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Measurements and Metrology: Mahesh Chandra
Measurements and Metrology: Mahesh Chandra
K BAHETI MAHESH
(1RV09IM024)
CHANDRA
DEEPAK
(1RV09IM021)
RATHOD
(1RV09IM009)
COMPARATORS
Introduction
A comparator works on relative measurements, i.e. to say, it gives only dimensional
differences in relation to a basic dimension. So a comparator compares the unknown
dimensions of a part with some standard or master setting which represents the basic size
anddimensional variations from the master setting are amplified and measured. The
advantages of comparators are that not much skill is required on the part of operator in its
use. Furtherthe calibration of instrument over full range is of no importance as comparison
is done with astandard end length. Zero error of instrument also does not lead to any
problem. Since rangeof indication is very small, being the deviation from set value, a high
magnification resultinginto great accuracy is possible. The comparators are generally used
for linear measurements,and various comparators available differ principally in the method
used for amplifying and recording the variations measured. According to the principles used
for obtaining suitabledegrees of magnification of the indicating device relative to the change
in the dimension beingmeasured, the various comparators may be classified as follows :
Uses of Comparators
The various ways in which the comparators can be used are as follows :
(i) In mass production, where components are to be checked at a very fast rate.
(ii) As laboratory standards from which working or inspection gauges are set and correlated.
(iii) For inspecting newly purchased gauges.
(iv) 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.
(v) In selective assembly of parts, where parts are graded in three or more groups
depending upon their tolerances.
Mechanical Comparators
(i)
Rack and Pinion. In it the measuring spindle integral with a rack, engages a
pinion
which amplifies the movement of plunger through a gear train. (Refer Fig. 5.1)
length thus making it further twist or untwist. Thus the pointer at the centre of the twisted
strip rotates by an amount proportional to the change in length of strip and hence
proportional to the plunger movement. The bell crank lever is formed of flexible strips with a
diagonal which is relatively stiff.The length of cantilever can be varied to adjust the
magnification of the instrument. Since the centre line of the strip is straight even when
twisted, therefore, it is directly stretched by the tension applied to the strip. Thus in order to
prevent excessive stress on the central portion,the strip is perforated along the centre line
by perforations as shown in Fig. 5.7.
Dial Indicator.
One of the most commonly used mechanical comparators is
essentially of the same type as a dial indicator. It consists of a robust base whose surface is
perfectly flat and a pillar carrying a bracket in which is incorporated a spindle and indicator.
The linear movement of the spindle is magnified by means of a gear and pinion train into
sizable rotation of the pointer on the dial scale. The indicator is set to zero by the use of slip
gauges representing the basic size of the part. This is generally used for inspection of small
precision-machined parts. This type of comparator can be used with various attachments so
that it may be suitable for large number of works. With a V-block attachment it can be used
for checking out-of-roundness of a cylindrical component.
magnified.The scale may be calibrated by means of gauge block (slip gauges) to indicate
any deviation from an initial setting.Comparators using this type of linkage have
sensitivities of the order of 0.25 micron per scale division.The mechanical amplification is
usually less than 100, but it is multiplied by the optical lens system. It is available in
amplifications ranging from x 500 to x 1000.
The plunger in Fig. 5.10 is mounted on a pair of slit diaphragms in order to have
frictionless linear movement. A knife edge is mounted on it and bears upon the face of the
moving member of a cross strip hinge. For details of cross strip hinge refer Fig. 5.11. The
cross strip hinge consists of the moving component and a fixed member which are
connected by thin flexible strips alternately at right angle to each other. Thus if an external
force is applied to the moving member ; it will pivot, as would a hinge, about the line of
intersection of the strips.To the moving member an arm of Y shape and having effective
length I is attached. If the distance of the hinge from the knife edge be a then the
magnification of the first stage
(a) Comparator
(b) Movement used in comparator.
Fig. 5.12. Mechanical comparator using rocking prism.
In order to adjust the magnification, distance a must be changed by slackening and
tightening the two screws attaching the knife edge to the plunger.
Some of the interesting features of the instrument are :
(1) As the knife edge moves away from the moving member of the hinge and is followed
by it, therefore, if too robust movement of the plunger is made due to shock load, that will
Mechanical Comparator
The diagram of a type which is used for comparative measurement of external surfaces is shown in Fig. 5.12 (a). In this instrument the movement of the measuring
tip attached at the end of the spindle is transmitted to the pointer through a
mechanism shown in Fig.5.12 (b). The upper end of the spindle bears against a
rocking prism (knife-edge). There is a frame member having two V-slots offset to
each other by distance a. The end of the spindle rests against the first V-slot and its
movement is transmitted to this frame through a prism. A knife edge which is
stationary relative to the body of the instrument enters the upper V-slot.The apex of
the upper knife-edge is the centre for all the moving
parts of the comparator. The distance a between; the V-slots forms the shorter lever
arm of the system, whereas, the longer lever arm is the distance L from the centre
of rotation of the system to the other end of hand,
is L/a and is of the order of 1000. The contact pressure is of the order of 300 to 400
grammes and is provided by a spring. The use of knife-edge pivots in the
comparator movement excludes the influence of possible clearance in the pivots on
the accuracy of this instrument. Yet another type of mechanical comparator is
shown in Fig. 5.13 in which the movement of the plunger (contact member) is
transmitted to the pointer through an angular lever which ends in the form of a
sector and pinion. It may be noted that a spring attached with the angular lever
avoids the play in comparator.
Mechanical Optical Comparators
In mechanical optical comparators small displacements of the measuring plunger
are
amplified first by a mechanical system consisting of pivoted levers. The amplified
mechanical
movement is further amplified by a simple optical system involving the projection of
an image.
The usual arrangement employed is such that the mechanical system causes a
plane reflector
to tilt about an axis and the image of an index is projected on a scale on the inner
surfac^ffta
ground-glass screen. Optical magnification provides high degree of measuring
precision |Mp
to reduction of moving members and better wear resistance qualities. Optical
magnificatioijis__
also free from friction, bending, wear etc.
Zeiss Ultra-optimeter.
The optical system of this instrument involves double reflection of light and thus gives
higher degree of magnification. (Refer Fig. 5.16) A lamp sends light rays to green filter,
which filters all but green light, which is less fatiguing to the eye. The green light then
passes to a condenser which via an index mark projects it on to a movable mirror Mi,
whence it is reflected to another fixed mirror M2, and then back again to the first moveable
mirror. The second objective lens brings the reflected beam from the first mirror to a focus at
a transparent graticule containing a precise scale which is viewed by the eye-piece. The
projected image of index line on the graticule can be adjusted by means of screw in order to
set the zero. When correctly adjusted, the image of the index line is seen against that of the
graticule scale. The special end of the contact plunger rests against the outer end of the first
movable mirror so that any vertical movement of the plunger will tilt the mirror. The extreme
sensitivity of this instrument necessitates special precautions in its operation to avoid
temperature effects.
Electrical Comparators.
Electrical comparators are also known as electro-mechanical measuring systems as these
employ an electro-mechanical device which converts a mechanical displacement into
electrical signal.Linear variable differential transformer (LVDT) is the most popular electromechanical device used to convert mechanical displacement into electrical signal. It, in
effect, is a transformer consisting of three symmetrically spaced coils carefully wound on an
insulated bobbin. It works on mutual inductance principle and consists of a primary coil
wound on an insulating form (bobbin) and two identical secondaries symmetrically spaced
from the primary. AC carried excitation is applied to the primary and two secondaries are
connected externally in a series opposition circuit. The lead wires exit through an opening in
the outer shield, usually in the end-cover washers. A cylindrical shield of ferromagnetic
material is spun over the metallic end-washer after the windings have been vacuum
impregnated with a potting compound suitable for the application environment. The
finished transformer there after becomes quite impervious to humidity or ordinary
magnetic influences. The device thus also becomes extremely rugged and reliable. There is
a non-contacting magnetic core, made from a uniformly dense cylinder of nickel-iron alloy,
carefully annealed to improve and homogenise its magnetic permeability, which moves in
the centre of these coils wound on the insulating form and the motion of this core varies the
mutual inductance of each secondary to the primary, which determines the voltage induced
from the primary to each secondary. If the core is centered in the middle of the two
secondary windings, then voltage induced in each secondary winding will be identical and
180 out-of-phase, and the net output will be zero. If the core is moved off middle position,
then the mutual inductance of the primary with secondary will be greater than the other, and
a differential voltage will appear across the secondaries in series. For off centre
displacements within linear range of operation, the output is essentially a linear
movement at the probe tip actuates inductance transducer which is supplied with an
alternating current from the oscillator.
adjustment is shown in Fig. 5.33. Magnification can be changed by passing some of the air
supply, using a screw at the inlet to the tapered glass tube. The float can be zeroed by a
bleed valve installed at the top of the tube. Size is measured by the velocity of air in a
tapered glass tube which is measured by the height of the float in tube. The straight portion
of the curve is utilized for the measuring range. It provides high amplification (10 : 1) and
thus within the linear range, it is possible to read accurately upto microns depending upon
scale length, or classify the sizes quickly and accurately. The amplification can be changed
by quick change of tube, float and scale. Air gauge amplification and range are based on
the tooling and instrument standards of manufacturer. The amplification and instrument are
selected by considering the total tolerance spread and choosing the instrument that covers
the range. About 50 to 100 mm of column is usually allowed for the actual tolerance spread.
In the gauging head, the air escapement orifices are recessed below its cylindrical
surface so that the orifices never contact the part being gauged. Thus the surface wear will
not affect the accuracy till it is worn down to orifice level. Also the orientation of gauge or the
way operator holds the gauge is of no consequence and same readings will be obtained for
given diameter. On the gauge, knobs are also provided for adjusting float position and
calibration.Air gauge is set by placing masters for maximum and minimum tolerances on
spindle alternatively and adjusting the float position for each master by turning the knurled
knobs at the base of the instrument.Free-flow column type gauges are usually assembled
together side by side and thus multiple interrelated readings can be seen at a glance. This
is the big advantage of air gauging that the multiple dimensions and conditions can be
inspected with great ease, accuracy and speed.Pneumatic circuits can be arranged to
determine dimensional differences like taper (comprising the diameter of bore at different
points along a part), bore centre distance and also to select parts to assemble to
predetermined clearances or interference fits.
diameter of the nozzle.Between these extremes, especially where the clearance is small
and where airgauging can be employed, the area of the escape orifice is n dl, that is, the
area of the curved surface of the cylinder shown in Fig. 5.38.
Overall Magnification.
In a practical pneumatic measuring apparatus the area M will be associated with the
measuring head and change in M will be the result of a change in the dimension which is
being measured e.g. a change in the separation L between nozzle and surface (Fig. 5.40).
The overall magnification of the apparatus, i.e. the ratio of the linear movement of the
pointer or index of the pressure measuring instrument to the change in the
This condition requires the measuring head to be correctly designed. The final escapement
of the air from the nozzle to the atmosphere is taken as being through an area of the
curved surface of the cylinder of length L and diameter D, where L is the separation
between the nozzle surface and the surface to be gauged and D is the internal diameter of
the nozzle.
Response Speed.
For a back pressure system the speed of response is not as fast as for free-flow type,
because some time is required for the pressure to build up. The speed of response
becomes of concern when the gauginghead is separated from indicating instrument
by long distance.A pneumatic measuring system will not correctly measure displacements
of frequency greater than about 2 cycles/second, because of its slow speed of response.
The response is considerably slower compared to the electrical system because of the
following reasons.Between the control orifice and the measuring head, there exists a closed
volume associated with the measuring instrument used to measure the pressure p. A
dimensional change, e.g., a displacement of the surface alters the flow so changing the
pressure p. The time needed to establish the new value of p depends on the total volume
and on the rate of air flow into and out of it. The latter in turn depends upon the operating
pressure P and the size of the control orifice and orifice in the measuring head. These
orifices are related in size and determine the pneumatic sensitivity, the smaller orifices
(corresponding to the higher magnification), having a more restrictive effect on the air flow
and so slowing the response.It has been examined theoretically and experimentally that
response is slowed by using a large operating pressure P and a large volume, but by these
high sensitivity (magnification) is obtained. In any practical pneumatic measuring system,
the overall response will be influenced by dynamic characteristics of the pressure
measuring device. Thus it follows that the use of a low operating pressure will not improve
the overall response if a low pressure measuring device of slow response is used to
measure the pressure changes. High sensitivity will inevitably be associated with slow
response and the only factor left to the designer is the volume, which should be made as
small as possible for quick response.Since gauge is always located at some distance from
the control unit, the effect of variations in the gauging position does not reach the control
unit instantaneously, though the size variations of the object will promptly affect the air flow
at nozzles. The time gap between the sensing and indication is known as response time
which depends upon : Length of air line between the nozzles and indicator, (ii) type of
gauge system, and (Hi) the design of control unit. Response in case of flow type pneumatic
gauges is relatively quick. Response in case of back pressure gauges is slow, the
compressibility of air also contributing to the delayed transmission of the variations sensed
at the nozzles.Response time of back pressure type pneumatic gauges can be improved by
utilizing following devices :
(i) Using filled system pressure gauge, thereby reducing volume of air.
(ii) Restricting the unimpeded escape of air through the orifices when the gauging head
is not in operation, by using a spring-charged cover sleeve around the gauge head.
(iii) Counteracting the unrestricted air escape by an auxiliary air supply relay whose
operation automatically discontinues as soon as a specific back pressure develops during
the actual gauging process.
(iv) Using a high speed relay to compensate for additions to the volume of the instrument
system.
Zero Setting.
It is accomplished by means of a bleed valve and consists in adjusting the indicating
element of the gauge to that marking on the scale which was selected to signal coincident
with the nominal limit size represented by a setting master.
Datum Control.
If means be provided to change the pressure in the cavity (between control orifice and
measuring orifice) using a variable bleed to atmosphere, a datumor zero can be provided
which varies the pressure 'p' when the escape orifice area remains fixed. This addition to a
circuit provides means of accommodating small differences which inevitably occur in the
manufacture of gauge heads. Limited use of a datum control in the form of a bleed to
atmosphere has an insignificant effect on linearity.However, this system depends highly
upon the pressure regulator to maintain the supply pressure within very close pressure
limits. Thus the pressure regulator is a critical component in this circuit. This problem is
overcome in differential back pressure circuit in
plification Adjustment.
This permits different range of gauge indications on same scale length and is carried out
with a precision valve of the control unit. Both zero setting and amplification adjustment
should be checked from time to time depending upon experience.
Jet Recession.
It has already been seen that when the surface being measured is very close to the nozzle
face, equal increments of change in clearance do not produce equal increments of pressure
change. The system is not linear under these conditions.Because of this the faces of the
jets on air plug gauges are ground below the body diameter of the plug as shown Fig. 5.43.
This grinding back is called jet recession and it is the means by which the non-linear portion
at the high pressure (low flow), end of the pressure/clearance curves is avoided.
tube and bubble out of water and the air moving towards control orifice will be at desired
constant pressure H. Now-a-days diaphragm type pressure regulators are readily available
in the market and they are better for regulating the pressure than the above device. The air
at reduced pressure then passes through the control orifice and escapes from the
measuring jets. The back pressure in the circuit is indicated by the head of water displaced
in the manometer tube. The tube is graduated linearly to show changes in pressure
resulting from changes in internal diameter of the work measured. This instrument is
capable of measuring to the accuracy of microns. It is very obvious from Fig. 5.46
that the diameter being measured at any instant is corresponding to the portion against two
jets. Now to find the concentricity (roundness of any job at any section), the workpiece may
be revolved around measuring gauge. If no change in reading is there, then it is perfectly
round hole. Similarly the diameter can be noted down at several places along the length of
bore and thus tapering of hole is determined. This method is, therefore, best suited for
measuring roundness and taperness of cylinder bores and gun barrel bores. By having
suitable measuring head this can be used for external gauging, and head in this case will be
as
in two thin discs, their effective areas may be appreciably different as a result of edge
effects on the air flow arising at the peripheries of the orifices. Again the relationship
between effective area and geometrical area is unlikely to be the same for air flow through
an orifice and the jet of air from a nozzle. In the experimental determination of the p/P, MIC
characteristics the value of M and C used were the geometrical areas of orifices Om and
Oc. Therefore due to effective area being different from the geometrical area, the empirical
equation obtained by analysing these characteristics would not be expected to provide a
completely accurate numerical forecast of performance.Nevertheless, experience has
shown that they do give a first approximation sufficiently reliable to permit the required
performance to be obtained by a single-step corrective adjustment of the control orifice.
Differential Comparators.
A later development brought out the balanced circuit type of air-gauge. In this equipment a
differential pressure indicating mechanism,connected across the two air-paths and a built-in
gauge zeroing valve is provided. Such a balanced circuit is shown schematically in Fig.
5.48. An air gauge based on this balanced circuit is called 'Differential Comparator'.
the workpiece or the master settings. The restriction of the workpiece builds up back
pressure as explained earlier. At the same time, other half of the air is flowing through the
other control orifice Oc2 to the reference jet Om. By closing or opening the valve of
reference jet Om, the pressure in the space between Oc2 and Om is regulated (adjusted) to
match the back pressure from the measuring jets, which is sensed by the pressure
indicating device fitted across the two channels as shown. At this adjustment of the
reference jet, the pressure indicator would indicate equal pressure in the two channels and
hence read zero on the scale. This zero setting (adjusting of reference jet Om) is done with
master workpiece whose dimension is exact nominal size. Now the variation of the
dimension at the measuring head would cause change of back-pressure in channel A. This
pressure would be different from the mean pressure which has been already set in the
channel B (by reference jet). Now the difference of pressure of the two channels would be
indicated by the pressure indicating device which can be directly calibrated in terms of
variation of dimension from the mean dimensions. Hence the instrument based on the
measurement of differential pressure is called Differential Comparator. If the dimension
causes a decrease in gap L as compared to La, this in turn decreases M and hence
increasing back pressure in channel A and vice versa. In these cases the pressure
indicator would show readings on both sides of zero corresponding to deviation from
mastersetting.
Non contact tooling is best suited for automatic gauging applications because of the
advantages of no contact, clearing of oil or foreign particles from gauging area, etc.
In the case of non-contact air gauge tooling, only the air coming out of the air escapement
orifice touches the part to be measured, the air flow rate depending on the cross-sectional
area of the jet and the clearance between the jet and the part to be measured. It may have
a single jet, two diametrically opposite jets or more evenly spaced jets. Single open-jet
tooling can be used for checking outside diameter, height, depth, straightness, squareness,
etc. and Fig. 5.49 shows a few of such applications. Dual jet techniques can be applied for
determining true diameter, out or round, bell mouth, thickness, etc. The various gauges may
be designed either for presenting the gauges to part or vice versa.Many modern mechanical
assemblies demand that holes should be closely controlled for straightness as well as
diameter. An air plug gauge for gauging hole straightness is shown in Fig. 5.50.
In the contact tooling, a mechanical member is incorporated between the air escapement
orifice and the part to be measured. The air flow from the jet changes due to displacement
of this mechanical member when it contacts the part. The mechanical member could be a
ball, lever, plunger or blade. A big advantage of contact type air gauge is that a much
bigger measuring range (upto 2.5 mm) is possible i.e. it is suitable for wide range of
gauging. Another advantage is that it eliminates surface roughness from size. It may be
mentioned that open jet type method would be subject to error for rough surfaces because it
measures a combination of size and surface finish ; further its range of measurement is
limited. Ball jet spindle gives a point reading rather than the average over a small area
and is best suited for gauging inside diameter of soft or porous parts and for rough bores.
Leaf jet spindle can be used for checking laminated bores, blind holes in which keyways
etc. do not permit the use of open jet spindles at extreme bottom of blind holes etc. Blade
jet spindles are used for inspecting gun bores in which oil grooves, or slots do not permit the
use of ball jet or leaf jet spindles. Fig. 5.51 shows a small plunger type air gauging cartridge
which is highly efficient size-sensing element for wide range of gauging, tooling, fixturing,
and machine control applications. It essentially consists of a spring loaded plunger. The
spring tries to keep the plunger outwards and when the part to be measured comes in
contact with it or it comes in contact with the part it moves in and at the end restricts the
orifice, thereby increasing the back pressure. The maximum and minimum limits of the
plunger movement can be set with the help of masters. Such cartridges can be secured in
gauging position on various types of fixtures and used for measurements like height, depth,
flatness, concentricity, squareness, inside/outside diameter, etc. Fig. 5.52 shows the same
principle used in a test indicator which is very efficient for several applications. It has a tiny
stylus capable of entering into small holes, keyways, slots etc. and its movement causes the
tapered end to act as a precision valve stem to regulate the amount of air flowing through
an orifice. It is free of hysteresis or lag or drag in indicationswhen the stylus is moved in any
direction across the workpiece.
orifice. The position of the stylus and consequently the position of the taper in the orifice
causes changes in the area of the orifice. Changes in the rate of taper change the
measuring range of the cartridge. Measuring ranges upto 3 mm can be obtained with this
type of cartridge.
Multi-gauging Systems.
Multi-gauging systems are used to measure a number of dimensions simultaneously. Parts
to be gauged are compared with a setting master which simulates the component. The
features gauged could be external/internal diameters, lengths, straightness, squareness,
ovality, run-out of faces, etc. The measuring head gauging fixture is specifically designed to
suit the component to be measured and may be completely special or it may be built using
a series of modular elements. It contains the means for sensing the dimensional difference
between the components and the master which may take the form of mechanical or
electronic probes or air jets connected to the means for amplifying the difference.
The amplifying and display of readings may take the form of dial gauges or some form
of electronic or air/electronic system. Display may be analogue, digital or graphic and may
be augmented by out of tolerance indication. Using electronic differential methods, the
relationship between different features can be related to a common datum.
The choice of system depends on number of factors like initial cost, dimensional
tolerances of the features to be measured, complexity of the component, complexity of the
features to be measured, number of features to be measured, speed of measurement
required, skill or otherwise of the user.
Multicheck Comparators
Now-a-days modern trend in comparison is towards the inspection of all dimensions at
the same time, as it is economical procedure. It is particularly desired where various
dimensions have some relationship with each other, e.g., diameter and concentricity
measurement. This job is done by multicheck comparators, which are of the following
types and incorporate the following systems of amplification.
(a) Electrical
(b) Air
(c) Combination 'air-electric'.
Electric Multichecks.
Air Multichecks.
In this instrument, group of air comparators are set up to check a number of dimensions. In
this type of instrument, initially some difficulty is experienced in setting the various
comparators to check various dimensions and to arrange them in compact form. But once
this is done things become very easy. In one setting all the dimensions can be checked and
the time of inspection is reduced considerably. Mass inspection becomes possible and high
quality can be ensured.
Disadvantages
(1) The mechanical comparators have got more moving parts
than other types. Due to more moving parts, the friction is more
and ultimately the accuracy is less.
(2) Any slackness in moving parts reduces the accuracy
considerably.
(3) The mechanism has more inertia and this may cause the
instruments to be sensitive to vibration.
(4) The range of the instrument is limited as the pointer moves
over a fixed scale.
(5) Error due to parallax is possible as the moving pointer moves
over a fixed scale.
(6) As the instrument has high magnification, heat from the lamp,
transformer etc. may cause the setting to drift.
(7) An electrical supply is necessary.
(8) The apparatus is usually large and expensive.
(9) When the scale is projected on a screen, then it is essential to
use the instrument in a dark room in order to take the readings
easily.