Digital Caliper Grating Sensor for Small-Hole Measurement Accuracy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional digital calipers suffer from inaccuracies in measuring small-diameter holes due to zero-point and displacement errors, necessitating specialized and expensive tools for high-precision measurements.
Innovation Solution
A digital caliper equipped with a displacement sensor, microcontroller, and correction mechanisms to automatically adjust for zero-point and displacement errors, using high-resolution sampling and quasi-constant-force methods to achieve micron-level precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional digital calipers use fixed-resolution conversion and integrated circuit design, then device simplicity is maintained, but measurement precision for small-diameter holes deteriorates due to zero-point and displacement errors
Solution Approach 1:
The patent segments the measurement function from the display function by using a high-resolution displacement sensor (1.25μm resolution) separate from the display unit. The sensor data is processed through a microcontroller that can apply different conversion factors and correction algorithms, allowing precise measurement to be separated from the final display resolution, thereby achieving high measurement precision without requiring the entire device to be complex.
Solution Approach 2:
The patent changes the measurement parameters by introducing variable conversion factors (first conversion factor for outer diameter, second conversion factor for inner diameter) and applying zero-point error correction and displacement error correction through software algorithms. This allows the system to adapt measurement parameters dynamically based on the measurement type, improving precision without hardware complexity.
2Ease of operation
If conventional calipers use knife-edge measuring surfaces, then ease of operation is improved, but measurement precision deteriorates due to displacement error increasing as inner diameter decreases
Solution Approach 1:
The patent implements feedback through the microcontroller that continuously monitors displacement sensor data and applies real-time corrections for zero-point errors and displacement errors. The system calculates corrected inner diameter values using the formula: corrected value = raw measurement - zero-point error - displacement error, where displacement error is calculated based on the measured inner diameter value. This feedback mechanism maintains measurement precision across different diameter ranges while keeping the knife-edge measuring surfaces for ease of operation.
3Adaptability or versatility
If conventional calipers are used for small-diameter hole measurement, then cost-effectiveness is improved, but measurement precision deteriorates requiring expensive specialized tools
Solution Approach 1:
The patent makes the conventional digital caliper universal by enabling it to perform both standard measurements and high-precision small-diameter hole measurements through software-based corrections. The microcontroller applies different conversion factors and correction algorithms depending on the measurement type, allowing a single device to replace both conventional calipers and expensive specialized tools, achieving versatility across different measurement requirements.
4Measurement precision
If high-resolution sampling with correction mechanisms is implemented, then measurement precision is improved to micron-level, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical correction mechanisms with electronic and software-based solutions. Instead of using separate mechanical adjustment mechanisms for zero-point and displacement errors, the system uses a displacement sensor with 1.25μm resolution and applies corrections through microcontroller algorithms. This substitution of mechanical systems with electronic/software systems achieves micron-level precision while minimizing the increase in physical device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The digital caliper provides enhanced accuracy and efficiency in measuring small-diameter holes by minimizing errors and improving measurement resolution to 0.001 mm, reducing the need for expensive specialized tools.
Implementation Method 1
The displacement sensor comprises a fixed grating plate and a movable grating plate. The displacement sensor further comprises a sensor chip disposed on the movable grating plate. The sensor chip is used to detect electrical signals corresponding to the displacement of the movable grating plate to the fixed grating plate.
Data Source
AI summary
A digital caliper, including a measurement assembly; and an electronic module. The measurement assembly includes a caliper frame and a caliper body; the caliper frame is slidable on the caliper body. The electronic module includes a displacement sensor and a function module; the displacement sensor includes a fixed grating plate and a movable grating plate; the displacement sensor further includes a sensor chip disposed on the movable grating plate; the fixed grating plate is fixedly disposed on the caliper body; the movable grating plate is electrically connected to the function module; the movable grating plate is fixedly disposed on the caliper frame, and is movable together with the caliper frame; the function module includes a microcontroller, a measurement trigger mechanism, and a set button; the measurement trigger mechanism is configured to generate an on/off electrical signal when the caliper frame is moved.