demands change. All connector interfaces are customized to meet your plant floor requirements.

The SuperIOr Controller system is the newest family of industrial control products designed and manufactured by DDI in our facilities in Scotts Valley, CA. DDI is an ISO 9001 registered company with 40 years of design and manufacturing experience and a worldwide installed base of more than 40,000 advanced electronic control system solutions. All DDI products are 100% tested before shipment. Typical manufacturing lead time is 4-6 weeks and our customers consistently rate us as one of their top suppliers for quality, reliability and on-time delivery. The SuperIOr Controller system incorporates patent pending-technology.

When you partner with us, you are assured of receiving well-engineered, high-value solutions.
 Contact us today to learn more.

Custom I/O Control System Capabilities

General Capabilities
Engineering Design and Development of new products
Re-engineering products for manufacturability
Control Engineering Experts
Hardware and Software design

Turnkey solution from design through complete manufacturing

Integrate control functions
Product Name
SuperIOr Controllers
Capabilities
Master Control for Whole Process
Slave to Master System
Data Logging / Auto-Capture
Access and monitor all I/O points

Visual verification of all activity for process control and troubleshooting.

I/O Control and Monitor
Multiple hosts
Temperature Control
Valve Monitoring
End Point Detection
Features
Customizable
Configurable I/O
Special Application
Automatic Calibration
Logging Control
Energy Management
Remote Data Acquisition Control
Programmable Control Systems
Process Control
Up to 31 Remote I/O Modules (RIM)
Benefits
Size and Performance
I/O Count
Integration

Improved timing Customized with Customer Designed Interfaces and Cabling

Easy, Fast and Inexpensive to Upgrade
Controlled Systems
I/O Control Systems
Gas and Liquid Flow Control
RF Generators
Turbo Pumps
Heaters
Material Processing
Robotics
Motion Control
Plasma
Vacuum
Monitoring of
Temperature
Pressure
Moisture
Semiconductor Wafer Process Tool Applications
Flow Control of Gases and Liquids
Control RF Generators
Turbo Pumps
Heaters
Robotics
Motion control
Plasma
Vacuum
Chemical Vapor Deposition (CVD)
Thin Film Deposition
Etch
Components
1 Master Control Module (MCM)
Up to 16 Remote I/O Modules (RIMs)
Configurable I/O Type and Count
Cat 6 Cables for Interconnect
Simple Connections (RJ45 and DSUB)
Custom Enclosures (Steel, Stainless Steel, Aluminum)
Human Machine Interface (HMI) Data Logging
Switches
Interlock (I/L) Boards
Hard Wired Relays
Connectors
Options
Customizable Remotes
Over Temperature Limit Monitor
Custom Modules
Integrated Features in EIOC Custom Software
Temperature Control
Valve Monitoring
End Point Detection
Multiple Hosts
Modbus/TCP support
Single Master Control Module (MCM)

Dedicated Diagnostic Port + a USB Port for Data Collection

Dual Redundant Programmable Safety Interlocks
Master Sizes Include Connections of up to 16 RIMs
Available for either Ethernet or EtherCAT Systems
Allows precise timing on all I/O on tool
Easy transition from Ethernet to EtherCAT
Remote I/O Modules (RIMs)
Customer Defined Interfaces
Customer Defined Cabling
Up to 16 remote I/O Modules (RIMs)
RIMS can be up to 200 feet away from MCM
Configurable I/O
Configurable I/O Control Tailored I/O Sizing
Digital I/O
Analog I/O
Thermocouples for Temperature Control
SSR Out Darlington Opto Out
Serial Drivers & Receivers
New Types Easily Added as Required
Precise Timing Between all I/O on Tool
Module Types
16 DOUT (Sourcing)
16 DOUT (Sinking)
8 SSR Out
8 Darlington Opto Out
16 Darlington Opto Out
8 Relay Dry Contact Out
16 DIN - for 24V Logic
16 DIN - for 5V Logic
8 AOUT (Offset Canceling 16 Bit)
16 AOUT (Common Ground)
8 AIN (Differential 16 Bit)
16 AIN (Single Ended)
7 Thermocouples
4 Serial (RS-232, 485, 422)
Performance
125us DIN/DOUT Update Rate (8 KHz)
500us AIN/AOUT Update Rate (2 KHz)
±30 ns Jitter
Intrinsic DOUT Monitoring
Diagnostic LCD Monitor
Displays state of all I/O and Interlocks from a tablet
Data logging Auto capture

Provides visual verification of all activity for process control and troubleshooting.

Displays system information
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Additional Information

Industry Focus
Original Equipment Manufacturers (OEM)
Semiconductor
Solar
Packaging Machinery
Medical Device Manufacturing
Food Processing Equipment
Tool Machine
Measurement
Target Markets

Large Equipment with High I/O Count control requirements

Semiconductor Processing Equipment
Material processing
Industrial Sterilization Chambers
Heavy Equipment
Process Instrumentation
Scientific
Production Equipment
Medical Sterilization
Manufacturing
Food and Beverage
PLC - Programmable Logic Controllers
Packaging machinery
Pharmaceutical
Subsystems
Capital equipment
Instrumentation
Industry Standards
ISO 9001:2008 Certified
CE
RoHS
FCC
Safety Standards
SEMI-S2
UL 991
IEC 61508
Protocols
Ethernet
EtherCAT
RS485
RS232
ModBUS
ModBUS/TCP
TCP/IP
Others
CAD File Formats
SolidWorks
P-CAD
Altium
ORCAD
AutoCAD
Software Programming
QNX
C
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