COMPARATOR

1
What is comparator ?
Comparator is an indirect precision instrument, which
compares the dimension of a given components with its
working standard.
It does not give the actual dimension, but indicates how
much it differs from basic dimension.
Generally the indicated difference is small, so it requires
suitable magnification device to measure the difference with
consistent accuracy.
It has a sensing device, magnifying or amplifying system and
display system to provide suitable read out.
2
To achieve inter changeability in mass production, the parts
should be produced to a close dimensional tolerance.
Therefore inspection is more concerns with dimensional
variation from standard or basic dimension.
The use of vernier calliper, micrometer is not suitable
because of the skill involved and the time required to
measure the dimension.
The use of comparator requires little or no skill for operator,
eliminate human error in measuring, quick and gives highly
consistent results.
Need of comparator
3
The comparator is first adjusted to zero on its dial with a
gauge block in position. The work piece to be checked is
then placed in position and the comparator gives the
difference in dimension in relation to gauge block.
If the dimension is less or greater than the standard, then
difference will be shown in magnified dial.
Ex:-
Suppose comparator has a magnification of 1000
Difference between standard and actual dimension is 0.02
mm.
Therefore pointer movement is 20mm on the dial or
recording device of the comparator.
Principle of operation
4
1. Laboratory standard:- From which working and
inspection gauges are set and co-related.
2. Working gauge:- To prevent work spoilage and to
maintain required tolerance at all important stages of
manufacturing.
3. Final inspection gauge:- Final inspection gauge where
selective assembly , of production parts is necessary.
4. For checking newly purchased gauge:- To check newly
purchased parts.
Use of comparator
MQR-JAM-COMPARATOR 5
1. Robust design and construction:- So that it can withstand
the effect of ordinary uses without affecting the measuring
accuracy.
2. Linear characteristic of scale:- Read out scale should be
linear, uniform and clear.
3. High magnification:- So that smallest deviation in size of
component can be easily detected.
4. Quick in result:- The reading are obtained within least time.
5. Versatility:- It can be used for wide range of measurement.
6. Minimum wear at contact point:- The measuring plunger
should have harden steel, contact pressure is low and
uniform.
7. Free from oscillation:- Pointer should come rapidly to rest.
8. Minimum inertia:-
9. Adjustable table:-
10. Compensation from temperature effect:-
Characteristic of a good comparator
MQR-JAM-COMPARATOR 6
Based on method used for amplifying and recording.

1. Mechanical Comparator
2. Optical Comparator
3. Mechanical-Optical Comparator
4. Electrical and Electronics Comparator
5. Pneumatic Comparator
6. Fluid displacement Comparator
7. Projection Comparator
8. Multi check Comparator
9. Automatic gauging machines
10. Electro-Mechanical Comparator
Classification of comparator
MQR-JAM-COMPARATOR 7
In these comparators, magnification is obtained by mechanical
linkages and other mechanical devices. The magnification may be of
following type
Rack and Pinion. In it the measuring spindle integral with a rack,
engages a pinion which amplifies the movement of plunger through
a gear train.
Mechanical Comparator
MQR-JAM-COMPARATOR 8
Cam and gear train. In this case the measuring spindle acts on a cam
which transmits the motion to the amplifying gear train.
MQR-JAM-COMPARATOR 9
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.
MQR-JAM-COMPARATOR 10
Compound Levers. Here levers forming a couple with compound
action are connected through segments and pinion to produce final
pointer movement.
MQR-JAM-COMPARATOR 11
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 the
attached pointer.
MQR-JAM-COMPARATOR 12
Lever combined with band wound around drum. In this case, the
movement of the measuring spindle tilts the hinged block, causing
swing of the fork which induces rotation of the drum.
MQR-JAM-COMPARATOR 13
The usual magnification obtained by these comparators is about 250
to 1000. Some mechanical comparators are :-

1. Dial Indicator


MQR-JAM-COMPARATOR 14

2. The Johansson Mikrokator

MQR-JAM-COMPARATOR 15

3. Reed type mechanical comparator

A Fixed block
B Floating block
C Horizontal reeds
D Vertical reeds
REED :- One of the thin pieces of metal, the
vibration of which produce the tone.
MQR-JAM-COMPARATOR 16
4. Sigma comparator
MQR-JAM-COMPARATOR 17
MQR-JAM-COMPARATOR 18
MQR-JAM-COMPARATOR 19
Advantages f Mechanical Comparator
1. Cheaper
2. No need of external energy
3. Linear scale
4. Robust and compact scale
5. Portable
MQR-JAM-COMPARATOR 20
Disadvantages of Mechanical Comparator
1. Less accuracy (More moving part)
2. Sensitive to vibration
3. Faults magnified (backlash error)
4. Limited range (pointer moved over a fixed scale)
5. Parallax error
MQR-JAM-COMPARATOR 21
Electrical Comparator
Electrical comparators are also known as
electromechanical measuring systems as these employ an
electro-mechanical device which converts a mechanical
displacement into electrical signal.
MQR-JAM-COMPARATOR 22
Electronic Comparator
The electronic comparator is based on the principle of
frequency modulation. A radio oscillator is used which
produces impulses of a definite value at a definite frequency.
The frequency is controlled by measuring head. The
measuring head is applied to the part to be measured. The
frequency of the oscillator is modified because of the variation
of dimension from preset value. The measuring instrument
dial is graduated directly in terms of physical standards of
length which compare with the electronic standards of
wavelength.
MQR-JAM-COMPARATOR 23
Pneumatic Comparator
Air gauging becomes more popular due to following important
characteristics:
(a) Very high amplifications are possible. It can be used to measure
diameters, length, squareness, parallelism, concentricity, taper,
centre distance between holes and other geometric conditions.
(b) As no physical contact is made either with the setting gauge or
the part being measured, there is no loss of accuracy because of
gauge wear.
(c) Internal dimensions can be readily measured not only with
respect to tolerance boundaries but also geometric form.
(d) It is independent of operator skill.
(e) High pressure air gauging can be done with cleansing of the
parts which helps to eliminate errors due to dirt and foreign matter.
(f) Gauging pressures can be kept sufficiently low to prevent part
deflection. (In general, high pressure gauges are suitable for those
parts in which tolerances are relatively large and low pressure air
gauges are preferable for highly precise work.)
MQR-JAM-COMPARATOR 24
Pneumatic Comparator
(g) Dimensional variations throughout the length of shaft or
cylinder bore can be explored for out of roundness,
taperness, concentricity, regularity and similar conditions.
(h) 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.
(i) The total life cost of the gauging heads in much less.
(j) It is accurate, flexible, reliable, universal and speedy
device for inspecting parts in mass production.
(k) It is best suited for checking multiple dimensions and
conditions on a part simultaneously in least possible time. It
can be used for parts from 0.5 mm to 900 mm diameter
having tolerance of 0.05 mm or less. It can be easily used for
on line measurement of parts as they are being machined
and take corrective actions.
MQR-JAM-COMPARATOR 25
Generally there are two types of pneumatic gauge :-
1. Flow or velocity 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.
2. Back pressure type
The basic principle and the theory of pneumatic gauging in the
back pressure gauges is described by the figure below.
Air from a constant pressure
source flows to the atmosphere
through two orifices O
c
and O
m

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.
p=P when i) O
m
is blocked
ii) O
m
is infinitely large
MQR-JAM-COMPARATOR 26
Principle
The pneumatic gauging is based on Bornoullis theory. The
basic principle used in gauging is to convert change in length of
surface displacement into change of pressure of air.

Solex pneumatic gauge.
MQR-JAM-COMPARATOR 27
There is a water manometer for indication of back pressure
along with a vertical metal cylinder filled with water upto a
certain level. A dip tube immerged into cylinder upto a depth
corresponding to the air pressure required. Calibrated
manometer tube is connected between the cylinder and control
orifice.
If the pressure of the air supplied is higher than the desired
pressure, some air will bubble out from the bottom of the dip
tube and air moving to the control volume will be at the desired
constant pressure . The constant pressure air then passes
through the control orifice and escape from the measuring jets
when there is no restriction to the escape of air , the level of
water in the manometer tube will coincide with that in the
cylinder . But if there is a restriction to the escape of air through
the jets , a back pressure will be induced in the circuit and level
of water in the manometer tube will fall . The restriction to the
escape of air depends upon the variation in the dimensions to
be measured.
MQR-JAM-COMPARATOR 28
Pneumatic sensitivity


P= Source pressure or
Pressure at O
c
p=Pressure between
two orifice
C= geometric area of O
c
M= geometric area of O
m


p=P when i) O
m
is blocked
p=0 when ii) O
m
is infinitely large
MQR-JAM-COMPARATOR 29
The characteristic of p/P and M/C is plotted on experimental
results. Here p & C is kept constant M varied and P varied
(0.13-5 kg/cm
2
), then the curve will be as shown below.
It is observed that 0.6 p/P to 0.8 p/P the curve is approximately
straight-line. So it can be written as
p/P=A-b(M/C) (1)
Where A=1.1, b=0.6 when P=0.13kg/cm
2

=0.4 when P=5.00 kg/cm
2

MQR-JAM-COMPARATOR 30
Differentiating eq. 1 w.r.t M




(Sensitivity )

Let at mid point i.e. p/P=0.7 & M=M
a
; putting in eq. (1)
0.7=1.1-b(M
a
/C) =>b(M
a
/C)=0.4 =>b/C= 0.4/M
a
Now putting b/C value in equation (2)




So the sensitivity is directly depends upon operating pressure P
and inversely varies with M
a
.
(2) P
c
b
- )P
C
M
b (A
M M
p

P
M
0.4
- P
c
b
-
M
p
a

MQR-JAM-COMPARATOR 31