Lindsay Epstein

Shirley Lu
2.77 Spring 2019

FPGA 3: Exaggerated Calipers

An object of known size is measured using calipers with a large
clearance between the slider and rail. This clearance allows the slider to
rotate, leading to a repeatable, but inaccurate, measurement of the
object due to abbe error. The resolution of the calipers is set by the tick
marks used to measure the object, while the fixed portion of the rail
acts as a reference feature.
Deterministic Design Process
Functional Req. Design Parameter Analysis & Ref. Risks & Counter Measures
Demonstrate - Calipers Abbe error calculation All principles not felt in system
Abbe, accuracy,  Choose simplest system
- Laser + Bull’s Accuracy, Precision,
that clearly includes all 3
precision, and Resolution
Eye Game
resolution, Intentional “error” in system
sensitive direction FUNdaMENTALs
seen as error in design 
and ref features book
clearly define what is expected
and measured
Stay within time Simple and quick fab: DFM and DFA, Hard to fabrication  Design
limit availability of with few components, simplest
- Laser cut vs. mill
machines machining operations
- Few parts

Close form Error measurable with Abbe error Small error hard to measure 
solution etched ruler prediction large clearance in slider, high
resolution on etched ruler
1
Design Sketches / Concepts

Bulls-Eye “Game” Concept Exaggerated Caliper Concept

2
MODEL

3
Analysis
Critical Analysis:
- Abbe error in measurement of object due to large clearance in slider and distance from slider to object being measured
- Accuracy, precision, and resolution of multiple sets of measurement of same object

4
 Slider – mimicking the sliding part of the
calipers, whose location along this top
DETAILED DESIGN rail corresponds to the caliper readout;
intentionally designed to wedge to
clearly show effect of Abbe error
L – rail on which
the slider moves

Support

Support
Base – etched with a
ruler for ease of testing

Object – object to be measured (nominal width of 0.75”);

Has a shelf to constrain part in the Z-direction so it doesn’t
get lost in FPGA play 5
MANUFACTURING

Simple fabrication while

effectively demonstrating FPGA
principles
- Parts are laser cut or 3D
printed – no post-processing
operations required
- Standard fasteners in
clearance holes for ease of
assembly Most Critical Part: Slider
- Force applied to cause wedging (designed to
have a clearly visible wedging effect)
- Angle of slider causes Abbe error in measured
width of object 6
MEASUREMENTS
Measured vs Theory

x’
Fa

θ
l

7
SUMMARY
TIME BUDGET
- General trend in data measured data
matches expected values
- Abbe error drastically impacts accuracy
Category Time [hours]
of object measurement
Design (Individual + Peer Review + Final) 3
- Precise and repeatable measurements
CAD 2
(all measurements within 1/32” of each
Analysis 2.5
other)
Fabrication + Assembly 2.5
- Possible sources of errors:
Testing 1
- Limited resolution of etched “ruler”
Documentation 3
- Deflection/bending in slider
Total 14