6/14/2020

WEEK 7
COMPARATORS

Introduction
 A device used for comparing a measurable property or thing
with a reference or standard.

 It is a precision instrument employed to compare the dimension

of a given component with a working standard.

 It does not measure the actual dimension but indicates how

much it differs from the basic dimension.

 The general principle of comparator is to indicate the

differences in size between the standard and the work.

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Need For A Comparator

 In mass production, where components are to be checked

at a very fast rate.
 As laboratory standards from which working or inspection
gauges are set and correlated.
 For inspecting newly purchased gauges.
 Attached with some machines, comparators can be used as
working gauges to prevent work spoilage and to maintain
required tolerances at all stages of manufacturing.
 In selective assembly of parts, where parts are graded in
three or more groups depending upon their tolerances.

Desirable features of Comparators

 Robust design and construction
 Linear characteristics of scale
 High magnification
 Quick in Results
 Versatility
 Minimum Wear of contact Point
 Free from Oscillations
 Free from backlash
 Quick insertion of work piece
 Adjustable table
 Compensation from temperature effects
 Means to prevent damage

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Principle of Comparators
All comparators consist of three basic features:
1)A sensing device
Which faithfully senses the input signal

2) A Magnifying or amplifying system

To increase the signal to suitable magnitude.
Mechanical, Optical, Pneumatic, hydraulic and electronic methods
are used for this purpose.

3) A display system (usually a scale and pointer)

Which utilizes the amplified signal to provide a suitable
readout.

Classification of Comparators
Mechanical comparators

Optical comparators

Electrical and Electronic comparators

Pneumatic comparators

Fluid displacement comparators

Projection comparators

Multi-check comparators

Automatic gauging machines

CMM

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Mechanical Comparator
 The mechanical comparator is also called as “microcator”.

 In mechanical comparators, magnification is achieved by

various mechanical devices and mechanical linkages.

 Mechanical comparator is a measuring instrument.

 The mechanism of this instrument is in the form of tape spring

twisted, and that is positioned in the middle part.

 The middle part of the mechanical comparator rotates

through a fixed angle upon tension.

Working principle of a Mechanical Comparator

 A mechanical comparator employees mechanical means

for magnifying the small movement of the stylus.

 the magnification of the small stylus movement is

obtained by means of levers, gear trains, rack and
pinion or a combination.

 The usual magnification obtained by these comparators

ranges from about 250 to 1000.

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Working Principle

Rack & Pinion Cam & Gear Train Lever with toothed Gear

Compound Levers Twisted Taut Strip Lever Combined

Types of Mechanical Comparators

 Dial Indicator

 Johansson Mikrokator

 Sigma Mechanical Comparator

 Dial Thickness Gauge

 Reeds Type Comparator

 External & internal Groove Comparator

 Plate Gauge Type comparator

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Dial Indicator
 Instrument which sense the measuring distance variations.

 It has a rack & pinion Mechanism Which Convert the axial

displacement of a measuring spindle into rotational movement.

 The movement is then amplified & displayed on a pointer graduated

scale or digital display.

 It has following Types:

 Mechanical Dial Indicator
 Mechanical Dial indicator with Limit Contacts
 Micrometer Dial Comparator
 Lever Type dial Indicator

https://www.youtube.com/watch?v=Kpuj
BaNPx5E

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Johansson Mikrokator

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Reeds Type Comparator

Advantages of Mechanical Comparator

 Cheaper than all the other type of comparators

 Does not require any external source of power or air supply

 These comparators use a linear scale that can be easily

understood.

 Usually these comparators are robust and compact but are very
easy to handle

 These are small in size and can are portable from one place to
other very easily without much difficulty

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Limitations of Mechanical Comparator

 Contains more number of moving parts so there develops friction

which in turn reduces the accuracy

 Slackness in the moving parts reduces accuracy very drastically

 These have more inertia so the instrument is prone to vibrational

effects

 Limited range of the instrument is another drawback as the pointer

moves over a fixed scale

 Parallax error may also arise when proper scale is used

Optical Comparators
 In this comparator a small dislocation of the measuring plunger
is first amplified by a mechanical system comprising of pivoted
levers.

 The mechanical movement which is amplified by an optical

system connecting the outcrop an image.

 The general arrangement of mechanical system causes a

reflector to angle near the image

 An axis of an index estimated on a scale on the inner glass

screen.

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Principle Of Optical Comparator

Types of Optical Comparator

 Profile (optical) Projector

 Mechanical Optical Comparator

 Zesis Optical Comparator

 Electrical Optical Comparator

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Mechanical Optical Comparator

Zesis Ultra Comparator

 It gives very high magnification, as it works on
double magnification principle.

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Advantages of Optical Comparators

 It has small number of moving parts and hence a higher

accuracy.

 In the optical comparators, the scale can be made to

move past a datum line and thus have high range and
no parallax errors.

 It has very high magnification.

 Optical lever is weightless

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Limitations of Optical Comparators

 As the instrument has high magnification, heat from the lamp,
transformer etc. may cause the setting to drift.

 An electrical supply is necessary.

 The apparatus is usually large and expensive.

 When the scale is projected on a screen, then it is essential to use

the instrument to a dark room in order to take the readings easily.

 The instruments in which the scale is viewed through the eyepiece

of a microscope are not convenient for continuous use.

Pneumatic Comparator
 In pneumatic comparators, either air flow or air
pressure is measured to give measurement
deviations from a standard.

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Basic Principle of Pneumatic

Types of Pneumatic Comparator

 Differential Back-Pressure-Type Comparator

 Solex Comparator

 Velocity Differential-Type Air gauge with Barr

Graph & Digital Display

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Advantages of Pneumatic Comparator

 The gauging member does not come into contact with the part to be
measured and hence practically no wear takes place on the
gauging member.
 It has usually very small number of moving parts and in some cases
none. Thus the accuracy is more due to less friction and less inertia.
 Measuring pressure is very small and the jet of air helps in cleaning
the dust, if any, from the part to be measured.
 It is possible to have very high magnification.
 The indicating instrument can be remote from the measuring unit.
 It is very suitable device for measuring diameter of holes where the
diameter is small compared with the length.
.

Limitations of Pneumatic Comparators

 It requires elaborate auxiliary equipment such as accurate

pressure regulator.

 The scale is generally not uniform.

 When indicating device is the glass tube, then high magnification

is necessary in order to avoid the meniscus errors.

 The apparatus is not easily portable and is rather elaborate for

many industrial applications.

 Different gauging heads are required for different dimensions.

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Electric & Electronic Comparators

 It is essentially consist of a transducer for converting a
displacement into a corresponding change in current or
Potential difference.

 The change in displacement is calibrated in three ways:

 Using Inductive Principle
 Using Capacitive Principle

 Using Resistive principle

Working Principle Electrical Comparators

 It requires elaborate auxiliary equipment such as accurate pressure

regulator.
 The scale is generally not uniform.
 When indicating device is the glass tube, then high magnification is
necessary in order to avoid the meniscus errors.
 The apparatus is not easily portable and is rather elaborate for
many industrial applications.
 Different gauging heads are required for different dimensions.
 It breaks against the W and spring and W1.
 If the armature is located between the coils W & W1, then the
inductance of these coils is equal.
 The Wheatstone bridge is stable and forms the datum line.

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Working Principle Electrical Comparators

 When the work piece is located under the stylus for the
measurement purpose due to the difference in datum.
 The armature, component size would either be raised up or down.
 It defeats the Wheatstone bridge balance that results the
unbalanced current flow.
 This current is directly adjusted into difference in size of the
component which is expanded by an amplifier specified by the
galvanometer.
 This current is directly adjusted into difference in size of the
component which is expanded by an amplifier specified by the
galvanometer.
 The main advantages of these comparators are no moving parts,
sensitivity and accuracy over long periods.

Linear Variable Differential Transducer

 This instrument works on inductive principle.

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Advantages & Limitations of Electrical

Comparators
 Advantages:
 It has got small number of moving parts.
 It is possible to have high & more number of magnification by
an instrument.
 The mechanism carrying the core is very light & is not sensitive
to vibrations.
 Limitations:
 Heating of the coil in measuring unit may cause zero drift and
hence alter the calibration.
 This is generally more expensive than others comparators.

 External Power source is required.

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