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Digital Caliper: Capacitive Scale and Slider with Two-Chip Electronics (Baxter and Buehler, Starrett, 1986)
Ed

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Ed

2. novembre 2026FI
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Digital Caliper: Capacitive Scale and Slider with Two-Chip Electronics (Baxter and Buehler, Starrett, 1986)

A six-inch caliper that reads out on a display. Under the slide, a strip of etched copper bars runs along the beam. Electrodes on the slider pass a signal through the bars by capacitance, and the slider's electronics count the bars crossed and work out the position in between. Result: a digital caliper reading in inches or millimetres, repeatable to a ten-thousandth of an inch, with floating zero, peak hold and high/low limits. It runs on two 1.5 V cells at 10-50 microamps. Source: L. K. Baxter and R. J. Buehler (L. S. Starrett Co.), US Patent 4,586,260 (1986). Unknown: the metal of the beam, slide and rod, their dimensions, the processor's program, and how the chips and display are made. Ours: the etchant, photoresist and glue. Picture: Wikimedia Commons.
Avanzato
2 days

Istruzioni

1

Etch the scale

Etch the scale pattern onto a strip of copper-clad epoxy fibreglass with photoresist and etchant. Each copper bar is 0.40 inch long, with a wider centre 0.12 inch long and two ends 0.14 inch long. Space the bars on 0.05 inch centres: the centres sit 0.004 inch apart, the ends 0.025 inch apart. Run the pattern the full length of the scale. Ours: dry film resist and ferric chloride.

Materiali per questo passaggio:

Basetta vergine per circuito stampato (ramata)Basetta vergine per circuito stampato (ramata)1 strip, length of the beam

Strumenti necessari:

Fotoresist a film seccoFotoresist a film secco
Soluzione di cloruro ferricoSoluzione di cloruro ferrico
Guanti resistenti agli agenti chimiciGuanti resistenti agli agenti chimici
2

Fix the scale into the beam

The beam is a metal bar with the fixed outside and inside jaws at one end, a wide shallow channel in its face and a second channel along its back. Fix the scale permanently into the face channel, copper up. The patent allows etching before or after this step. Not given: the metal, the dimensions and how the scale is fixed. Ours: epoxy.

Materiali per questo passaggio:

Asta del calibroAsta del calibro1 with integral jaws
Resina epossidica bicomponenteResina epossidica bicomponente1 a little

Strumenti necessari:

Dimensioni sconosciuteDimensioni sconosciute
3

Fit the parts to the circuit

The circuit is one folded piece: a double-sided slider board joined by a flexible hinge to a circuit board. Its bottom face has two pickup electrodes, 0.750 x 0.110 inch and 0.0625 inch apart. On each side of them is an interdigitated transmitter array: fingers 0.115 inch long on 0.025 inch spacing, opening to 0.0375 inch at the centre. On the circuit board, solder or wire-bond the two chips: an NEC uPD7503 3 V processor (768 bits RAM, 2 kB ROM) and a CMOS gate array. Then fit the LCD, the 100 kHz crystal, the integrating capacitor and the MODE and SET buttons. Not given: the processor's program. Ours: a capacitor from a kit.

Materiali per questo passaggio:

Circuito stampato rigido-flessibileCircuito stampato rigido-flessibile1 slider board + circuit board
Circuito integratoCircuito integrato2 uPD7503 CPU, CMOS gate array
Display LCD a segmentiDisplay LCD a segmenti1 5 digits
Cristallo di quarzoCristallo di quarzo1 100 kHz
Kit di condensatoriKit di condensatori1 one integrating capacitor
PulsantePulsante2 MODE, SET
Filo per saldaturaFilo per saldatura1 a little

Strumenti necessari:

Saldatore a stagnoSaldatore a stagno
4

Build the slide

The slide frame wraps the back and edges of the beam and carries the movable jaws. Fix it to the depth rod, which runs in the back channel of the beam; the rod's free end is the depth gauge. Put the moulded plastic housing between the frame ends. Fasten two metal wear strips under the slider board, one on each side of the scale. They ride on the beam and connect the board's copper to it. Not given: the metal and sizes.

Materiali per questo passaggio:

Telaio del cursoreTelaio del cursore1 with jaws
Metallo sconosciutoMetallo sconosciuto1 depth rod and two wear strips
Custodia del cursoreCustodia del cursore1 pezzo

Strumenti necessari:

Dimensioni sconosciuteDimensioni sconosciute
Set di cacciaviti di precisioneSet di cacciaviti di precisione
5

Assemble and check

Fold the circuit into the housing recess, slider board facing the scale, and screw it to the frame. The electrodes must lie parallel to the scale bars at every point of travel. Put the two 1.5 V cells (the patent says 'zinc oxide') in the battery pockets of the circuit. The display shows five digits, a ten-thousandths bar graph, a minus sign and 'mm', plus PEAK, LOW, HIGH and LIMIT. Ours: check the reading against a vernier caliper.

Materiali per questo passaggio:

Viti da metalloViti da metallo2 pezzi
Pila a bottone da 1,5 VPila a bottone da 1,5 V2 pezzi

Strumenti necessari:

Set di cacciaviti di precisioneSet di cacciaviti di precisione
Calibro a corsoioCalibro a corsoio

Materiali

15

Strumenti richiesti

7

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