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Introduction to comparators, ComparatorsCharacteristics & Classification Mechanical comparators, Sigma, Dial comparators Optical ComparatorsPrinciples, eiss ultra optimeter
!lectrical & !lectronic Comparator, "#DT, Pneumatic Comparator, $ac% pressure gauges Sole& Comparators Multi-Chec% comparators
COMPARATORS
The general principle of comparator is to indicate the differences in si'e (et)een the standard and the )or% (eing measured (* means of some pointer on a scale )ith sufficient magnification All comparators consist of three (asic features +,A sensing device )hich faithfull* senses the input signal -, A magnifying or amplifying system to increase the signal to suita(le magnitude. Mechanical, Optical, Pneumatic, h*draulic and electronic methods are used for this purpose. /, A display system (usually a scale and pointer) which utilizes the amplified signal to provide a
Design Consideration 1.Ability to record variation of at least 0.0025 mm 2.Linear recording scale 3.Variance free (Instr ment readings s!o ld not vary "!en re#eated meas rements of given $ antity are made %.&cale indicators clear and free from oscillations 5.'ree from bac(las!) nnecessary friction * clearances inertia s!o ld be lo". +.,eas ring #ress re s!o ld be lo" and constant -.& ##orting frame to be rigid and "it!stand reasonable ill sage "it!o t #ermanent damage ..Ca#able of meas ring "ide range.
Mechanical Comparators
In Mechanical t*pe, the re3uired magnification is o(tained (* using mechanical lin%ages, le2ers, gears and other mechanical de2ices. Magnification ;M,< It is the ratio (et)een the mo2ement of the plunger and the resultant mo2ement of the pointer M= P;pointer mo2ement,>p Plunger mo2ement
Mechanical comparators t*pes< +. Dial test indicator. -. ?ohansson mi%ro%ator. /. Sigma mechanical comparator
REED COMPARATOR
Scale Pointer
Fixed link
Flexure strips
Spindle
Spindle displacement
R!!D COMPARATOR
As sho)n in fig, the mo2a(le lin% is constrained (* thin metal fle&ure strips to mo2e 2erticall* relati2e to fi&ed lin% attached to housing. The change of orientation of the fle&ure strips due to relati2e motion, the reeds pro2ide a large angular mo2ement of the pointer. The scale ma* (e cali(rated to indicate an* de2iation from an initial setting.
Light pointer
JOHANSSON MIKROKATER
Scale Twisted strip Spring elbow
Cantilever strip
Attachment screws
Slit washer
Plunger tip
Measuring plunger
?O@A0SSO0 MIAROAATOR
B It )or%s on the principle of a (utton spinning in a loop of string. B A t)isted thin metal strip carries a 2er* light pointer made of thin glass at the center of its length. B The t)o hal2es of the strip from the centre are t)isted in opposite directions so that an* pull on the strip )ill cause the centre to rotate. B One end of the strip is fi&ed to an adCusta(le cantile2er and the other is anchored to the spring el(o). B One arm of spring el(o) carries the measuring plunger.
The ampli ication increases with the number o turns# The magni ication is o the order $%%%
The Mikrokator is an instrument for measuring differences in length The Mikrokator !rinci!le greatl" magnifies an" de#iation in si$e so that e#en small de#iations !roduce large deflections of the !ointer o#er the scale The transference of mo#ement from the measuring ti! to the !ointer is mechanical% com!letel" frictionless and free from &acklash The 'E Johansson Mikrokator (as introduced in )*+, and is still toda" the finest mechanical com!arator in the (orld A (ide range of models are a#aila&le% (hich gi#es graduations #ar"ing &et(een ---). / --0 mm1 and ----2. / ---) mm1 The uni3ue 4T(isted Stri!. !rinci!le on (hich all Mikrokators are &ased% !ro#ides man" features (hich are not a#aila&le on an" other measure instrument
SIEMA COMPARATOR
It has magnifications in the range of /FF to 5FFF. It has a plunger attached to a rectangular (ar )hich is supported at its upper and lo)er ends (* fle&ure plates. A %nife edge is fi&ed to the side of rectangular (ar )hich (ears on a mo2ing (loc%. The mo2ing (loc% and the fi&ed (loc% are connected (* fle&i(le strips at right angles to each other.
SIEMA COMPARATOR
Scale Flexure plate Flexible strips Pointer Fixed block &rum )ni e edge
Flexure plate
DIA" I0DICATOR
DIA" I0DICATOR
&ial Scale Pointer Pinion Rack
Plunger
Pillar
'ase + block
OPTICAL COMPARATORS
Screen
Lamp A
Screen -ormal
, Mirror
Lamp A
"
l -orma , Mirror C
angle
o tilt
Pivot
Plunger
OPTICA" COMPARATORS
An optical comparator )or%s on one of the follo)ing t)o main principles< +,1se of optical le2er -, 1se of enlarged image 5 If a (eam of light AC is directed on to a mirror as sho)n in fig, it )ill (e reflected onto the screen at O as a dot. The angle of incidence = angle of reflection 5 Hhen the plunger mo2es up, the mirror tilts (* . Then the reflected (eam mo2es through - . i.e. the illuminated dot mo2es to $. 5 Also the increase in distance CO of the screen from the tilting mirror )ill increase the magnification.
Mechanical0,ptical Comparator
Light source Screen with scale Collimating lens Pro.ection lens & Mecahnical lever /lass plate carr*ing index line Mirror Mirror pivot
L 4
Measuring Plunger Pivot
L 1
L 2
L 3
Mechanical Optical Comparator In this comparator, small displacements of the measuring plunger are first amplified (* a mechanical le2er. It is e3ual to ;"->"+, The amplified mechanical mo2ement is further amplified (* optical s*stem due to tilting of mirror (* . The reflected ra* D ;image of inde& line, )ill (e turned through an angle -, and hence optical amplification =-;"4>"/, The o2erall magnification = ;"->"+,I -;"4>"/,
4*e piece
/reen Filter ,b.ective lens Fixed mirror M" Movable Mirror M1 Plunger 2ork piece Condenser 3ndex lens
Ad2antages< +, 6e) mo2ing lin%ages and hence no friction & )ear. -, @igh range of measurements and no paralla& error /, Magnification is usuall* high. Disad2antages< +, @eat from the source of light, transformers etc., ma* cause the setting to drift. -, An electric suppl* is re3uired to operate these comparators. /, The si'e is large and costl*. 4, 1se of e*epiece to 2ie) is incon2enient for prolonged use. Also a dar% room is essential to ta%e readings.
R5
R6
Coils
3ron Armature
Measuring Plunger
These comparators depend on the principle of (alancing the Hheatstone (ridge, ;R+>R-, = ;R/>R4, applica(le for onl* to direct current o(tained from a (atter*. In actual instruments, one pair of inductances ta%es the form of a pair of coils in the measuring head of the instrument. An iron armature inside these coils mo2es along )ith the measuring plunger, and upsets the (alance of the circuit and causes the deflection of the pointer meter )hich is cali(rated directl* in linear units. Magnifications of the order of /F,FFF are possi(le.
!lectrolimit gauge
Armature Spring A Thin steel strips
"inear #aria(le Differential Transformer "#DT is the most popular electro mechanical de2ice used to con2ert mechanical displacement into electrical signal. It is a differential transformer )hich pro2ides an A.C 2oltage output proportional to displacement of a core passing through the )indings. Of the three s*mmetricall* placed coils, the center coil is energi'ed from an A.C source and the t)o end coils connected together in phase opposition are used as pic% up coils.
3nput displacement
Fig#b
"inear #aria(le Differential Transformer ;contdD, $ased on the position of the core, a 2oltage is induced in each of the pic% up coils. A position of the core at )hich the 2oltages induced in the pic% up coils are same, (ut cancel each other due to phase opposition, is called the Jnull positionK. The fig sho)s the t*pical differential transformer characteristics o(tained (* plotting output 2oltages 2s. core displacements. All commercial de2ices are designed to operate onl* in the linear range and hence the name "#DT. Suppl* re3uirements 7./ # at 7F @', Range of displacement--5 mm.
Linear range
-ull position
Core &isplacement
Fig c
Commercial L+&Ts
Ad2antages of "#DT It can (e used as a primar* detector transducer, as it does not re3uire assistance of another element such as a strain gauge to con2ert mechanical displacement into electrical 2oltage. The core is completel* separa(le from the rest of the e3uipment and hence no mechanical losses. It is insensiti2e to temperature changes. Pro2ides a comparati2el* high output and does not re3uire amplification. It is of reasona(le cost.
Disad2antages of "#DT +, It cannot (e used for d*namic measurements due to its apprecia(le mass compared to strain gauge. -, Re3uirement of 7F cps suppl* 2oltage (ecomes a limiting factor for d*namic measurements. /, The direction from the null point is to (e indicated )hich ma%es the circuit arrangement comple&.
Pneumatic comparators
In Pneumatic comparators air is used as a means of magnification and hence the* use principle of air Cet. A cham(er is fitted )ith control orifice C and a gauging orifice E through )hich air flo)s from a suppl* at a constant pressure P+. If the si'e of the control orifice C remains constant, an* 2ariation in si'e of E )ill cause alteration of pressure P- in the cham(er. This 2ariation is measured (* a suita(le pressure gauge graduated to read in linear units.
Air 9 constant Pr P1
Pressure P"
To pressure gauge
2orkpiece
Principle o back pressure t*pe Pneumatic comparator Scale 'ourdon tube 2ork piece
Column
Spirit level
'racket
Levelling scews
7c8
7d8