Mechanical-Optical Comparators
K. S. R. Varun Teja
Department of Mechanical Engineering
NIT Trichy
Mechanical-Optical Comparators
This is also termed as Cooke’s Optical Comparator.
Small displacements of a measuring plunger are
initially amplified by a lever mechanism pivoted
about a point
The plunger is spring loaded such that it is biased
to exert a downward force on the work part. This
bias also enables both positive and negative
readings, depending on whether the plunger is
moving up or down.
K. S. R. Varun Teja, Department of Mechanical Engineering, NIT
Trichy
The amplified mechanical movement is further amplified
by the optical system due to the tilting of the plane
reflector.
A condensed beam of light passes through an index,
which normally comprises a set of cross-wires. This
image is projected by another lens onto the plane
mirror.
mechanical amplification = l2/l1
and
optical amplification = 2 (l4/l3).
K. S. R. Varun Teja, Department of Mechanical Engineering, NIT
Trichy
Zeiss Ultra-optimeter
The Zeiss ultra-optimeter is another
mechanical optical comparator that
can provide higher magnification
than the simple mechanical optical
comparators
This magnification is made possible
by the use of two mirrors, which
create double reflection of light.
K. S. R. Varun Teja, Department of Mechanical Engineering, NIT
Trichy
It is preferable to have a
monochromatic light source passing
through a condenser lens followed
by an index that carries the image of
two cross-wires onto a tilting mirror.
K. S. R. Varun Teja, Department of Mechanical Engineering, NIT
Trichy
Optical Projector
• An optical projector is a versatile
comparator, which is widely used
for inspection purpose.
• It is especially used in tool room
applications.
• It projects a two-dimensional
magnified image of the workpiece
onto a viewing screen to facilitate
measurement.
K. S. R. Varun Teja, Department of Mechanical Engineering, NIT
Trichy
It comprises three main elements:
• The projector itself comprising a light source and
a set of lens housed inside the enclosure
• A work table to hold the workpiece in place
• A transparent screen with or without a chart
gauge for comparison or measurement of parts.
In most projectors, the table can be moved in two
mutually perpendicular directions in the horizontal
plane.
The movement is effected by operating a knob
attached with a double vernier micrometer, which
can provide a positional accuracy of up to 5 μm or
better. K. S. R. Varun Teja, Department of Mechanical Engineering, NIT
Trichy
The light beam originating from the lamp is
condensed by means of a condenser and falls on the
workpiece.
The image of the workpiece is carried by the light
beam, which passes through a projection lens. The
projection lens magnifies the image, which falls on a
highly polished mirror kept at an angle.
The light beam, after passing through the projection
lens, is directed by a mirror onto the viewing screen.
Screens are made of glass, with the surface facing the
operator, ground to a very fine grain size.
K. S. R. Varun Teja, Department of Mechanical Engineering, NIT
Trichy
Advantages of Mechanical Optical Comparators
1. They have less number of mechanical moving parts, hence less friction and inertial effect and gives higher
accuracy.
2. The scale can be made to move past a datum line and thus have high range and no parallax error.
3. They have high magnification and hence suitable for precision measurement.
4. The scale in the optical comparators are illuminated in general and hence enables readings to be taken
irrespective of the lighting conditions in the room.
Disadvantages of Mechanical Optical Comparators
1. They require a light source to operate.
2. The comparator is usually bulky and expensive.
3. Generally dark rooms are preferred to take the readings, when the scale is projected on to the screen.
4. Instrument is inconvenient for continuous use since the scale is to be viewed through eyepiece.
5. Due to high magnification, heat generated from transformers and lamp may cause the setting to drift.
K. S. R. Varun Teja, Department of Mechanical Engineering, NIT
Trichy
Thank You
K. S. R. Varun Teja, Department of Mechanical Engineering, NIT
Trichy
