To get air gage readings into SPC software, Excel or a PLC, you need a digital readout or an air-to-electronic module, not a dial or column. A Metro M5 sends data out by USB (CSV file or keyboard emulation), RS232 ASCII or Modbus RTU; for Ethernet, PLC I/O or many gages, Metro M-Bus modules add Modbus TCP, EtherNet/IP, digital I/O and network export.
Pick the connection by where the data is going
| Where the data goes | Simplest way | What you need |
|---|---|---|
| Excel or a CSV file | Save readings to a USB stick, or type them straight into an open spreadsheet with keyboard emulation | Metro M5 or Air Gage Pro; nothing extra |
| SPC software on a PC | RS232 ASCII (Q-DAS compatible) or keyboard emulation into the SPC data-entry screen | M5 + RS232 cable ($95) |
| A PLC, one or two gages | Modbus RTU over RS232 | M5 + RS232 cable |
| A PLC over Ethernet | Modbus TCP | MB-AG air modules + MB-IP master ($790) |
| A PLC over EtherNet/IP (Allen-Bradley and others) | EtherNet/IP | MB-AG air modules + EtherNet/IP master ($815) |
| A robot cell or sorting gate | Digital I/O: start, done, pass/fail, master | Metro M400 + FMB-IO modules ($575, 8 I/O each) |
| The company network or a server | Automatic export of every result | MB-NET ($565) + Data Server software ($1,505) |
One or two gages: the Metro M5's built-in outputs
For most bench gages, the readout you already need does the job. The Metro M5 ($1,595), also inside every Air Gage Pro ($2,895), has:
- USB export to Excel/CSV. Readings are stored and saved to a USB stick.
- USB keyboard emulation. The M5 "types" each reading into whatever field is open on the PC: Excel, an SPC package or a web form. No driver or software to install.
- RS232 ASCII (Q-DAS compatible) for SPC software that reads a serial port.
- Modbus RTU for a PLC.
- Foot pedal input, so the operator sends a reading without letting go of the part. A footswitch is $155; a handswitch is $185.
- QR code setup. Scan a code to recall the right program; the QR code reader is $440.
- An M-Bus port to add Metro modules later.
Up to 3 characteristics show on one screen, with math between the two air inputs for features such as taper or average diameter.
Many gages or a PLC on Ethernet: Metro M-Bus modules
M-Bus is Metro's modular measuring network. Each module does one job and snaps onto a DIN rail, so you build exactly the system the cell needs.
| Module | What it does | Price |
|---|---|---|
| MB-AG air module | Converts one air gage circuit to an electronic reading; 2- or 3-point calibration. One per air circuit; needs a restrictor set and clean, regulated air. | $715 |
| MB-IP master | Sends readings from M-Bus modules to a PC, PLC or supervision system over Ethernet or USB, using Modbus TCP | $790 |
| MB-RS master | Same over RS232 or USB, using Modbus RTU | $715 |
| EtherNet/IP master | Connects M-Bus modules directly to EtherNet/IP PLCs, such as Allen-Bradley. Contact us to order. | $815 |
| FMB-MA master | For PC-based gaging: Ethernet, USB or RS232 with simple ASCII commands, up to 255 inputs, works with SPC software such as Q-DAS | $565 |
| FMB-IO | 8 optocoupled inputs/outputs for PLC handshakes, sorting gates and lights; up to 4 on an M400 for 32 I/O | $575 |
| MB-RO | One relay output, for example to switch an air-saving valve | $285 |
| MB-NET | Exports results from an M400 or M-Bus network to your company network or server | $565 |
The same network also takes inductive probes, encoders, digital instruments, temperature and more, so one system can combine air and contact gaging on the same part. See all M-Bus modules.
Running Allen-Bradley or another EtherNet/IP PLC? Our EtherNet/IP master module ($815) puts M-Bus air gaging straight onto your EtherNet/IP network, with no protocol converter in between. Contact us to order or to check your PLC.
A full gaging station: the Metro M400
When a part has many features, the Metro M400 ($3,430) is the display and controller in one: up to 99 inputs, 32 characteristics and 128 programs on a 7″ touchscreen. It shows SPC on the spot (histogram, run chart, Q-Q and Pareto, up to 1,000 readings per part reference), links to a PLC by Modbus RTU or PROFINET, drives up to 32 I/O, and exports by USB, RS232 or the network. It runs Metro's own operating system, not Windows, so there's no software license to renew and no virus risk on the shop floor.
How a PLC or robot handshake works
In an automated cell, the PLC and the gage trade a few simple signals:
- The PLC signals start once the part (or master) is loaded.
- The gage measures and signals done, with a pass or fail result.
- The PLC or robot sorts the part, and can read the actual values over Modbus for SPC or tool offsets.
- On a timer or part count, the PLC loads the masters and triggers mastering the same way.
Read more about full cells in automation and air gaging, in-process air gaging and our Fanuc robot station case study.
Three common setups
| Goal | Parts list | Readout side |
|---|---|---|
| One bore, readings into Excel at the bench | Air Gage Pro, 1 input | $2,895 |
| One bore into SPC software on a PC | Metro M5 1-input + filter-regulator + restrictor set + RS232 cable | $2,300 |
| Several bores into a PLC over Ethernet, no display | One MB-AG per air circuit + MB-IP master, plus air preparation | From $715 per circuit + $790 |
Tooling and masters are extra; price them in the free online quote. For a whole cell, send us the print and the PLC you use, and we'll put together the parts list.
What about dial gages and columns?
Dial air gages have no data output at all; every reading is written down by hand. That's one of the main reasons plants replace them. An Air Gage Pro runs the same plugs and rings and adds USB, RS232 and Modbus. Older electronic columns often have a serial port, but a protocol that modern software and PLCs no longer speak. See air-to-electronic converters.
Quick answers
Do I need special software to get data into Excel?
No. With keyboard emulation the M5 types readings into an open spreadsheet like a keyboard would. Or save a CSV file to a USB stick and open it in Excel.
Will it work with Q-DAS?
Yes. The M5 outputs RS232 ASCII in a Q-DAS-compatible format, and the FMB-MA master works with SPC software such as Q-DAS.
Can a PLC read the actual size, not just pass/fail?
Yes. Over Modbus RTU (M5, MB-RS), Modbus TCP (MB-IP) or EtherNet/IP, the PLC reads the measured values. Digital I/O gives pass/fail signals for sorting.
Can I add data output to my existing air gages?
Yes. Keep the plugs and rings and replace the readout with an M5 or Air Gage Pro, or connect each air circuit to an MB-AG module.
Q-DAS, PROFINET, EtherNet/IP, Allen-Bradley and Fanuc are trademarks of their respective owners.