Hi again Brad.
Thanks for your suggestion. Unfortunately, the sync command doesn't change anything. I still get error code 6.
As I see it, we have confirmed that the error is due to the power loss. The reason is, that FAT32 does not supports journaling. So we have a couple of options:
1) Use a journaling file format like EXT3 (or NTFS if that was an option).
2) Monitor which power source is active (officially supported with NI-RIO 14 release) and safely power down the system.
3) If error code 6 happens, then reboot the system (and do a fdisk, which seems to improve the failure rate).
Personally, I like option 2 the most, because we can stick with a file format that Windows and read. Do you have any final recommendations?
I wholeheartedly agree that detecting the circumstances that lead up to the failure and taking action to avoid it is ideal (well, at least for the current situation).
For somebody that might be interesting in running fsck automatically - here is possible solution explained: https://forums.ni.com/t5/Real-Time-Measurement-and/How-to-run-fsck-vfat-for-USB-stick-during-cRIO-90...