Mechanical comparators:

Comparators are those instruments which can be used to compare,

generally, linear dimensions of similar components with a slip gauge
standard.

Features:

Comparators have no built in standards of their own; they indicate only the
differences in size between the nominal dimension set on the comparator by SLIP
Gauges and the dimension of the component being measured.

They have precisely engineered mechanisms used in the principle of its operation.
They can be built to give a magnification as high as X50000.
They are so designed to allow smallest scale division of 0.00025 mm

In principle, a comparator works on relative measurements, i.e., it gives only
dimension difference in relation to a basic dimension.

So, a comparator is to compare the unknown dimensions of a part with some
standard or a master setting which represents the basic size and the dimensional
variations from the master setting have to be amplified and measured.

The function of a comparator is to detect to a high degree of precision the small
difference, if any, between a suitable length standard ad the measured part.

In construction, a comparator consists of three essential elements:

1. A sensing device, usually, a plunger, which faithfully senses the input signal
represented in this case by a change of length or a surface displacement.
2. A magnifying or amplifying system to increase the signal to suitable
magnitude.
3. A display system (usually a scale and pointer) which utilizes the amplified
signal to provide a suitable readout.








Desirable Characteristics of a good comparator:

The fundamental requirements to be fulfilled by every comparator are as follows:

1. Robust in design and construction: in order to withstand ordinary usage to
maintain consistent measuring accuracy.

2. Indicating device used shall be such as to show readings at least possible
time, for which the magnification system should be such as to get readings
dead beat.

3. Provision for compensation against temperature effects.

4. Scale must have linear characteristic.

5. Though sensitive, the instrument should be rigid enough to accommodate
mishandling to some extent without permanent harm.

6. Should have maximum versatility, to accommodate to be used for
measuring wide range of dimensions.


Uses of Comparators:

a) In mass production, where components are to be checked at very fast rate.
b) As laboratory standards from which working or inspection gauges are set
and calibrated/correlated.
c) For inspecting newly purchased gauges.
d) As working gauges, in some machines, for stage inspection of parts
produced. This prevents rejection and ensured maintenance of tolerances
at various stages of manufacturing.
e) For grading of parts into groups depending on their tolerances, for use in
selective assembly of parts.






Classification of comparators:

According to the principles used for obtaining suitable degrees of magnification of
the indicating device relative to the change in the dimension being measured,
comparators may be classified as:

1. Mechanical Comparator
2. Mechanical- Optical Comparator
3. Electrical & Electronic Comparator
4. Pneumatic Comparator
5. Fluid displacement Comparator
6. Projection Comparator
7. Multi check comparator
8. Automatic gauging machines

The most obvious choice of a comparator mechanism is Mechanical, because it is
relatively easy to magnify linear movement by gearing, levers or some similar
means.

Major type of mechanical comparator which is popularly used in industries are:
Dial Indicators, SIGMA Comparator, and Johanssons Mikrokator.

Dial Indicator:

Dial indicator, is one of the widely used mechanical comparator. Figure 1.0 below
shows exploded view of dial indicator.

Figure 1 Mahr make dial indicator
The mechanism of dial indicator is illustrated in Figure 2

The dial indicator mechanism is a simple example of the application of gearing to
magnify the linear movement of the probe to the radial movement of the pointer.

There are number of disadvantages inherent in gearing, which prevent its use in
more accurate instruments. The clearances which must exist between meshing
gear teeth and the resulting backlash in the mechanism limit the degree of
magnification that can be used. The spinning of the mechanism also develops
inertia forces which affect the repeatability of the plunger.

A mechanical lever overcomes all these problems, and compound lever (figure 3)
arrangements are the mechanisms most commonly used for mechanical
comparators

Mechanical lever magnification is equal to R/r (refer Figure 3)

An efficient pivot which is free from play and, ideally frictionless is essential to
overcome the above problems.
















FIGURE 2 FIGURE 3









Two types of such crossed strip hinge can be found as shown in figure 4 below.
















FIGURE 4

SIGMA Comparator and Johanssons Mikrokators are the ones which makes use of
above said cross stripped hinges and bell crank strip type hinges.



SIGMA COMPARATOR:

This instrument is shown in figure 5. The plunger is attached to a rectangular bar
which is supported at its upper and lower ends by flexure plates. The vertical
movement of the bar is limited by stops. A knife edge is fixed to the side of the bar
which bears on a sapphire block attached to the moving member of a crossed
strip hinge. A forked arm attached to the moving member of the hinge transmits
rotary motion to the indicator driving drum through a bonze band wrapped round
the drum.

FIGURE 5


In this a small movement of the plunger is allowed by the elastic deflection of the
two slit diaphragm supports.

The instrument is damped by a horseshoe magnet fixed to the frame and anon
ferrous (aluminium) disc fixed to the pointer spindle. Rotation of the disc in the
magnetic field of the magnet sets up eddy currents which are proportional to the
rotational velocity and in opposition to the motion.

The range of the instruments available provides magnification of X300 to X5000,
the most sensitive models allowing scale estimations of the order of 0.0001 mm to
be made.







Johansson Mikrokator:


The essential detail of Johansson Mikrokator is as shown in figure 6 below.







This instrument makes use of the Abramson movement to provide a virtually
frictionless system. The plunger is supported at its lower end by a flexure plate and
at its upper end by the foot of a flexure spring. The end of the twisted metal band
wraps round the knee of the spring and is firmly attached through its vertical leg.
Vertical movement of the plunger is transformed into rotational movement of the
vertical leg thus stretching the twisted band which partially unwinds and rotates
the attached pointer against the scale.

This system provides a large angle of rotation for a small plunger movement which
is further amplified by the pointer.

Damping is provided by immersing a portion of the twisted band in a spot of oil.
The cantilever spring fulfils two functions:

a) The band can be brought to correct tension by adjustment of the
attachment screws.
b) The magnification may be varied by increasing or reducing the length of the
cantilever.

A large range of Mikrokators are available, the most sensitive having a scale
division of 0.000 01 mm, for closely controlled calibration work. Magnifications up
to X5000 are available for industrial use.

The set up of dimension measurement using Mikrokator and its details from
A. A. Jansson, Inc. is given below.







Details compiled and presented by Dr. N. S. SRIRAM on 04.02.2011