Comparators

• Works on relative measurement

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 Method of Use of Comparator
• Set the comparator to a
reference value (H1 )
• Replace the standard with the
work-piece and measure (H2).
• The difference is magnified 1000
to 3000 times.
• Result = H1˜ H2

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 Components of Comparators
All comparators consist of three basic components:
• A sensing device:
– senses the input signal faithfully
• A Magnifying or amplifying system:
– Increases the signal to suitable magnitude.
– Mechanical, Optical, Pneumatic, hydraulic
and electronic methods are used for this purpose.
• A display system (usually a scale and pointer)
– Utilizes the amplified signal to provide a suitable
readout.

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Desirable Features of Comparators
• A good comparator must be:
• High degree of accuracy & precision
• Linear scale
• High amplification
• Wide range
• Freedom from backlash, friction, inertia
• Good resolution*
*least possible unit of measurement

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 Functional Requirements
• Also…..
• Compact & easy to handle.
• Quick response.
• Sensitive.
• Robust.
• Low maintenance.
• Durable: Hard contact point, with long life.
• Reliable.
• Compensation for temperature effects

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 Classification of Comparators
• Mechanical Comparator:
– Gears pinions, linkages, levers, springs etc.
• Optical Comparator:
– Lens, mirrors, light source etc.
• Pneumatic Comparator:
– High pressure air, valves, back pressure etc.
• Electrical Comparator:
– Step up, step down transformers.
• Electronic Comparator:
– Amplifier, digital signal etc.
• Combined Comparator

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 Mechanical Comparator
• Based on displacement amplification system
• Simple & cost effective
• Self controlled
• Does not require external power.
• Employs mechanical means for magnifying the small
movement of the measuring stylus.
• Stylus movement is due to the difference between the
standard and the actual dimension being checked

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 Mechanical Comparators
Advantages Disadvantages:
• Do not require any external • Range is limited as the
source of energy. pointer moves over a fixed
• Cheap and portable. scale.
• Robust construction and • Pointer scale system used
compact design. can cause parallax error.
• Simple linear scales are • Large number of moving
easy to read. parts limit accuracy due to
• Unaffected by variations friction.
due to external source of • May become sensitive to
energy such air, electricity vibration due to high
etc. inertia.

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 Dial Indicator
• Indicator is set to zero using
slip gauges
• Pressure on spindle is
multiplied through a system
of gears and levers.
• Stylus movement is indicated
on the face of the dial.
• Used on a wide range of
standard measuring devices • Magnification: Between 40
and 1500
such as dial box gauges,
portal dial, hand gauges, dial • Resolution:
0.001mm
0.02mm to
depth gauges, diameter
gauges and dial indicator snap • Range: 0.075 to 50 mm
gauge.

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 Contact Point
• Contact point
– Is interchangeable: flat or round
– Made of heat treated steel, boron carbide

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 Requirements of Good Dial Indicator
• The pointer should indicate the direction of
movement of the measuring plunger.
• Accuracy of the readings should be within close
limits of the various sizes and ranges
• Movement of the plunger should be in both
directions without affecting the accuracy.
• Pointer movement should be damped.

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 Typical Applications
• Comparing two heights or distances between
narrow limits.
• To determine the errors in geometrical form
such as ovality, roundness and taper.
• For accurate measurement of deformation
• To determine positional errors of surfaces such
as parallelism, squareness and alignment.

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 Dial Test Indicator
• Has a smaller measuring range than a standard
dial indicator.
• Measuring arm swings around its hinge point.
• Lever may be interchanged for length or ball
diameter
• Permits measurements in narrow grooves and
small bores where the body of a probe type may
not reach.
• The indicators actually measure angular
displacement; linear distance is correlated to the
angular displacement based on the correlating
variables.
• Contact points of test indicators are made of
alloy tool steel, HSS or carbides such as tungsten
carbide

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 Reed Type Comparator
• The gauging head is a sensitive,
high quality, dial indicator
mounted on a base supported by a
sturdy column.
• The reed mechanism is a
frictionless device for magnifying
small motions of spindle.

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 Reed Type Comparator
• Block A is rigidly fastened to the
gauge head case,
• Block B, connected to the block A
by reeds C, carries the gauging
spindle
• Vertical reed is attached to each
block with upper ends joined
together.
• Linear motion of spindle moves the
free block vertically causing the
vertical reed on moving block to
slide past the one on the fixed
block.
• As these vertical reeds are joined at
the upper end, both reeds swing
through an arc.
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 Reed Type Comparator
• Target swing is proportional to the
distance moved by the floating
block.
• Scale may be calibrated by means
of gauge blocks to indicate
deviations from an initial setting.
• Sensitivity: 0.25 µ / scale division.
• Amplification: 500x to 1000x.

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Construction of Johansson Mikrokator
• Developed by C.F. Johansson.
• Measuring plunger passes through
the slit washer and transmits its
motion through the bell crank lever
to the twisted metal strip.
• The other end of the twisted metal
strip is fastened to the cantilever
strip.
• A light pointer made of glass tube
is attached to the centre of the
twisted metal strip.

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Working of a Johansson Mikrokator
• Plunger movement turns the
bell crank lever.
• Crank movement causes a
change in strip length
• This results in rotation of the
pointer at the centre
• Magnification
– up to 5000X can be obtained
– May be varied by changing the
overhanging length of the
cantilever strip
– Longer the cantilever, higher the
magnification.

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 Sigma Comparator
Construction
• A plunger is attached to a bar
supported between bending
plates at the top and bottom.
• The bar can move in the
vertical direction only
• A knife edge is fixed to the bar
• Movement of knife edge exerts
a force on the moving block
through sapphire plate.
• Moving block is attached to the
fixed block with the help of
crossed strips.
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 Working of Sigma Comparator
Working
• Force applied to the
moving block, results in
angular deflection.
• A Y-arm transmits the
rotary motion to the
Magnification = (L/l) *(D/R)
driving drum of radius r. where
• This deflects the pointer l = Distance from hinge pivot
and the reading is noted. to the knife edge
L = Length of y-arm
R = Driving drum radius
D Length of the pointer
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 Mechanical - Optical Comparator
Principle:
• Small variation in the plunger
movement is magnified by:
– Mechanical system
Magnification = x2 / x1.
– Optical system
Magnification = 2(x4 / x3)
• Mirror used: Front reflection type.

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Comparison with Chart Gauges
• Chart gauges contain lines denoting tolerance
limits of parts
• Used in optical comparators
• Chart gauges are made of dimensionally stable
material e.g. plastic or soda lime glass

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Standard Chart Gauges

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 Some Common Ones…
• Zeiss Ultra Optimeter
• Zeiss Optotest Comparator
• Newall OMS Horizontal Optimeter
• Eden-Rolt Millionth Comparator

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 Zeiss Ultra Optimeter
• Provides a high degree of magnification.
• Light rays pass through the green filter to a condenser which
projects it on to a movable mirror M1 then to a fixed mirror M2,
and then to M1.
• The objective lens focusses light from M1 to a transparent
graticule containing a precise scale which is viewed by the eye-
piece.
• The projected image on the graticule can be adjusted by means
of screw in order to set the zero.
• Vertical movement of the contact plunger moves a mirror
mounted on a knife edge. Mirror movement causes the scale to
move past a translucent screen.
• Movement of scale image is measured with reference to the
fixed line.
• The overall magnification of the comparator is given by
2 f/d * Eye-piece magnification
– where f is the focal length of the lens
– d is the distance between the knife-edge and the plunger.

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 Advantages of Mechanical - Optical
Comparator
• Almost weightless
• Fewer moving parts result in low wear & friction.
• The scale can be made to move past a datum line
and without having any parallax errors.
• Higher range even at high magnification is possible
as the scale moves past the index.
• Optical magnification provides high degree of
measuring precision due to low friction & wear.

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 Disadvantages of Mechanical - Optical
Comparator
• Accuracy of measurement is limited to 0.001 mm
• Built in illuminating device tends to heat the instrument.
• Electrical supply is required.
• Eyepiece type instrument may cause strain on the operator.
• Projection type instruments occupy large space and are
expensive.
• As the scale is projected on a screen a dark room is needed in
order to take the readings easily.

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 Electrical Comparators
• Principle: Whetstone bridge
• Converts mechanical displacement to electrical signal
• In d.c. circuit, a change of balance of the electrical resistance in
each arm of the bridge is caused by the displacement of an
armature relative to the arm under the action of the measuring
plunger.*
*In a.c. circuits capacitance and inductance need to be considered
• Out of balance is measured by a galvanometer graduated to read
in units of linear movement of plunger.
• Magnification: 104 : 1

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 Linear Variable Differential Transformer
• Electromechanical system
• Working
– If the core is centered in the middle of the
two secondary windings, the voltage
induced in each secondary winding will be
equal and 180° out-of-phase, and the net
output will be zero.
– Motion of the core varies the mutual
inductance in secondary coils. This
determines the voltage induced from the
primary to secondary coil.
– Output is a linear function of core
displacement.

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 Electrical Comparators
Applications :
• Used as measuring heads for e.g.
checking or comparison of workshop slip
gauges against inspection slip gauges.
• Used for electrical gauging heads, to
provide usual indication to check the
dimensions within the limits laid down.
– Green light indicates that the dimension is
within the limits
– Red light indicates undersize dimension
– Yellow light indicates an oversize dimension.

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Visual Gauging Head

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 Advantages of Electrical Comparators
• Measuring units can be remote from indicating units.
• Variable sensitivity which can be adjusted as per
requirement.
• No moving parts, hence it retains accuracy over long
periods.
• Higher magnification as compared to mechanical
comparator (105: 1).
• Compact sizes of probes are available.
• Instantaneous response.

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 Disadvantages of Electrical Comparators

• The accuracy of working of these comparators is

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 Electronic Comparator: Principle
• Movement at the probe tip actuates inductance transducer
which is supplied with an a.c. from the oscillator.
• The transducer converts this movement into an electrical
signal which is then amplified and fed via an oscillator to the
demodulator.
• The current in D.C. form, then passes to the meter and the
probe tip movement is displayed as a linear measurement.

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 Electronic Comparators: Advantages
• Reduced size & power consumption
• High accuracy & reliability
• High sensitivity in all ranges
• Wide range of single or multiple measurements to be made
simultaneously
• Easy provision for multiple amplification ranges
• Used for dynamic measurements: measurement rate 500 /
min
• Easy integration in automated systems

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 Pneumatic Comparators
• Based on pressure differential due to air flow
• Types of pneumatic comparators
– Flow or velocity type pneumatic gauges
• Sense and indicate the momentary rate of air flow.
They have a glass tube with tapered bore, mounted
over a graduated scale. Inside the bore a float is lifted
by the air flow.
– Back pressure gauge
• Air from a constant pressure source flows to the
atmosphere through two orifices Oc and Om in series.
• P is the gauge pressure upstream of the first orifice
and p is the gauge pressure between the two orifices.
• The relationship between p and P will depend upon
the relative sizes of the two orifices
– p will be equal to P when Om is blocked
– p tends to zero as Om is increased indefinitely.

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 Working of a Solex Gauge
• Compressed air passes through the
orifice at a constant pressure.
• Restriction at A1 results in a back
pressure, measured by the head of water
(h).
• To determine the roundness of the job,
the job is rotated along the jet axis.
• Then the same procedure is repeated at
various positions A2, A3, A4, position.
Any variation in the dimension changes
the value of h.
• Moderate and constant supply pressure
is required to have the high sensitivity of
the instrument

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 Pneumatic Comparators: Advantages
• Cheap and simple to operate
• Free from mechanical hysteresis and wear.
• Magnification as high as 10,000 X can be obtained.
• The gauging member is not in direct contact with the
work.
• Indicating and measuring is done at two different
places.
• Tapers and ovality can be easily detected.
• Ideal to be used on shop floor as it is self cleaning
due to continuous flow of air through the jets

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 Pneumatic Comparators:
Disadvantages
• Very sensitive to temperature and humidity changes.
• Accuracy may be influenced by the surface roughness
of the component being checked.
• Different gauging heads are needed for different jobs.
• Auxiliary equipments such as air filters, pressure
gauges and regulators are needed.
• Non-uniformity of scale is a peculiar aspect of air
gauging as the variation of back pressure is linear, over
only a small range of the orifice size variation.

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