MEC 220T –QUALITY INSPECTION & PRODUCT VALIDATION

Module 5: Comparators

Siva Prasad AVS,

219 – D, Laboratory Building.
avs@iiitdm.ac.in
Direct measurement Vs Comparison

Mechanical Comparator
Mechanical Comparators – Dial Gauge

Continuous dial gauge Balanced dial gauge

Dial Indicator
Dial Gauge – Working Mechanism

Rack–Pinion drive

1. The rack drives gear A.

2. Gear B and gear A are mounted on the same shaft.
3. Gear B drives gear C.
4. Gear C and gear D are mounted on the same shaft.
5. Gear D drives gear E, which is mounted on the indicator pointer
spindle.
6. The indicator pointer spindle is brought back to its initial position
by the gear F which is controlled by the hair spring.
𝑇𝐷 𝑇𝐵
Overall Magnification =
𝑇𝐸 𝑇𝐶
Dial Gauge – Working Mechanism

𝑇𝐷 𝑇𝐵
Overall Magnification =
𝑇𝐸 𝑇𝐶
Dial Gauge – Contact Points and Applications
Johansson Mikrokator

If θ is the rotation by the glass pointer, l is the length of the metal

strip along the neutral axis,
𝑑𝜃 1
∝
𝑑𝑙 𝑛𝑤 2
Where, n is the number of turns and w is the width of the metal strip.
Sigma Comparator

Based on compliant mechanism (deformable links)

Magnification = L/x*R/r

L is the length of the Y – arm,

R is the length of the pointer
r is the radius of the drum on which the pointer is mounted.
Mechanical – Optical Comparator

Cooke’s Optical Comparator

Working Principle

φ θ+φ

θ θ 2φ

Magnification = l2/l1 * 2*l4/l3

Zeiss Optical Comparator
Enhanced magnification with the help of two mirrors.
Optical Projector
Used to inspect the gears and screws.

Measurement of pitch circle diameters of holes located on

components.

Measurement of unusual profiles (involute/cycloid)

Assessment of tool wear by comparison with the standard

(drawn on a tracing paper which can be attached to the screen).
Electrical/Electronic Comparators
An electronic comparator can achieve
magnifications as high as 105:1.

Wheatstone bridge circuit.

Electrical/Electronic Comparators – LVDT
Linear variable differential transformer.

Linear variable differential transformer.

Electronic Comparators
Sigma Electronic Comparator
Pneumatic Comparators
Principle: Changes in flow over the part being inspected can
be corresponded with the changes in the part feature.

Can be used to measure the length, diameter, squareness,

parallelism, taper, concentricity etc.

No contact between the component and the gauge.

Free Flow Air Gauge

 Back Pressure Gauge
Working Principle: Based on the measurement of changes in
pressure due to change in the gap between the work piece and the
measuring orifice.

O1 → Control orifice; O2 → Measuring orifice;

P → Input pressure (source pressure); Pb → Back pressure
Methods of transducing the change in the back pressure

Methods of transducing the change in the back pressure

Water column back pressure gauge

Differential back pressure gauge

Venturi back pressure gauge

Solex Pneumatic Gauge
Applications of Pneumatic Gauges

Widely used in inspection of holes.

Contactless measurement.

Automobile cylinder bores,

carburettor nozzles.
Fluid Displacement Comparators

Prestwitch fluid gauge

Magnification = area of chamber/area of capillary tube