Mechanical Engineering

Engineering Metrology (4th Sem/2nd Year)

Unit – 04, (Comparators)

The measurement of an unknown quan ty is done by comparing it with the known quan ty known as
standard. If this measuring device has a built-in standard, it will enable us for direct measurement of
unknown quan ty. These are called direct measurement instruments like micrometre, vernier calliper, etc.
In other hand, the standard is separated, such an instrument is called comparator. It will not give the direct
measurement. Instead, it compares unknown with the standard. So, the comparator is a precision instrument
used to compare the measurement of unknown with a known working standard.

Direct Measuring Device Comparators

Used for checking and measurement purpose Used for comparison purpose only
The instrument has built-in standard Standard is separated from the device
Works on direct measurement Works on rela ve measurement
Give the actual measurement of objects Give the devia on of measurement of objects
Less sensi ve instruments More sensi ve instruments

 Characteris cs of a good Comparators:

To be effec ve in industry, a comparator must fulfil some func onal requirements, and they are-
i) Comparator is desirable to be versa le and has provision to select different ranges and other
flexible means to be put to various use.
ii) High degree of accuracy and precision.
iii) The scale should be linear and have a wide range.
iv) It should have high amplifica on capability so that the reading can be recorded easily.
v) Indica on should be clear and free from oscilla on.
vi) Design should be robust.

 Classifica on:

With respect to the principles used, the comparators can be classified into the following categories-
i) Mechanical Comparators: Mechanical comparator employs mechanical means for magnifying
small devia ons. The method of magnifying small movement of the indicator in all mechanical
comparators are affected by means of lever, gear train, or a combina on of these elements.
Mechanical comparators are available having magnifica ons from 1 to 1000. These are mostly
used for inspec on of small parts machined to close limits. Example: Dial Indicator, Sigma
Comparator, Jonasson Mikrokator.

ii) Mechanical Op cal Comparators: As the name suggests, this comparator consists of mechanical
as well as op cal parts, for the reading inputs we need mechanical components and for the
outputs we have op cal instruments in this type of device. Example: Zeiss op meter, Zeiss
optotest comparator.
 Mechanical Engineering
Engineering Metrology (4th Sem/2nd Year)
Unit – 04, (Comparators)
iii) Electrical Comparators: Even though the Electrical Comparator uses electrical and electronic
means to get magnifica on and display output, it relays on mechanical contact with the work to
be measured. The movement of mechanical contact is converted to the electrical signals. They
are widespread because of their instantaneous response and convenience in amplifica on.
Example: Linear Variable Differen al Transformer, Sigma Electronic Comparator.

iv) Pneuma c Comparators: Use air as means for the measurement. This type of comparators
working on the principle of Bernoulli's theory. The main advantage of this comparator is that it
eliminates metal-to-metal physical contact between the gauge and component. Example: Free-
flow air gauge, back-pressure gauge.

 Dial Gauge:

 Construc on:
A dial indicator or a dial gauge is used as a mechanical comparator. The essen al parts of the instrument
are like a small clock with a plunger projec ng at the bo om. Very slight upward movement on the
plunger moves it upward and the movement is indicated by the dial pointer. The dial is graduated into
100 divisions. A full revolu on of the pointer about the scale corresponds to 1 mm travel of the plunger.
Thus, a turn of the pointer on the scale division represents a plunger travel of 0.01 mm.
This is a rack and pinion arrangement inside the gauge which helps to deflect the pointer and gives the
reading.
 Working:
The plunger has a rack tooth, a set of gears with the rack. The pointer is connected to a small pinion. This
pinion is independently hinged, means it is not connected to the plunger. The ver cal movement of the
plunger is transmi ed to the pointer through a set of gears.
Let us assume that the required height of the component is 32.5 mm. Ini ally, this height is built up with
slip gauges. The slip gauge block is placed under the plunger of the dial gauge. The pointer in the dial
gauge is adjusted to zero and the slip gauge is removed.
Now the component to be checked is introduced under the plunger of the dial gauge. If there is any
devia on in height of the component, it will be pointed by the pointer of the dial gauge.
 Mechanical Engineering
Engineering Metrology (4th Sem/2nd Year)
Unit – 04, (Comparators)
 Applica ons:
i) Centering Workpiece to Machine Tool Spindles
ii) Offse ng Lathe Tailstock
iii) Aligning a Vise on a Milling Machine
iv) Checking Dimensions.

 Electrical Comparators:
An electrical comparator employs electrical means to get the magnifica on. In this, the movement of the
measuring contact plunger is converted into an electrical signal. The electrical signals are recorded by an
instrument which can be calibrated in terms of plunger movement.
Magnifica on is very high and a smaller number of moving parts are required for opera on. Two or more
magnifica ons are provided in the same instrument to have higher range of opera ons. As the pointer is
light, so this is more sensi ve to vibra on. External agency is required to meter for the actua on and
varia on of voltage or frequency may affect the accuracy of output.

 Op cal Comparators:
This device used a rota ng mirror for giving the comparison data. A light beam is reflected off that mirror
and simply by the virtue of distance The small rota on of the mirror can be converted to a significant
transla on with li le fric on.
 Mechanical Engineering
Engineering Metrology (4th Sem/2nd Year)
Unit – 04, (Comparators)
 Pneuma c Comparators:
A pneuma c comparator is a precision device operated using a pneuma c system or compressed air. Like
other mechanical, electrical, and op cal comparators, pneuma c comparators are used to analyse the
dimensional difference between the workpiece to be measured and the standard workpiece. A
pneuma c comparator uses compressed or pressurized air as a working medium. Therefore, it has a lot
of advantages than the other comparators as there is no physical contact between them.