The document describes an FPGA design project to demonstrate Abbe error in calipers. The design uses exaggerated calipers with a large clearance between the slider and rail to induce repeatable but inaccurate measurements due to Abbe error. A laser cut part with etched ruler is used to measure the error in a simple and quick to fabricate design. Analysis shows the design achieves the goals of demonstrating Abbe error's impact on accuracy while allowing for precise and repeatable measurements.
The document describes an FPGA design project to demonstrate Abbe error in calipers. The design uses exaggerated calipers with a large clearance between the slider and rail to induce repeatable but inaccurate measurements due to Abbe error. A laser cut part with etched ruler is used to measure the error in a simple and quick to fabricate design. Analysis shows the design achieves the goals of demonstrating Abbe error's impact on accuracy while allowing for precise and repeatable measurements.
The document describes an FPGA design project to demonstrate Abbe error in calipers. The design uses exaggerated calipers with a large clearance between the slider and rail to induce repeatable but inaccurate measurements due to Abbe error. A laser cut part with etched ruler is used to measure the error in a simple and quick to fabricate design. Analysis shows the design achieves the goals of demonstrating Abbe error's impact on accuracy while allowing for precise and repeatable measurements.
The document describes an FPGA design project to demonstrate Abbe error in calipers. The design uses exaggerated calipers with a large clearance between the slider and rail to induce repeatable but inaccurate measurements due to Abbe error. A laser cut part with etched ruler is used to measure the error in a simple and quick to fabricate design. Analysis shows the design achieves the goals of demonstrating Abbe error's impact on accuracy while allowing for precise and repeatable measurements.
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
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
