Calipers

A caliper (British spelling also calliper, or in plurale tantum sense a pair of

calipers) is a device used to measure the distance between two opposite sides
of an object. Many types of calipers permit reading out a measurement on a
ruled scale, a dial, or a digital display. But a caliper can be as simple as a
compass with inward or outward-facing points. The tips of the caliper are
adjusted to fit across the points to be measured and then the caliper is then
removed and the distance read by measuring between the tips with a
measuring tool, such as a ruler. Caliper detail view

It is used in many fields such as mechanical engineering, metalworking,

forestry, woodworking, science and medicine.

Contents
Nomenclature variants
History
Types
Inside caliper
Outside caliper
Divider caliper
Oddleg caliper
Vernier caliper
Dial caliper
Digital caliper
Micrometer caliper
Comparison
Use
Zero error
See also
References
External links

Nomenclature variants
A plurale tantum sense of the word "calipers" coexists in natural usage with the regular noun sense of "caliper". That is,
sometimes a caliper is treated cognitively like a pair of glasses or a pair of scissors, resulting in a phrase such as "hand me
those calipers" or "those calipers are mine" in reference to one unit.

Also existing colloquially but not in formal usage is referring to a vernier caliper as a "vernier" or a "pair of verniers". In
imprecise colloquial usage, some speakers extend this even to dial calipers, although they involve no vernier scale.
In machine-shop usage, the term "caliper" is often used in contradistinction to "micrometer", even though outside
micrometers are technically a form of caliper. In this usage, "caliper" implies only the form factor of the vernier or dial
caliper (or its digital counterpart).

History
The earliest caliper has been found in the Greek Giglio wreck near the Italian coast. The ship find dates to the 6th century
BC. The wooden piece already featured a fixed and a movable jaw.[1][2] Although rare finds, caliper remained in use by the
Greeks and Romans.[2][3]

A bronze caliper, dating from 9 AD, was used for minute measurements during the Chinese Xin dynasty. The caliper had
an inscription stating that it was "made on a gui-you day at new moon of the first month of the first year of the Shijian guo
period." The calipers included a "slot and pin" and "graduated in inches and tenths of an inch."[4][5]

The modern vernier caliper, reading to thousandths of an inch, was invented

by American Joseph R. Brown in 1851. It was the first practical tool for exact
measurements that could be sold at a price within the reach of ordinary
machinists.[6]

Types

Caliper with graduated bow 0–

Inside caliper
10 mm
The inside calipers are used to measure the internal size of an object.

The upper caliper in the image (at the right) requires manual adjustment
prior to fitting. Fine setting of this caliper type is performed by tapping the
caliper legs lightly on a handy surface until they will almost pass over the
object. A light push against the resistance of the central pivot screw then
spreads the legs to the correct dimension and provides the required,
consistent feel that ensures a repeatable measurement.
The lower caliper in the image has an adjusting screw that permits it to be
carefully adjusted without removal of the tool from the workpiece.

Two inside calipers

Outside caliper
Outside calipers are used to measure the external size of an object.

The same observations and technique apply to this type of caliper, as for the above inside caliper. With some
understanding of their limitations and usage, these instruments can provide a high degree of accuracy and repeatability.
They are especially useful when measuring over very large distances; consider if the calipers are used to measure a large
diameter pipe. A vernier caliper does not have the depth capacity to straddle this large diameter while at the same time
reach the outermost points of the pipe's diameter. They are made from high carbon steel.
 Three outside calipers.

Divider caliper
In the metalworking field, a divider caliper, popularly called a compass, is
used in the process of marking out locations. The points are sharpened so that
they act as scribers, one leg can then be placed in the dimple created by a
center or prick punch and the other leg pivoted so that it scribes a line on the
workpiece's surface, thus forming an arc or circle.

A divider caliper is also used to measure a distance between two points on a

A pair of dividers
map. The two caliper's ends are brought to the two points whose distance is
being measured. The caliper's opening is then either measured on a separate
ruler and then converted to the actual distance, or it is measured directly on a scale drawn on the map. On a nautical chart
the distance is often measured on the latitude scale appearing on the sides of the map: one minute of arc of latitude is
approximately one nautical mile or 1852 metres.

Dividers are also used in the medical profession. An ECG (also EKG) caliper transfers distance on an electrocardiogram; in
conjunction with the appropriate scale, the heart rate can be determined. A pocket caliper versions was invented by
cardiologist Robert A. Mackin.[7]

Oddleg caliper
Oddleg calipers, Hermaphrodite calipers, or Oddleg jennys, as
pictured on the left, are generally used to scribe a line at a set distance from the
edge of a workpiece. The bent leg is used to run along the workpiece edge while
the scriber makes its mark at a predetermined distance, this ensures a line
parallel to the edge.

In the diagram at left, the uppermost caliper has a slight shoulder in the bent
Oddleg calipers leg allowing it to sit on the edge more securely, the lower caliper lacks this
feature but has a renewable scriber that can be adjusted for wear, as well as
being replaced when excessively worn.

Vernier caliper
The vernier,
dial, and
digital
calipers give a
direct reading
of the
distance
measured
with high
accuracy and
precision.
They are Diagram of Vernier calipers. The labeled parts are
functionally 1. Outside large jaws: used to measure external diameter or width of an object
identical, with 2. Inside small jaws: used to measure internal diameter of an object
different ways
3. Depth probe/rod: used to measure depths of an object or a hole
of reading the
4. Main scale (Metric): scale marked every mm
result. These
5. Main scale (Imperial): scale marked in inches and fractions
calipers
6. Vernier scale (Metric) gives interpolated measurements to 0.1 mm or better
comprise a
7. Vernier scale (Imperial) gives interpolated measurements in fractions of an inch
calibrated
8. Retainer: used to block movable part to allow the easy transferring of a measurement
scale with a
The calipers in the diagram show a primary reading on the metric scale of about 2.475 cm (2.4 cm
fixed jaw, and
read from the main scale plus about 0.075 cm from the Vernier scale). Calipers often have a "zero
another jaw, point error", which is when the calipers do not read 0.000 cm when the jaws are closed. The zero
with a point error must always be subtracted from the primary reading. Let us assume these calipers have a
pointer, that zero point error of 0.013 cm. This would give us a length reading of 2.462 cm. For any measurement,
slides along reporting the error on the measurement is also important. Both the primary reading and the zero
point reading are bounded by plus/minus half the length corresponding to the width of the smallest
the scale. The
interval on the Vernier scale (0.0025 cm). These are "absolute" errors and absolute errors add, so
distance
the length reading is then bounded by plus/minus the length corresponding to the full width of the
between the smallest interval on the Vernier scale (0.005 cm). Assuming no systematics affect the measurement
jaws is then (the instrument works perfectly), a complete measurement would then read 2.462 cm ± 0.005 cm.
read in
different ways
for the three types.

The simplest method is to read the position of the pointer directly on the scale. When the pointer is between two
markings, the user can mentally interpolate to improve the precision of the reading. This would be a simple calibrated
caliper; but the addition of a vernier scale allows more accurate interpolation, and is the universal practice; this is the
vernier caliper.

Vernier, dial, and digital calipers can measure internal dimensions (using the uppermost jaws in the picture at right),
external dimensions using the pictured lower jaws, and in many cases depth by the use of a probe that is attached to the
movable head and slides along the centre of the body. This probe is slender and can get into deep grooves that may prove
difficult for other measuring tools.

The vernier scales may include metric measurements on the lower part of the scale and inch measurements on the upper,
or vice versa, in countries that use inches. Vernier calipers commonly used in industry provide a precision to 0.01 mm (10
micrometres), or one thousandth of an inch. They are available in sizes that can measure up to 1,829 mm (72 in).[8]
Dial caliper
Instead of using a vernier mechanism, which requires some practice to use, the
dial caliper reads the final fraction of a millimeter or inch on a simple dial.

In this instrument, a small, precise rack and pinion drives a pointer on a

circular dial, allowing direct reading without the need to read a vernier scale.
Mitutoyo dial caliper
Typically, the pointer rotates once every inch, tenth of an inch, or 1 millimeter.
This measurement must be added to the coarse whole inches or centimeters
read from the slide. The dial is usually arranged to be rotatable beneath the pointer, allowing for "differential"
measurements (the measuring of the difference in size between two objects, or the setting of the dial using a master object
and subsequently being able to read directly the plus-or-minus variance in size of subsequent objects relative to the master
object).

The slide of a dial caliper can usually be locked at a setting using a small lever or screw; this allows simple go/no-go checks
of part sizes.

Digital caliper
A popular refinement replaces the analog dial with an electronic digital display
that displays the reading as a numeric value. Rather than a rack and pinion,
these calipers use a linear encoder. 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 a "reading
hold" feature, allowing the reading of dimensions after use in awkward
locations where the display cannot be seen. Ordinary 6-in/150-mm digital

Digital caliper calipers are made of stainless steel, have a rated accuracy of 0.001 in
(0.02mm) and a resolution of 0.0005 in (0.01 mm).[9] The same technology is
used to make longer 8-in and 12-in calipers; the accuracy for longer
measurements declines to 0.001 in (0.03 mm) for 100–200 mm and 0.0015 in (0.04 mm) for 200–300 mm.[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]
Sylvac interface. This is the common protocol for inexpensive, non-name brand, calipers. Format is 24 bit 90 kHz
synchronous.[14][15]
Starrett[16]
Brown & Sharpe[16]
Federal
Tesa[16]
Aldi. Format is 7 BCD digits.[15]
 Mahr (Digimatic, RS232C, Wireless FM Radio, Infrared and USB)[17]
Like dial calipers, the slide of a digital caliper can usually be locked using a lever or thumb-screw.

Some digital calipers contain a capacitive 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. The two capacitances are out of phase. As the
slider moves the capacitance changes in a linear fashion and in a repeating pattern. 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. Other digital calipers contain an inductive linear encoder, which allows robust performance
in the presence of contamination such as coolants.[18] Magnetic linear encoders are used in yet other digital calipers.

Micrometer caliper
A caliper using a calibrated screw for measurement, rather than a slide, is called an external micrometer caliper gauge, 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.)

Comparison
Each of the above types of calipers has its 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. In production environments, reading vernier calipers all day long is error-prone and is annoying to
the workers.

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 in, but accuracy may not be better than about ±0.02 mm or
0.001 in for 150 mm (6 in) calipers, and worse for longer ones.[19]

Use
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 Using the vernier caliper
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. A vernier caliper does not easily lose its calibration but a
sharp impact or accidental damage to the measuring surface in the caliper jaw can be significant enough to displace
zero.[20] Digital calipers have zero set buttons, for quick recalibration.

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).

Zero error
The method to use a vernier scale or caliper with zero error is to use the
formula "actual reading = main scale + vernier scale − (zero error)". Zero error
may arise due to knocks that affect the calibration at 0.00 mm when the jaws
are perfectly closed or just touching each other. Positive zero error refers to the
fact that when the jaws of the vernier caliper are just closed, the reading is a
positive reading away from the actual reading of 0.00 mm. If the reading is
0.10 mm, the zero error is referred to as +0.10 mm. Negative zero error refers When the jaws are closed and if the
to the fact that when the jaws of the vernier caliper are just closed, the reading reading is 0.10 mm, the zero error is
referred to as +0.10 mm. The
is a negative reading away from the actual reading of 0.00 mm. If the reading
method to use a vernier scale or
is −0.08 mm, the zero error is referred to as −0.08 mm. caliper with zero error is to use the
formula "(actual reading) = (main
See also scale) + (vernier scale) − (zero
error)", thus the actual reading is
Dial indicator 19.00 + 0.54 − (0.10) = 19.44 mm.
The resolution of the measurement,
Cruising rod
based on the width of the smallest
Lens clock
sub-interval, is ±0.02 mm.

References
1. Mensun Bound: The Giglio wreck: a wreck of the Archaic period (c. 600 BC) off the Tuscany island of Giglio, Hellenic
 Institute of Marine Archaeology, Athens 1991, pp. 27 and 31 (Fig. 65)
2. Roger B. Ulrich: Roman woodworking, Yale University Press, New Haven, Conn., 2007, ISBN 0-300-10341-7, p.52f.
3. "hand tool." Encyclopædia Britannica from Encyclopædia Britannica 2006 Ultimate Reference Suite DVD. [Accessed
July 29, 2008]
4. Colin A. Ronan; Joseph Needham (24 June 1994). The Shorter Science and Civilisation in China: 4 (https://books.goo
gle.com/books?id=PehoSnJfstUC&pg=PA36#v=onepage&q&f=false). Cambridge University Press. p. 36. ISBN 978-
0-521-32995-8. "adjustable outside caliper gauge... self-dated at AD 9". An abridged version.
5. "Archived copy" (https://web.archive.org/web/20140831052938/http://history.cultural-china.com/en/56H2758H7991.ht
ml). Archived from the original (http://history.cultural-china.com/en/56H2758H7991.html) on 2014-08-31. Retrieved
2013-11-26.
6. Joseph Wickham Roe, English and American tool builders (1916) p. 203 (https://archive.org/stream/englishamericant
00roej/englishamericant00roej_djvu.txt)
7. http://www.mackinmfg.com/ shows a picture of the calipers but does not support the RAM claim.
8. "Archived copy" (https://web.archive.org/web/20100525030431/http://www.starrett.com/download/246_p108_114.pdf)
(PDF). Archived from the original (http://www.starrett.com/download/246_p108_114.pdf) (PDF) on 2010-05-25.
Retrieved 2010-06-25.
9. "Harbor Freight Tools – Quality Tools at Discount Prices Since 1977" (http://www.harborfreight.com/cpi/ctaf/displayite
m.taf?Itemnumber=47257). www.harborfreight.com.
10. "Archived copy" (https://web.archive.org/web/20070726053453/http://www.msi-viking.com/digital_caliper/). Archived
from the original (http://www.msi-viking.com/digital_caliper/) on 2007-07-26. Retrieved 2009-06-12.
11. DRO System: Linear Scales & Counters (https://web.archive.org/web/20131103082232/http://www.mitutoyo.com/pdf/
1715.pdf) (PDF), Mitutoyo, n.d., p. 22, Bulletin No. 1715, archived from the original (http://www.mitutoyo.com/pdf/171
5.pdf) (PDF) on 2013-11-03
12. Linear Gage (https://web.archive.org/web/20131103082151/http://www.mitutoyo.com/pdf/E4174-542.pdf) (PDF),
Mitutoyo, n.d., p. 33, Catalog No. E4174-542/572/575, archived from the original (http://www.mitutoyo.com/pdf/E4174-
542.pdf) (PDF) on 2013-11-03
13. Lancaster, Don (February 2000), "Tech Musings" (http://www.tinaja.com/glib/muse145.pdf) (PDF), Tech Musings, 145
14. "Chinese Scales" (http://www.shumatech.com/support/chinese_scales.htm). www.shumatech.com.
15. Yadro (http://www.yadro.de/digital-scale/protocol.html) archive-date=2013-12-09 archive-
url=https://web.archive.org/web/20131209053512/http://yadro.de/digital-scale/protocol.html
16. Lancaster, Don (November 1999), "Tech Musings" (http://www.tinaja.com/glib/muse142.pdf) (PDF), Tech Musings,
142: 142.3
17. "New Mahr 2015 Catalogue" (http://www.cutwel.co.uk/new-mahr-2015-catalogue). www.Cutwel.co.uk. Cutwel.
18. ABS Coolant Proof Caliper; Coolant Proof Micrometer (https://web.archive.org/web/20131103082314/http://www.mitut
oyo.com/pdf/ABS1813-293.pdf) (PDF), Mitutoyo, January 2005, Bulletin No. 1813-293/500, archived from the original
(http://www.mitutoyo.com/pdf/ABS1813-293.pdf) (PDF) on 2013-11-03
19. "Accuracy of Calipers" (http://www.tresnainstrument.com/accuracy_of_calipers.html). www.tresnainstrument.com.
20. Mitutoyo. E 12024 Check Points For Measuring Instruments (https://archive.org/details/E12024CheckPointsForMeasu
ringInstruments). pp. 2, 3.

External links
RS-232 Interface Design Details For Digital Caliper (http://www.compendiumarcana.com/caliper/)

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