A refinement now popular is the replacement of the analog dial with an electronic digital display on which the reading is displayed as a single value. Some digital calipers can be switched between centimeters or millimeters, and inches. All provide for zeroing the display at any point along the slide, allowing the same sort of differential measurements as with the dial caliper. Digital calipers may contain some sort of "reading hold" feature, allowing the reading of dimensions even in awkward locations where the display cannot be seen.
Ordinary 6-in/150-mm digital calipers are made of stainless steel, have a rated accuracy of .001" (.02mm) and resolution of .0005" (.01mm). [7] The same technology is used to make longer 8-in and 12-in calipers; the accuracy for bigger measurements declines to .001" (.03mm) for 100-200mm and .0015" (.04mm) for 200-300mm. [8]
Many Chinese-made digital calipers are available very cheaply, and perform reasonably well. One point worth noting is battery current and switching. Many calipers do not stop drawing power when the switch is in the off position; they shut down the display but continue drawing nearly as much current. The current may be as much as 20 microamperes,[9] much higher than for many established brands. Sometimes calipers may not work properly when the battery voltage has dropped relatively little; silver cells, preferably selected from a datasheet to have a constant voltage for most of their life, may give a much longer usable life than alkaline button cells (e.g., SR44 instead of LR44).[9][10]
Increasingly, digital calipers offer a serial data output to allow them to be interfaced with a dedicated recorder or a personal computer. The digital interface significantly decreases the time to make and record a series of measurements, and it also improves the reliability of the records. A suitable device to convert the serial data output to common computer interfaces such as RS-232, Universal Serial Bus, or wireless can be built or purchased. With such a converter, measurements can be directly entered into a spreadsheet, a Statistical Process Control program, or similar software.
The serial digital output varies among manufacturers. Common options are
* Mitutoyo's Digimatic interface. This is the dominant name brand interface. Format is 52-bits arranged as 13 nibbles.[11][12][13][14]
* Sylvac interface. This is the common protocol for inexpensive, non-name brand, calipers. Format is 24 bit 90 kHz synchronous.[15][16]
* Starrett[17]
* Brown & Sharpe[17]
* Federal
* Mahr (appears to offer Digimatic, RS232, and USB)
* Tesa[17]
* Aldi. Format is 7 BCD digits.[16]
Like dial calipers, the slide of a digital caliper can usually be locked using a lever or thumb-screw.
Digital calipers contain a linear encoder. A pattern of bars is etched directly on the printed circuit board in the slider. Under the scale of the caliper another printed circuit board also contains an etched pattern of lines. The combination of these printed circuit boards forms two variable capacitors. As the slider moves the capacitance changes in a linear fashion and in a repeating pattern. The two capacitances are out of phase. The circuitry built into the slider counts the bars as the slider moves and does a linear interpolation based on the magnitudes of the capacitors to find the precise position of the slider.
Micrometer caliper
Main article: Micrometer
A caliper using a calibrated screw for measurement, rather than a slide, is called a micrometer caliper or, more often, simply a micrometer. (Sometimes the term caliper, referring to any other type in this article, is held in contradistinction to micrometer.)
[edit] Comparison
Each of the above types of calipers have their relative merits and faults.
Vernier calipers are rugged and have long lasting accuracy, are coolant proof, are not affected by magnetic fields, and are largely shock proof. They may have both centimeter and inch scales. However, vernier calipers require good eyesight or a magnifying glass to read and can be difficult to read from a distance or from awkward angles. It is relatively easy to misread the last digit.
Dial calipers are comparatively easy to read, especially when seeking exact center by rocking and observing the needle movement. They can be set to 0 at any point for comparisons. They are usually fairly susceptible to shock damage. They are also very prone to getting dirt in the gears, which can cause accuracy problems.
Digital calipers switch easily between centimeter and inch systems.They can be set to 0 easily at any point with full count in either direction, and can take measurements even if the display is completely hidden, either by using a "hold" key, or by zeroing the display and closing the jaws, showing the correct measurement, but negative. They can be mechanically and electronically fragile. Most also require batteries, and do not resist coolant well. They are also only moderately shockproof, and can be vulnerable to dirt.
Calipers may read to a resolution of 0.01 mm or 0.0005", but accuracy may not be better than about ±0.02 mm or 0.001" for 150 mm (6") calipers, and worse for longer ones.[18]
[edit] Use
Using the vernier caliper
A caliper must be properly applied against the part in order to take the desired measurement. For example, when measuring the thickness of a plate a vernier caliper must be held at right angles to the piece. Some practice may be needed to measure round or irregular objects correctly.
Accuracy of measurement when using a caliper is highly dependent on the skill of the operator. Regardless of type, a caliper's jaws must be forced into contact with the part being measured. As both part and caliper are always to some extent elastic, the amount of force used affects the indication. A consistent, firm touch is correct. Too much force results in an underindication as part and tool distort; too little force gives insufficient contact and an overindication. This is a greater problem with a caliper incorporating a wheel, which lends mechanical advantage. This is especially the case with digital calipers, calipers out of adjustment, or calipers with a poor quality beam.
Simple calipers are uncalibrated; the measurement taken must be compared against a scale. Whether the scale is part of the caliper or not, all analog calipers—verniers and dials—require good eyesight in order to achieve the highest precision. Digital calipers have the advantage in this area.
Calibrated calipers may be mishandled, leading to loss of zero. When a calipers' jaws are fully closed, it should of course indicate zero. If it does not, it must be recalibrated or repaired. It might seem that a vernier caliper cannot get out of calibration but a drop or knock can be enough. Digital calipers have zero set buttons.
Vernier, dial and digital calipers can be used with accessories that extend their usefulness. Examples are a base that extends their usefulness as a depth gauge and a jaw attachment that allows measuring the center distance between holes. Since the 1970s a clever modification of the moveable jaw on the back side of any caliper allows for step or depth measurements in addition to external caliper measurements, in similar fashion to a universal micrometer (e.g., Starrett Mul-T-Anvil or Mitutoyo Uni-Mike).
http://en.wikipedia.org/wiki/Caliper
