COMPARATOR

S
 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.
 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
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
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
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.
 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

 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
Johansson Mikrokator
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
 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
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.
Principle Of Optical Comparator
Types of Optical Comparator
 Profile (optical) Projector

 Mechanical Optical Comparator

 Zesis Optical Comparator

 Electrical Optical Comparator

Mechanical Optical Comparator
Zesis Ultra Comparator
 It gives very high magnification, as it works on
double magnification principle.
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

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