Comparators

Comparators are used only for relative Measurement of dimension i.e. they give only dimensional difference in relation to a basic dimension. The comparator compares the unknown dimensions of a part with some standard or master setting which represents the basic size. The dimensional variations from the master setting are amplified and measured.
Use of comparators is easier and not much skill is required to operate them. Calibration over full range is not required as the comparison is done with a standard end length. Various types of comparators are as follows. Mechanical Mechanical optical Electrical & electronics Pneumatic

Characteristics of Comparators
The instrument must be of robust design and construction so as to withstand the effects of ordinary usage without impairing its measuring accuracy. Provision must be made for maximum compensation for temperature effects. The scale must be linear and must have straight line characteristics. Indicator should be constant and it should return to zero. Instrument , though very sensitive, must withstand a reasonable ill usage without permanent harm. Indicating device must be such that readings are obtained in least possible time and for this, magnification system used should be such that the readings are accurate. The system should be free from backlash, and wear effects and the inertia should be minimum possible.

Uses of Comparators
In mass production to check components at very fast rates. 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 tolerances.

Mechanical Comparators
In these comparators, magnification is obtained by mechanical linkages and other mechanical devices. Displacement amplification is achieved through Rack & Pinion : measuring spindle is integral with a rack, which engages with pinion. The pinion and further gear train amplify the movement further. Cam and gear train : In this case measuring spindle acts on a cam which transmits the motion to the amplifying gear train. Lever with toothed sector : in this case a lever with a toothed sector at its end engages a pinion in the hub of a crown gear sector which further meshes with a final pinion to produce indication. Compound levers : Here levers forming a couple with compound action are connected through segments and pinion to produce final pointer movement.

 Twisted taut strip : The movement of measuring spindle tilts the knee causing straining which further causes the twisted taut band to rotate proportionally. The motion of strip is displayed by attached pointer. Lever combined with band wound around drum : The movement of measuring spindle tilts the hinged block, causing swing of fork which induces rotation of the drum Reeds combined with optical display : In this case parallelogram reeds are used which transfer measuring spindle movement to a deflecting reed whose extension carries a target utilised in optical path. Tilting mirror projecting light spots.

Dial Indicator
It operates on the principle, that a very slight upward pressure on the spindle at the contact point is multiplied through a system of gears and levers. It is indicated on the face of the dial by a dial finger. Dial indicators basically consist of a body with a round graduated dial and a contact point connected with a spiral or gear train so that the hand on the dial face indicates the amount of movement of the contact point. They are used for a wide range of devices such as dial box gauges, hand gauges, diameter gauge and sap indicator snap gauge. The movement mechanism of the instrument is housed in a metal case for its protection. The large dial is graduated into 100 divisions.

Johansson Mikrokator
It works on the principle of button springing on a loop of string like in the case of childrens toys.

 It employs a twisted metal strip which

Mechanical Optical Comparators

In mechanical optical comparators small displacements of the measuring plunger are amplified first by 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 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 surface of a ground glass screen.

 Optical magnification provides high degree of measuring precision due to reduction of moving members and better wear resistance qualities. Optical magnification is also free from friction, bending, wear etc. In this system, Mechanical amplification = l2/l1 Optical amplification = l4/l3x 2. It is multiplied by 2, because if mirror is tilted by an angle q, then image will be tilted by 2 x q. Thus overall magnification of this system = 2 x (l2/l1). (l4/l3)

 Thus optical comparators are capable of giving a high degree of measuring precision owing to high magnification and the reduction of moving members to minimum. They possess better wear resistance qualities as the only wearing members are the plunger and its guide and the mirror pivot bearing. Another advantage of the optical comparators is that provision of an illuminated scale enables readings to be taken without regard to the room lighting conditions. The mirror used must be of front reflection type and not of normal back reflection type. In normal back reflection type there are two reflected images, one each from front and back. Thus the reflected image is not well defined one, as one bright and other blurred image are observed. The front reflection type of mirror requires considerable care in its use to avoid damage to the reflecting surfaces.

Digital Comparator
Incremental measuring system with optoelectronic reading of a grid line glass scale. Main features : Clear and high contrast digital display. Large measuring range and high resolution. Compact design with Universal power supply by choice of batteries or grid connection. Conveniently placed operating elements for the various measuring functions. Measuring spindle mounted in high precision ball bush guide, virtually friction free and without play. Advantages : Digital read-out High measuring accuracy Small dimensions Processing of measuring results Setting of tolerance limits Direction of counting reversible for outside and inside measurements Data transfer to computer

Electrical Comparators
Electrical comparators: are also known as electromechanical measuring systems as these employ an electromechanical device which converts a mechanical displacement into electrical signal. These depend for their operation on Wheatstone bridge circuit. In D.C circuits, a change of balance of the electrical resistance in each arm of the bridge is caused by the displacement of an armature relative the measuring plunger. It is measured by a galvanometer graduated to read in units of linear movement of plunger. This circuit is operated by battery. For the bridge to balance, the ratios of resistances in two arms must be equal. Linear variable differential transformer (LVDT) is the most popular electro-mechanical device used to convert mechanical displacement into electrical signal.

Electronic Comparator
Its based on the principle of application of frequency modulation or radio oscillation. A special radio oscillator is used which produces impulses of a definite value at a definite frequency. The frequency is controlled by the measuring head. When the measuring head is applied to the part to be measured the frequency of the instrument oscillator is modified because of the variation of the dimension from that of the preset standard. The modified frequency is negated by suitable controls to restore it back to the basic value. The measuring instrument dial is graduated directly in terms of the physical standards of length which compare with the electronic standards of wavelength. By using various adaptors to suit the work, the comparator can be put to many applications such as external and internal gauging, flatness, testing, thickness gauging, tube wall thickness, measurement of electro-plate coating, gauging on curved or flat surfaces etc., to a very high limit of measuring precision.

Pneumatic Comparator
Air gauges have rapidly increased in the past couple years due to the following important characteristics: 1. Very High amplifications are possible. 2. Since there is no physical contact with the gauge or the part being measured, there is no loss of accuracy because of gauge wear. 3. It is independent of operator skill. 4. High pressures air gauges can be done with cleansing of the parts which helps to eliminate errors due to dirt and foreign matter. 5. Not only it measures the actual size but it can also be used to salvage oversized pieces for rework or to sort out for selective assembly. 6. It is accurate, flexible, reliable, universal and speedy device for inspecting parts in mass production. 7. It is best suited for checking multiple dimensions and conditions on a part simultaneously in least possible time.

 Based on the physical phenomena on which the operation of pneumatic gauges is based, these may be classified as : (i) Flow or velocity type, (ii) Back pressure type. Flow or velocity type pneumatic gauges operate by sensing and indicating the momentary rate of air flow. Flow could be sensed by a glass tube with tapered bore, mounted over a graduated scale. Inside the bore a float is lifted by the air flow. Velocity of air in velocity type pneumatic gauges can also be sensed by sensing the velocity differential i.e., differential pressure across a venturi chamber. Such systems have quick response. These permit use of large clearance between nozzle and object surface, resulting in reduced wear of the gauging members. There is less air consumption. Magnification of the order of 500 to 5000 times is possible.

Free Flow Air Gauges

In this case the compressed air after the filtering and pressure reducing unit flows through a tapered glass tube containing a small metal float and then through a plastic tube to the gauge head having two diametrically opposed orifices for air escapement into atmosphere. The position of the tube is dependent upon the amount of air flowing through the gauge head, which in turn is dependent upon the clearance between the bore to be measured and the gauge head. Fig. below shows a curve between the air flow and the clearance between the part and the orifice in gauge head.

 The flow velocity type pneumatic comparator with zero adjustment and magnification adjustment is shown in Fig. below. Magnification can be changed by bypassing 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.

Back Pressure Gauges

Air from a constant pressure source flows to the atmosphere through two orifices Oc and Om in series. P is the pressure upstream of the first orifice and p is the pressure between the two orifices, both measured with reference to the atmospheric pressure as datum.

 The relationship between p and P will depend upon the relative sizes of the two orifices : p being equal to P when 0m is blocked and tends to zero as Om is increased indefinitely. Let C be the geometrical area of Oc and M that of Om.Then if p and C are kept constant while M is varied, the relationship between the dimensionless quantities p\P and M/C is of the type.(The general form of this curve is quite well predicted by an analysis employing Bernoulis equation for flow of a compressible fluid.) We are interested in linear portion of this curve. For design purposes we follow an empirical approach which is based on an experimental study at N.P.L. (London) of the relationships between pressures and orifices areas.