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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.
Advanced
2 days
Instructions
1
1
Etch the scale
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.
Materials for this step:
PCB Blank (Copper Clad)1 strip, length of the beamTools needed:
Dry Film Photoresist
Ferric Chloride Solution
Chemical-Resistant Gloves2
2
Fix the scale into the beam
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.
Materials for this step:
Caliper Beam1 with integral jaws
Two-Part Epoxy Adhesive (Quick Set)1 a littleTools needed:
Unknown Dimensions3
3
Fit the parts to the circuit
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.
Materials for this step:
Rigid-Flex Circuit Board1 slider board + circuit board
Integrated Circuit2 uPD7503 CPU, CMOS gate array
Segment LCD Panel1 5 digits
Quartz Crystal1 100 kHz
Capacitor Kit1 one integrating capacitor
Push Button2 MODE, SET
Solder Wire1 a littleTools needed:
Soldering Iron4
4
Build the slide
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.
Materials for this step:
Caliper Slide Frame1 with jaws
Unknown Metal1 depth rod and two wear strips
Caliper Slide Housing1 pieceTools needed:
Unknown Dimensions
Precision Screwdriver Set5
5
Assemble and check
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.
Materials for this step:
Machine Screws2 pieces
1.5 V Button Cell2 piecesTools needed:
Precision Screwdriver Set
Vernier CaliperMaterials
15- 1 strip, length of the beamPlaceholder
- 1 with integral jawsPlaceholder
- 1 a littlePlaceholder
- 1 slider board + circuit boardPlaceholder
- 2 uPD7503 CPU, CMOS gate arrayPlaceholder
- 1 5 digitsPlaceholder
- 1 100 kHzPlaceholder
- 1 one integrating capacitorPlaceholder
- Placeholder
- 1 a littlePlaceholder
- 1 with jawsPlaceholder
- 1 depth rod and two wear stripsPlaceholder
- 1 piecePlaceholder
- 2 piecesPlaceholder
- 2 piecesPlaceholder
Tools Required
7- Placeholder
- Placeholder
- Placeholder
- Placeholder
- 2 vendors sell this, none ship to you yetPlaceholder
- Placeholder
- Placeholder
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