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JD COLLEGE OF ENGINEERING AND MANAGEMENT

Education to Eternity

Department of Mechanical Engineering

Report on Comparators (Mechanical Comparators)

Subject : Measurement and Quality Control

Guided By : Prof. siddhart Ghosh

Submitted by

11. Krunal Deshmukh

12. Nishant Nikhade
13. Piyush Turankar
14.Priyanshu Wankhede
15.Priyanshu Kamble

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CONTENT PAGE

1. INTRODUCTION__________________________________ page No. 3

2.1 Comparators_____________________________________ page No. 4

2.1.1 Classifications of Comparators_____________________ page No. 5

2.1.2 Mechanical Comparators_________________________ page No.6

2.1.2.1 Dial Guages____________________________________ page No.6

2.1.2.2 Uses of Dial Guages_____________________________ page No. 8

2.1.2.3 Johansson Mikrokator __________________________ page No.10

2.1.2.4 Sigma Comparator_____________________________ page No. 12

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INTRODUCTION

All measurements require the unknown quantity to be compared with a

known quantity, called the standard. A measurement is generally made with
respect to time, mass, and length. In each of these cases, three elements are
involved: the unknown, the standard, and a system for comparing them. we
came across linear measurement instruments, such as verniers and micrometers,
in which standards are in-built and calibrated. , a comparator has to be set to a
reference value (usually zero setting) by employing a standard. Once it is set to
this reference value, all subsequent readings indicate the deviation from the
standard. The deviation can be read or recorded by means of a display or
recording unit, respectively.

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2.1 Comparators

All measurements require the unknown quantity to be compared with a

known quantity, called the standard. A measurement is generally made with
respect to time, mass, and length. In each of these cases, three elements are
involved: the unknown, the standard, and a system for comparing them. we
came across linear measurement instruments, such as verniers and micrometers,
in which standards are in-built and calibrated.

As can be seen in the figure, a calibrated standard directly gives the

measured value in case of direct measurement. On the other hand, a comparator
has to be set to a reference value (usually zero setting) by employing a standard.
Once it is set to this reference value, all subsequent readings indicate the
deviation from the standard. The deviation can be read or recorded by means of
a display or recording unit, respectively. Accuracy of direct measurement
depends on four factors: accuracy of the standard, accuracy of scale, least count
of the scale, and accuracy of reading the scale. The last factor is the human
element, which depends on the efficiency with which the scales are read and the
accurate interpretation of the readings.

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Fig. 2.1Direct measurement versus comparison measurement

Accuracy of comparison measurement primarily depends on four factors: a

ccuracy of the standard used for setting the comparator, least count of the
standard, sensitivity of the comparator, and accuracy of reading the scale. In
contrast to direct measurement, the role of the sensing element is significant in a
comparator. The sensitivity of the comparator to sense even a minute variation
in the measured value is equally important. The variation in the measured value
may be in terms of change in displacement, pressure, fluid flow, temperature,
and so on.

2.1.1 CLASSIFICATION OF COMPARATORS

We can classify comparators into mechanical device and electrical device on

the basis of the means used for comparison. In recent times, engineers prefer
to classify comparators as low-and high-amplification comparators, which
also reflect the sophistication of the technology that is behind these devices.
Accordingly, we can draw the following classification. With respect to the
principle used for amplifying and recording measurements, comparators are
classified as follows:

1. Mechanical comparators

2. Mechanical–optical comparators

3. Electrical and electronic comparators

4. Pneumatic comparators

5. Other types such as projection comparators and multi-check comparators

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Each of these types of comparators has many variants, which provide

flexibility to the user to make an appropriate and economical selection for a
particular metrological application.

2.1.2 Mechanical comparators

Mechanical comparators have a long history and have been used for many
centuries. They provide simple and cost-effective solutions. The skills for
fabricating and using them can be learnt relatively easily compared to other
types of comparators.

The following are some of the important comparators in metrology.

2.1.2.1 (a) Dial Indicator

The dial indicator or the dial gauge is one of the simplest and the most
widely used comparator. It is primarily used to compare workpieces against a
master. The basic features of a dial gauge consist of a body with a circular
graduated dial, a contact point connected to a gear train, and an indicating
hand that directly indicates the linear displacement of the contact point. The
contact point is first set against the master, and the dial scale is set to zero by
rotating the bezel. Now, the master is removed and the workpiece is set
below the contact point; the difference in dimensions between the master and
the workpiece can be directly read on the dial scale. Dial gauges are used
along with V-blocks in a metrology laboratory to check the roundness of
components. A dial gauge is also part of standard measuring devices such as
bore gauges, depth gauges, and vibrometers. Figure illustrates the functional
parts of a dial indicator.

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Fig. 2.2 Functional parts of a dial indicator

The contact point in a dial indicator is of an interchangeable type and

provides versatility to the instrument. It is available as a mounting and in a
variety of hard, wear-resistant materials. Heat-treated steel, boron carbide,
sapphire, and diamond are some of the preferred materials. Although flat and
round contact points are commonly used, tapered and button-type contact
points are also used in some applications. The stem holds the contact point
and provides the required length and rigidity for ease of measurement. The
bezel clamp enables locking of the dial after setting the scale to zero. The
scale of the dial indicator, usually referred to as dial, provides the required
least count for measurement, which normally varies from 0.01 to 0.05 mm.
The scale has a limited range of linear measurements, varying from 5 to 25
mm. In order to meet close least count, the dial has to be large enough to
improve readability. The dials are of two types: continuous and balanced. A
continuous dial has graduations starting from zero and extends to the end of
the recommended range. It can be either clockwise or anti-clockwise. The
dial corresponds to the unilateral tolerance of dimensions. On the other hand,
a balanced dial has graduations marked both ways of zero. This dial
corresponds to the use of bilateral tolerance. Figure 6.3 illustrates the
difference between the two types of dials.

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Fig. 2.40 Method for designating numbers

Metrological features of a dial indicator differ entirely from measuring

instruments such as slide callipers or micrometers. It measures neither the
actual dimension nor does it have a reference point. It measures the amount
of deviation with respect to a standard. In other words, we measure not
length, but change in length. In a way, this comparison measurement is
dynamic, unlike direct measurement, which is static. Obviously, the ability to
detect and measure the change is the sensitivity of the instrument.

2.1.2.2 (b) Use of Dial Indicators

A dial indicator is frequently built into other measuring instruments or

systems, as a read-out device. It is more often used as a comparator in order
to determine the deviation in a dimension from a set standard. The setting of
the indicator is done using a master or gauge block.

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Fig. 2.3 Dial indicator mounted on a stand

The dial indicator can be moved up and down and clamped to the stand at
any desired position, thereby enabling the inspection of components of various
sizes. To start with, the indicator is moved up and the standard is placed on the
reference surface, while ensuring that the spindle of the indicator does not make
contact with the standard. Next, the stand clamp is loosened and the spindle of
the indicator is gently lowered onto the surface of the standard such that the
spindle is under the required gauge pressure. Now, the indicator is held in
position by tightening the stand clamp. The bezel clamp is loosened, the bezel is
rotated, and the reading is set to zero. The dial indicator should be set to a
dimension that is approximately in the centre of the spread over which the
actual object size is expected to vary.

The following guidelines are recommended for the proper use of dial
indicators:
1. A dial indicator is a delicate instrument as the slender spindle can be
damaged easily. The user should avoid sudden contact with the workpiece
surface, overtightening of contact points, and side pressure.

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2. Any sharp fall or blow can damage the contact points or upset the
alignment of bearings, and hence should be avoided.

3. Standard reference surfaces should be used. It is not recommended to use

nonstandard attachments or accessories for reference surfaces.

4. The dial indicator should be cleaned thoroughly before and after use. This
is very important because unwanted dust, oil, and cutting fluid may seep
inside the instrument and cause havoc to the maze of moving parts.

5. Periodic calibration of the dial gauge is a must.

2.1.2.3 Johansson Mikrokator

Fig. 2.4 Johansson Mikrokator

The basic element in this type of comparator is a light pointer made of glass
fixed to a thin twisted metal strip. Most of us, during childhood, would be
familiar with a simple toy having a button spinning on a loop of string.
Whenever the loop is pulled outwards, the string unwinds, thereby spinning
the button at high speed. This type of comparator, which was developed by
the Johansson Ltd Company of USA, uses this principle in an ingenious
manner to obtain high mechanical magnification. The basic principle is also

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referred to as the ‘Abramson movement’ after H. Abramson who developed

the comparator. The two halves of the thin metal strip, which carries the light
pointer, are twisted in opposite directions. Therefore, any pull on the strip
will cause the pointer to rotate. While one end of the strip is fixed to an
adjustable cantilever link, the other end is anchored to a bell crank lever. The
other end of the bell crank lever is fixed to a plunger. Any linear motion of
the plunger will result in a movement of the bell crank lever, which exerts
either a push or a pull force on the metal strip. Accordingly, the glass pointer
will rotate either clockwise or anticlockwise, depending on the direction of
plunger movement. The comparator is designed in such a fashion that even a
minute movement of the plunger will cause a perceptible rotation of the glass
pointer. A calibrated scale is employed with the pointer so that any axial
movement of the plunger can be recorded conveniently. We can easily see
the relationship of the length and width of the strip with the degree of
amplification.

It is clear from the preceding equation that magnification varies inversely

with the number of turns and width of the metal strip. The lesser the number
of turns and thinner the strip, the higher is the magnification. On the other
hand, magnification varies directly with the length of the metal strip. These
three parameters are varied optimally to get a compact but robust instrument.
A pull on the metal strip subjects it to tensile force. In order to prevent
excessive stress on the central portion of the metal strip, perforations are
made in the strip. A slit washer is provided to arrest the rotation of the
plunger along its axis.

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2.1.2.4 Sigma Comparator

Fig. 2.5 Sigma mechanical comparator

It is a simple but ingenious mechanical comparator developed by the Sigma

Instrument Company, USA. A linear displacement of a plunger is translated into
the movement of a pointer over a calibrated scale.

The plunger is the sensing element that is in contact with the work part. It
moves on a slit washer, which provides frictionless linear movement and also
arrests rotation of the plunger about its axis. A knife edge is screwed onto the
plunger, which bears upon the face of the moving member of a cross-strip
hinge. This unit comprises a fixed member and a moving block, connected by
thin flexible strips at right angles to each other. Whenever the plunger moves up
or down, the knife edge drives the moving member of the cross-strip hinge
assembly. This deflects an arm, which divides into a ‘Y’ form. The extreme ends
of this Y-arm are connected to a driving drum by means of phosphor-bronze
strips. The movement of the Y-arm rotates the driving drum and, in turn, the
pointer spindle. This causes the movement of the pointer over a calibrated scale.

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accurate and reliable, which has made them the preferred choice in many
applications. The most significant advantage offered by electronic
comparators is the speed of response. A measurement rate of 500 per minute
is easily accomplish

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