Managing Analog and Digital Counter Sensors in DewesoftX

Course overview

This course provides a comprehensive walkthrough of managing both analog and digital counter sensors within DewesoftX. You’ll begin by learning to use the Analog Sensor Editor, an integrated database for creating and maintaining sensor definitions. You’ll configure metadata such as type, serial number, physical and electrical units, calibration dates, and scaling methods (linear, polynomial, and lookup tables). You’ll also learn how to apply frequency-dependent transfer curves to correct amplitude and phase errors—essential for high-precision frequency-domain applications.

Next, you’ll explore the Counter Sensor Editor, which supports various pulse-based sensors like encoders, tacho, geartooth, and tape sensors. You’ll define key parameters including sensor types, pulses per revolution, missing tooth configurations, TTL level settings, debounce filters, signal edges, and zero-pulse for synchronization.

The training also covers linking these sensor definitions to measurement channels—streamlining setup by selecting sensors from dropdown menus in channel configurations. For digital counting, you’ll discover SuperCounter® technology, which provides high-precision, time-synchronized pulse and frequency measurements up to 10 MHz—far beyond standard digital inputs.

Lastly, you’ll learn how to manage sensor data lifecycle: import/export sensor databases (.dxb/.xml), enforce unique serial numbering to avoid conflicts, monitor calibration status (with expired entries flagged), and ensure database integrity when sensors are edited or removed.

Successful completion of this course ensures you can confidently configure sensor databases in DewesoftX, link sensors to measuring channels, and gather accurate, high-resolution measurements from both analog transducers and digital encoding/counting sensors.

DewesoftX offers an Analog Sensor Database that stores the list and properties of all sensors to be used. In addition to linear scaling—which can also be performed in the input channel setup—the sensor database allows scaling by table or polynomial, and even transfer curves can be defined.

To open the Sensor Editor, go to:
Options → Editors → Analog Sensors

The sensor database can be created and customized to match your specific requirements and the measurement hardware in use. The Sensor (Database) Editor provides several functions for creating, editing, and managing sensors:

• Add sensor (creates a new sensor in the sensor database)

• Remove sensor (removes the sensor from the sensor database)

• Shown Columns (show or hide different columns in sensor database) 

• Import (import existing *.xml, *.dxb sensor databases or custom XML files *.e2x)

• Save (store the sensor database to file)

Each sensor is defined by the following information in the database:

• Physical quantity, serial number, calibration date, calibration period

• General sensor information

• Scaling type (linear, polynomial, table)

• Transfer curve (used for sensor correction)

Learn how to create and edit analog sensors to suit your needs. Select the sensor type, enter the sensor's serial number and model, adjust the scaling, add a transfer curve, and configure many other options.

After entering the Sensor Editor, a list of all available sensors will be displayed. Any previously defined (or pre-defined) sensors, along with connected TEDS sensors, will be listed automatically.

The sensor table provides a wide range of properties. You can manage the displayed properties using the Shown Columns option. Some of the available properties are described in the following list:

• Sensor type - the sensor type should contain the name or type of the sensor but can contain any text desired

• Serial number - the serial number has to be unique! It is not allowed to use the same serial number because this information is used for sensor identification.

• Scale type - the sensors editor differs between linear, polynomial and table scaling

• Transfer curve - can be used for sensors with phase characteristics like current clamps, geophones, ...

• Recalibration data - enter the date when the sensor has to be recalibrated. When the date expires, the Recal. date will change to red color.

Editing sensor properties is simple—just click on the desired field in the table to begin editing.

At the bottom of the Sensor Editor, you’ll find additional information about the scaling or transfer curve for the selected sensor:

• Scaling - contains the scaling information of the selected sensor

• Transfer curve - is only available if the transfer curve is enabled

All general sensor information that can be saved in the Sensor Database.

The general information about the sensor includes:

• Physical (input) unit - the physical unit of the sensor, e.g.V, A, °C, mm, psi, %,...

• Electrical (output) unit - the electrical output unit of the sensor, most times V or A

• Channel name - use this field to pre-define the channel name for the setup

• Channel description - additional information about the sensor, helps to select the right sensor in the input setup

DewesoftX supports three different scaling types within the sensor database: Linear, Polynomial, and Table scaling.

When you select the Scaling type field in the sensor database, a selection list of available scaling types appears, and the Scaling tab is automatically activated. Once you choose a scaling type from the list, the appropriate scaling input fields will be displayed automatically.

DewesoftX supports three different scaling types within the sensor database.

Linear

Linear scaling is used for linear sensors and is calculated using the following formula:

• y = physical value

• k = scale

• x = measured value

• d = offset

The Scale and Offset values are defined manually in their respective columns:

Polynomial

Polynomial scaling is used for nonlinear sensors. The output is calculated using the polynomial equation:

Example: Polynom scaling (a0 + a1*x + ... +an*xn) enter the n number and the coefficients in the Coef. column (coefficient a0 defines the offset).

You can also copy and paste coefficient values from an external source using the Copy/Paste buttons.

Table

Table scaling is also used for nonlinear sensors, but it is typically easier to enter, especially when calibration data includes multiple measurement points.

To define table scaling:

Enter the number of points (i.e., the number of rows in the table).

In the table below, fill in the X and Y values that represent the calibration data.

Like with polynomial scaling, table values can also be copied from an external source using the Copy/Paste buttons.

The transfer curve compensates for both amplitude and phase, depending on the signal frequency. In the table under the Transfer Curve column, you need to enter the individual points that define the curve.

Transfer curve calibration can be used when the frequency response of the sensor is known.

• transfer curves for most common sensors are already measured,

• copy it from the calibration sheet of the sensor (if the calibration sheet includes the transfer curve),

• the third option is to measure it with DewesoftX FRF modal test, but this requires some additional equipment.

Some manufacturers provide calibration reports in the frequency domain, such as those available for current clamps. These reports allow you to accurately define how the sensor behaves at different frequencies.

We can enter the sensors transfer curve in two ways:

• Manually enter the number of points (rows of the table) and in the numbers below the columns Freq[Hz] (signal frequency), Ampl[dB] (amplitude deviation), and Phase[deg] (phase angle).

• Using the Windows copy and paste the values from a table created in the external program (e.g. Excel, ...). You can choose between two options: Copy Re/ Im to clipboard and Copy Ampl/ Phase to clipboard.

When copying data from external programs such as Excel, make sure the column names match the expected format in Dewesoft.

Once you're finished, save the sensor configuration by clicking the Save button, and close the sensor editor by clicking the Exit (X) button.

You can easily add, remove, import, or delete any sensors in the database.

Add sensor

If you want to add new sensors, click the plus button. A new row—representing the new sensor—will be added to the table.

Remove sensor

To remove a sensor, simply click on it. The entire row will be highlighted with a grey background. Then, press the minus button to delete it.

Import sensor database

You can also import an existing sensor database from supported formats, including standard XML files(*.dxb, *.xml) and Custom XML files (*.e2x).

Save file

To save all changes to the sensor database, click the Save file icon.

The data will be stored immediately in an XML-styled file named AnalogSensors.dxb ,which is located in the DewesoftX installation folder.

Exit sensor database editor

To exit the sensor database editor, click the X button. If you haven't already saved your changes, Dewesoft will prompt you to either save or discard them.

Here you can find an introduction to the Counter Sensor Editor.

DewesoftX offers a Counter Sensor database that stores a list and properties of counter sensors, which can be used in applications such as order tracking, combustion analysis, and angle sensor math. You can define encoders, gear tooth sensors, and other types of angle sensors.

The Counter Sensor Editor can be accessed via Options → Editors → Counter Sensors.

When you open the editor, the following window appears, allowing you to define counter sensors:

Several predefined sensors are already available in the list—these are installed by default with DewesoftX. You can always add new sensors, modify existing ones, or delete them. In the upper right corner of the Counter Sensor Editor, you will find common command icons:

Rename sensor – Renames the newly created sensor.

Add sensor – Adds a new sensor named "New sensor," which you can then rename.

Remove sensor – Deletes the currently selected sensor.

Save and Exit – Saves the counter sensor database and closes the editor.

Exit (X) – Closes the editor without saving. Make sure to use Save and Exit if you've made any changes, or confirm saving when prompted upon exit.

In the Counter Sensor Editor window, you can choose any sensor from the Current Sensor drop-down list to view and edit.

Settings and values entered for each counter sensor are divided into the following sections:

• Sensor type

• Signal level

• Encoder setup or Geartooth setup (depend on selected sensor type)

You can choose between different Counter Sensor types from the drop-down list.

Several basic sensor types are available and can be selected from the Sensor Type drop-down menu:

• Encoder - classic angle encoder with A, B, and Z signals. The signal can be only digital.

• Tacho - sensor with one pulse per revolution. The signal can be either analog or digital.

• Geartooth, CDM - sensor with a defined number of pulses per revolution, but without any zero pulses.

• Geartooth with zero, CDM + TRG - sensor with a defined number of pulses per revolution with zero pulses.

• Geartooth with missing teeth - a classic in-vehicle sensor with any number of pulses where one tooth is missing for zero pulse recognition. A typical example is a 36+1 sensor.

• Geartooth with double teeth - an in-vehicle sensor with any number of pulses per revolution with some double teeth missing. A typical example is the geartooth with 60 teeth where two of them are missing, so in fact there are 58 teeth and there is a gap for two teeth.

• Linear encoder - sensor measuring displacement with any number of pulses per millimeter and pulses per revolution.

• Linear pulses sensor - a linear sensor, measuring displacement with any number of pulses per millimeter.

• Tape sensor - an angle sensor with white tape and black stripes attached to the rotating disc.

Learn how to adjust Signal Level settings – Signal Type, Signal Filter, and Signal Edge

There are several signal level settings available.

Signal type

Encoder and geartooth signal types can only be defined as digital (TTL level) and are therefore used exclusively with counters. All other sensors can also be analog, which means that a trigger level must be defined.

Signal filter

A signal filter is a debounce filter used to prevent glitches in the signal. The signal must be present for a specified amount of time before it is accepted as valid by the logic. Note: This also introduces a delay in the signal response!

Signal edge

The signal edge can be either positive or negative.

Zero pulse edge

When an encoder or geartooth with zero, CDM + TRIG is selected, an additional Zero Pulse setting becomes available.

Additional Settings for Different Geartooth Sensors

Geartooth sensor settings

For these sensors, we need to define the number of pulses per revolution (#Teeth).

Geartooth with zero sensor settings

For these sensors, we need to define the number of pulses per revolution (#Teeth) and the direction of the zero pulse edge (Positive/Negative).

Geartooth with missing teeth sensor settings

We also need to define the number of teeth (#Teeth) and the gap lengths (#Gap) for custom sectors of the sensor. A new sector can be added by clicking the plus button. There is also an additional Angle [°] column, which shows the degrees of each sector.
For the number of teeth, enter the actual number of physical teeth on the sensor. The example in the image below shows the settings for a 60-2 sensor. If there were no gaps, there would be 60 teeth, but two teeth are missing to create a gap, so only 58 teeth are physically present.

To configure a 60-2-2 sensor, you would enter 28-2-28-2, ensuring that the total sum of all values always equals the original number of teeth (60 in this case).

Geartooth with double teeth sensor settings

For these sensors, you must also define the number of double teeth (#Double teeth). The example below shows the settings for a 36+1 sensor, which has 36 teeth and one additional double tooth.