COMPARATOR

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 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.

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 Need of comparator
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 caliper, 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. (Advantages)

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 Principle of operation
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.

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 Use of comparator
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.

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 Characteristic of a good comparator
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:- 6
 Classification of comparator
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

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 Mechanical Comparator
In these comparators, magnification is obtained by mechanical
linkages and other mechanical devices. The magnification may be of
following type
Rack and Pinion. In this the measuring spindle integral with a rack,
engages a pinion which amplifies the movement of plunger through
a gear train.

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Cam and gear train. In this case the measuring spindle acts on a cam
which transmits the motion to the amplifying gear train.

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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.

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Compound Levers. Here levers forming a couple with compound
action are connected through segments and pinion to produce final
pointer movement.

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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.

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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.

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The usual magnification obtained by these comparators is about 250
to 1000. Some mechanical comparators are :-

1. Dial Indicator

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2. The Johansson Mikrokator

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3. Reed type mechanical comparator

REED :- One of the thin pieces of metal, the

vibration of which produce the tone.

A  Fixed block
B  Floating block
C Horizontal reeds
D Vertical reeds

Sensitivity order

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 Principle of the
Reed Mechanism
• Fixed steel block and free-reed block
have reeds (2 pieces of spring steel)
attached
• Upper ends of reed joined and
connected to a pointer FIXED BLOCK
• Movement of spindle attached to
free-reed block will move it up and
down (moving pointer to right or
left)
• Light beam through aperture,
movement of free block cause target
to interrupt light beam, casting
shadow on scale

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Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
 Cutaway Section Showing Reed Mechanism

Upper part of reed deflects greater

distance than the lower part
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Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
 To Measure with a Reed Comparator

1. Raise gaging head above required height,

and clean anvil and master thoroughly
2. Place master gage or gage block buildup
on anvil
3. Carefully lower gaging head until end of
spindle just touches the master
– Shadow will begin to appear on left side of
scale
4. Clamp gaging head to column
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 To Measure with a Reed Comparator

• Turn adjusting sleeve until shadow coincides

with zero on the scale
• Remove gage blocks and carefully slide
workpiece between anvil and spindle
• Note reading
– If shadow to right of zero, part is oversize
– If shadow to left of zero, part undersize

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4. Sigma comparator

A= steel spring
B = shank
C = stop
D = hinge assembly
E = forked arm
F = Metal ribbon
G = Spindle
H = Pointer
J = Trigger

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Magnification range: 300 to 5000

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 Advantages of Mechanical Comparator

1. Cheaper
2. No need of external energy
3. Linear scale
4. Robust and compact scale
5. Portable

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 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

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 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.

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 Elementary Electro-Mechanical Measuring System

Mechanical Electrical
displacement Electro- signal Read out
mechanical Signal conditioning
or Display
transducer

Observer

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Linear variable differential transformer (LVDT)

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Feature of LVDT

1. Due to no physical contact between core and coil, its

mechanical components do not wear out, as a result friction is
absent and true infinite resolution with no hysteresis is
obtained.

2. The small core mass and lack of friction enhance the

response capabilities for dynamic measurements and thus it
becomes very suitable for taking measurements for online
machining.

3. It is not affected by overhead and its reliability is high.

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Visual Gauging Heads

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 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.

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Principle of Operation in Electronic Comparator

OSCILATOR AMPLIFIER Large DEMODULATOR

A.C. D.C.
Small Signal
A.C.
Signal

TRANSDUCER

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Advantages of Electronic Comparator
1. This system has high magnification with small number of moving
parts.
2. The measuring unit can be remote from the indicating instrument.
3. The mechanism carrying the pointer is light and not sensitive to
vibration.
4. The measuring unit can be small, and the instrument can have
several magnification.
Disadvantages of Electronic Comparator

1. It requires an external agency to operate, i.e., an A.C. electronic

supply. The fluctuation in voltage or frequency supply may affect
the results.
2. Heating in coil may alter the calibration.
3. When a fix scale is used with the moving pointer, then with high
magnification a very small range is obtained.
4. Expensive compared to the mechanical comparator.
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 Pneumatic Comparator
Air gauging important characteristics:

(a) Very high amplifications are possible. It can be used to measure

diameters, length, squareness, parallelism, concentricity, taper, center
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) High pressure air gauging can be done with cleansing of the parts
which helps to eliminate errors due to dirt and foreign matter.
(e) 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.)

(f) It is independent of operator skill

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 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.
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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.

p=P when i) Om is blocked

ii) Om is infinitely large
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Pneumatic sensitivity

P= Source pressure or
Pressure at Oc
p=Pressure between
two orifice
C= geometric area of Oc
M= geometric area of Om

p=P when i) Om is blocked

ii) Om is infinitely large

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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/cm2), 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/cm2
=0.4 when P=5.00 kg/cm2
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Differentiating eq. 1 w.r.t M

p  M b
 (A  b )P  - P (2)
M M C c
(Sensitivity )

Let at mid point i.e. p/P=0.7 & M=Ma ; putting in eq. (1)
0.7=1.1-b(Ma/C) =>b(Ma/C)=0.4 =>b/C= 0.4/Ma
Now putting b/C value in equation (2)
p b 0.4
- P- P
M c Ma
So the sensitivity is directly depends upon operating pressure P
and inversely varies with Ma.
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Principle
The pneumatic gauging is based on Bornoulli’s 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.

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