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Comparators

comparators in metrology

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SASUBILLI JAGADEESH (N170309)
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61 views39 pages

Comparators

comparators in metrology

Uploaded by

SASUBILLI JAGADEESH (N170309)
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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COMPARATORS

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What is a comparator?
• A comparator is a precision instrument employed to compare the
dimension of a given component with a working standard (usually
slip gauges).

• It does not measure the actual dimension but indicate how much it
differs from the basic dimension.

• The indicated difference is usually small and suitable magnification


device is provided to measure the difference with consistent
accuracy.
A comparator is an indirect type of precision instrument which:
– Gives linear measurement
– Works on relative measurement
– Indicates only dimensional difference in relation to the basic
dimension.
– Has a sensing device, magnifying or amplifying system and or
display system (usually scale and pointer) to provide suitable
read out.
– Eliminates human element in taking measurement and gives
accurate results consistently.
Need for a comparator

• In mass production identical component parts are produced on a


very large scale.
• To achieve interchangeability these parts should be produced to a
close dimensional tolerances.
• As a result, inspection is often more concerned with the dimensional
variation from the standard or basic dimension of the part.
• The micrometer and Vernier caliper are not more feasible because
skill involve, and time required to measure the dimension.
• In such case comparator is more suitable for the measurement. It
requires little or no skill for the operator, eliminates human element
for taking measurement and gives quick and highly consistent
results.
Basic principle of operation
• The comparator is first adjusted to zero on its dial or recording
device with a gauge block in position.
• The gauge block is of dimension which the work piece should have.
• The work piece to be checked is then placed in position and
comparator gives the difference in dimension in relation to the
gauge block.
• Dimension may be greater, less or equal than the standard
dimension.
• If the dimension greater or equal than the standard gauge its indicate
on dial gauge.
• Thus comparator does not give the dimension of the work piece but
just give the difference b/w work piece and standard gauge.
Essential characteristics of a good comparator
1. Robust design and construction
2. Linear characteristics of scale
3. High magnification
4. Quick in results
5. Versatility
6. Minimum wear of contact point
7. Free from oscillations
8. Free from back lash
9. Quick insertion of workpiece
10. Adjustable table
11. Compensation from temperature effects
12. Means of prevent damage
Classification
• A wide variety of comparators are commercially available at present.
• They are classified according to the method used for amplifying and
recording the variations measured in to the following types.
1. mechanical comparators
2. Optical comparators
3. Mechanical optical comparators
4. Electrical and electronics comparators
5. Pneumatic comparators
6. Fluid displacement comparators
7. Projection comparators
8. Multi check comparators
9. Automatic gauging machines
10. Electro mech comparators
In addition to above, comparators of particularly high sensitive and
magnification, used in standard rooms for calibration of gauges include.
1. The brookes level comparator
2. The Eden-Rolt ‘millionth’ comparator
Mechanical Comparators
• Principle of working: employs mechanical means for magnifying the
small movement of the measuring stylus, brought about due the
difference between the standard and the actual dimension being
checked.
• In these comparators 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.
• Mechanical comparators are of the following types:
1. Dial indicator (Dial guage)
2. Johansson Mikrokator
3. Reed type mechanical comparator
4. Sigma comparator
0
Dial Indicator
2.The Johansson Mikrokator

Principle of working:
when a tension is applied to
the twisted strip, it causes the
strip to untwist resulting in
rotation of pointer which is
attached at center of the
twisted strip
• The magnification of the instrument is approximately equal to the
ratio of rate of change of pointer movement to rate of change in
𝑑𝑄 w
length of the strip i.e.,
𝑑𝐿

𝑑𝑄 𝐿
The magnification of the instrument is ∝
𝑑𝐿 𝑤2𝑛
• Where, Q = twist of mid point of strip with respect to the end
• L = length of twisted strip measured along its neutral axis
• w = width of twisted strip and,
• n = number of turns.
• In order to increase the magnification of the instrument a very thin
rectangular strip must be used.
Johansson Mikrokator
The mechanical amplification
is usually less than 100 but it is
multiplied by the optical lens
system.
It is available in amplification
ranging from 500 to 1000.
4. Sigma Comparator
Cross strip liver used in
sigma comparator
• The ratio of the effective length (L) of the arm and the distance (a)
of the knife edge from the pivot gives the first stage magnification
and the ratio of the pointer length (l) and radius (r) of the driving
drum gives second stage magnification of the instrument. Total
magnification of the instrument is thus (L/a x l/r).
• The range of instruments available provides magnification of 300 to
5000.
• The most sensitive models allowing scale estimation of the order of
0.0001 mm to be made.
Advantages of Mechanical Comparators
1. Cheaper
2. No need of external agency:
3. Linear scale:
4. Robust and compact:
5. Portable:

Disadvantages of Mechanical Comparators:


1. Less accuracy:
2. Sensitive to vibrations:
3. Faults magnified:
4. Limited range:
5. Parallax error
Optical Comparators
In these comparators, use is made of a fundamental optical law and
instead of a pointer, the edge of the shadow is projected on to a curved
graduated scale to indicate the comparison measurement.

Fig. Optical lever Principle

∠𝑂𝐴𝑁 = ∠𝑁𝐴𝐵
In optical comparators, the mirror is tilted by the measuring plunger
movement and the movement of the reflected light is recorded as an image
on a screen
Mechanical Optical Comparators

Fig. Mechanical Optical Comparator


Zeiss Ultra Optimeter

Fixed
Mirror

Movable Mirror

Fig. Zeiss Ultra Optimeter


Advantages of Optical Comparators

1. High accuracy: These comparators have very few moving parts and
hence gives higher accuracy.
2. No parallax error: The scale can be made past a datum line and thus
have high range and no parallax error.
3. High magnification: hence suitable for precision measurements.
4. Optical lever is weightless
5. Illuminated scale: since scale is illuminated, it enables readings to
be taken irrespective of room lighting conditions.
Disadvantages
1. As the magnification is high, heat from the lamp, transformers
etc…may cause the setting the drift.
2. Depends on external electrical power supply.
3. Apparatus is usually bulky and expensive
4. When scale is projected on a screen, the instrument is to be used in
dark room
5. Instrument is inconvenient for continuous use, because the scale is
to be viewed through eyepiece.
Electrical Comparators

Principle:
• These comparators depend on
their operation on an AC
Wheatstone bridge circuit
incorporating a galvanometer.
• The movement of the measuring
contact is converted into an
electrical signal.
• This electrical signal is recorded
by an instrument which can be
calibrated in terms of plunger
movement.
• Magnification of the order of
X3000 are possible with these
comparators.
Visual Gauging Heads
• The purpose of the visual gauging heads it to give visual inspection,
using small coloured signal lamps, of the acceptability of an engineering
component with regard to dimension under test.

• Rod C in central position, Green Light glows, the size of workpiece is OK.
• If size is more rod C moves to right and makes contact with B, Red light glows
• If workpiece is undersize, Roc C moves to left and makes contact with A, Yellow
light glows.
Multi gauging Machines

• The work piece to be inspected is pushed onto the table, between the
gauging plungers, and the indicating panel will display whether the
4 dimensions are OK.

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