Supercharging Your Digital Calipers

August 8, 2013 by 56 Comments

supercapCalipers01

A dead battery in your digital calipers usually means a trip to the store for a new button cell. Not for [Trevor]. His hack substitutes a super capacitor, guaranteeing you’ll never need to rummage around for one of those pesky watch batteries again.

These calipers require only 20 seconds to reach a full charge that can last for a few days. Better still, [Trevor] designed a simple circuit with a voltage regulator at the end of the cord to allow charging via USB: just remember to flip the switch from “discharging” to “charging” mode. Although this is a fairly straightforward hack, its design is impressively tidy. The super capacitor fits perfectly at the end of the display and slides along with it, keeping it away from any important printed numbers. If these are the same calipers everyone seems to have these days, it looks like it may still fit in the provided case, too.

If you’re looking for more ways to beef up your calipers, try upgrading them with a Bluetooth module.

Giving Digital Calipers Bluetooth

June 20, 2013 by 28 Comments

[Fede]’s wife uses a pair of digital calipers to take measurements of fruits, leaves, and stems as part of her field research. Usually this means taking a measurement and writing it down in a log book. All things must be digitized, so [Fede] came up with a way to wirelessly log data off a pair of cheap Chinese calipers with a custom-made Bluetooth circuit.

Most of these cheap Chinese digital calipers already have a serial output, so [Fede] only needed to build a circuit to take the serial output and dump it in to an off-the-shelf Bluetooth module. He fabbed a custom circuit board for this, and after seeing the increased battery drain from the Bluetooth module, decided to add an external battery pack.

In addition to etching his own board for sending the serial output of the calipers to a Bluetooth module, [Fede] also put together a custom flex circuit to connect the two boards. It’s just a small bit of brass glued to a transparency sheet etched with ferric chloride, but the end result looks amazingly professional for something whipped up in a home lab.

Talking Digital Calipers Make Engineering More Accessible

November 9, 2011 by 14 Comments

talking-digital-calipers

The team over at NerdKits recently put together a device aimed to help make the process of measuring things more accessible to those with disabilities. [Terry Garrett] is a Mechanical Engineering student, and as anyone who is in the field knows, it’s a discipline which requires taking tons of measurements. Since [Terry] cannot see he was often asking classmates to assist in measuring items during labs, but when he got a job at a nearby design studio, he knew he would have to find a way to take those measurements on his own.

Enter NerdKits.

[Humberto] wrote in to share how he and his team built a set of talking digital calipers to assist [Terry] in his daily tasks. They based the design off a previous project they worked on, getting digital readout data from a set of calipers. The DRO information is fed into an ATmega382p, which pieces together pre-recorded sound bites to announce the size of the object being measured.

As you can see in the video below, the system looks to work very well, and [Terry] is quite pleased with his new talking tool. We love seeing these sorts of hacks, because they truly make a difference in people’s lives – excellent job!

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Hold, Fast, And Max Features On A Digital Caliper

January 12, 2011 by 67 Comments

While adding an RJ-11 connector to his digital calipers [BadWolf] slipped, shorting out a pin and accidentally discovered new features. He intended to add a port for reading measurement data electronically, but after the slip-up an ‘H’ appeared on the LCD screen and the measurement was frozen at the same number. At first it seemed like he may have killed the device, but this is actually a hold function. A little bit more playing around and he discovered that a combination of button presses can also enable a fast function which speeds up the rate at which the display changes its reading. There is even a max function that only updates the display if the reading is higher than any previously displayed measurement. These are nice features which he uses by connecting a momentary push switch between two of the output pins, details we gleaned from the annotated video after the break. He doesn’t say which pins work for him, but we’d bet one of them is the ground pin on the port, and the other is one of the two data pins. Do some investigating with your own calipers and let us know what you find in the comments.

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Reading A Digital Caliper With A Microcontroller

December 15, 2010 by 21 Comments

[Maris] wanted a way to read measurements from a digital caliper electronically. He ended up using the TI Launchpad to accomplish this, but not all of the necessary hardware is seen above. The calipers cost him about $7 on eBay, and they have four interface pins which made this hack quite a bit easier. After a bit of probing he established their purpose; voltage, ground, clock and data. A bit of scoping proved that data was being sent in 24-bit burst in packets that are quite easy to decode.

From there it’s just a matter of interfacing with a microcontroller. The chip he’s using is an MSP430G2231 that runs at 3.3V, but the caliper’s logic high is only 1.5v. By constructing an adapter using a pair of transistors, the data and clock from the calipers are able to pull pins on the MSP430 low. This is collected and analyzed by [Maris’] firmware and can be read on a PC using a terminal program.

[Thanks Chris]

Digital Caliper Modding

March 11, 2007 by 6 Comments


This particular hack is actually used in a kit design, but it’s still pretty sweet. This is a digital read out unit that’s a kit sold by shumatech. I’ve even mentioned it in passing before. The design takes in the pulses from inexpensive chinese made digital scales/calipers, and allows one stop calibration and ouput of three axis’s of measurement. Using the interface and a usb enabled pic, and you could make your own usb digital calipers… (Hmm, I might have to make some.)

Custom Caliper Tracks For When You’re Going The Distance

August 5, 2021 by 15 Comments

The working principle of digital calipers is mysterious enough that we’d never think to dismantle, much less improve them, right? Well, think again, as [Limi DIY] retrofits the processing element onto a custom track, extending the calipers measurement distance to a whopping 650 mm. Combined with a prior project to extract the measurement data, the result makes for a working multi-axis digital readout, a handy device for machine tools like a manual lathe or milling machine.

Digital calipers operate on the principle of measuring an array of variable capacitors. If we scratch our heads and look back at our physics notes, we’ll recall that the capacitance between two parallel conductive plates is linearly proportional to the surface area. By fixing one dimension of both plates and by sliding one plate over the other, we effectively change the area, giving ourselves a simple linear displacement sensor! (There are some classy error-correcting techniques too, and this [PDF] is a great place to look for more details.)

The theory takeaway is that this array of parallel plates can be embedded directly into a printed circuit board. We just need to know the dimensions. After some close measurement work, [Limi DIY] extracted the crucial measurements and fabbed a PCB with the pattern duplicated over 650 mm. After retrofitting the original processing element onto this new track, they had a working measurement device that’s far longer than the original!

If you’ve ever been tempted to disassemble your calipers but too nervous to bite off the investment, now’s your chance to follow along as [Lima DIY] demonstrates the gratuitous disassembly process for you in video format. And the fruits of their labor is also captured on a project post that includes the key dimensions if you’re looking to do the same thing.

If you’re looking for other ways to improve your calipers, why not start by giving them a major battery life boost.

Thanks to [absd] via [Jubilee Discord] for the tip!

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