COMPARATORS

Comparators can give precision measurements, with consistent accuracy by eliminating human error.
They are employed to find out, by how much the dimensions of the given component differ from that of
a known datum. If the indicated difference is small, a suitable magnification device is selected to obtain
the desired accuracy of measurements. It is an indirect type of instrument and used for linear
measurement. If the dimension is less or greater, than the standard, then the difference will be shown
on the dial. It gives only the difference between actual and standard dimension of the workpiece. To
check the height of the job H2 ,with the standard job of height H1

Initially, the comparator is adjusted to zero on its dial with a standard job in position as shown in
Figure(a). The reading H1is taken with the help of a plunger. Then the standard job is replaced by the
work-piece to be checked and the reading H2 is taken. If H1and H2 are different, then the change in the
dimension will be shown on the dial of the comparator. Thus difference is then magnified 1000 to 3000
X to get the clear variation in the standard and actual job.

In short, Comparator is a device which

(1) Picks up small variations in dimensions.

(2) Magnifies it.

(3) Displays it by using indicating devices, by which comparison can be made with some standard value.

Classification:

1. Mechanical Comparator: It works on gears pinions, linkages, levers, springs etc.

2. Pneumatic Comparator: Pneumatic comparator works by using high pressure air, valves,

back pressure etc.

3. Optical Comparator: Optical comparator works by using lens, mirrors, light source etc.
4. Electrical Comparator: Works by using step up, step down transformers.

5. Electronic Comparator: It works by using amplifier, digital signal etc.

6. Combined Comparator: The combination of any two of the above types can give the best

result.

Characteristics of Good Comparators:

1. It should be compact.

2. It should be easy to handle.

3. It should give quick response or quick result.

4. It should be reliable, while in use.

5. There should be no effects of environment on the comparator.

6. Its weight must be less.

7. It must be cheaper.

8. It must be easily available in the market.

9. It should be sensitive as per the requirement.

10. The design should be robust.

11. It should be linear in scale so that it is easy to read and get uniform response.

12. It should have less maintenance.

13. It should have hard contact point, with long life.

14. It should be free from backlash and wear.

Mechanical Comparator:

It is self controlled and no power or any other form of energy is required. It employs mechanical means
for magnifying the small movement of the measuring stylus. The movement is due to the difference
between the standard and the actual dimension being checked The method for magnifying the small
stylus movement in all the mechanical comparators is by means of levers, gear trains or combination of
these. They are available of different make and each has it's own characteristic. The various types of
mechanical comparators are dial indicator, rack and pinion, sigma comparator, Johansson mikrokator.
a. 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 consists of a body with a round graduated dial and a contact point connected with a
spiral or gear train so that hand on the dial face indicates the amount of movement of the contact point.
They are designed for use on a widerange of standard measuring devices such as dial box gauges, portal
dial, hand gauges, dial depth gauges, diameter gauges and dial indicator snap gauge. The movement
mechanism of the instrument is housed in a metal case for it's protection.

Requirements of Good Dial Indicator:

1. It should give trouble free and dependable readings over a long period.

2. The pressure required on measuring head to obtain zero reading must remain constant

over the whole range.

3. The pointer should indicate the direction of movement of the measuring plunger.

4. The accuracy of the readings should be within close limits of the various sizes and ranges

5. The movement of the measuring plunger should be in either direction without affecting

the accuracy.
6. The pointer movement should be damped, so that it will not oscillate when the readings

are being taken.

Applications:

1. Comparing two heights or distances between narrow limits.

2. To determine the errors in geometrical form such as ovality, roundness and taper.

3. For taking accurate measurement of deformation such as intension and compression.

4. To determine positional errors of surfaces such as parallelism, squareness and alignment.

5. To check the alignment of lathe centers by using suitable accurate bar between the

centers.

6. To check trueness of milling machine arbours and to check the parallelism of shaper arm

with table surface or vice.

Advantages of Mechanical Comparator:

1. They do not require any external source of energy.

2. These are cheaper and portable.

3. These are of robust construction and compact design.

4. The simple linear scales are easy to read.

5. These are unaffected by variations due to external source of energy such air, electricityetc.

Disadvantages:

1. Range is limited as the pointer moves over a fixed scale.

2. Pointer scale system used can cause parallax error.

3. There are number of moving parts which create problems due to friction, and ultimately

the accuracy is less.

4. The instrument may become sensitive to vibration due to high inertia.

c) Mechanical - Optical Comparator:

Principle:
In mechanical optical comparator, small variation in the plunger movement is

magnified: first by mechanical system and then by optical system.

Construction:

The movement of the plunger is magnified by the mechanical system using a pivoted lever. From the
Figure the mechanical magnification = x2 / x1. High optical magnification is possible with a small
movement of the mirror. The important factor is that the mirror used is of front reflection type only.

The back reflection type mirror will give two reflected images as shown in Figure, hence the exact
reflected image cannot be identified.

Advantages:

1. These Comparators are almost weightless and have less number of moving parts, due to

this there is less wear and hence less friction.

2. Higher range even at high magnification is possible as the scale moves past the index.

3. The scale can be made to move past a datum line and without having any parallax errors.
4. They are used to magnify parts of very small size and of complex configuration such as intricate
grooves, radii or steps.

Disadvantages:

1. The accuracy of measurement is limited to 0.001 mm

2. They have their own built in illuminating device which tends to heat the instrument.

3. Electrical supply is required.

4. Eyepiece type instrument may cause strain on the operator.

5. Projection type instruments occupy large space and they are expensive.

6. When the scale is projected on a screen, then it is essential to take the instrument to a dark

room in order to take the readings easily.

Electrical Comparators:

Electrical comparators give a wide range of advantages. As we know, components like levers, gears,
racks and pinions, activate mechanical devices. The accuracy and life of the instruments are affected as
they are subjected to wear and friction
Electrical comparators have no moving parts. Thus a high degree of reliability is expected from these
instruments. Generally there are two important applications of electrical comparators:

1. Used as measuring heads

2. Used for electrical gauging heads, to provide usual indication to check the dimensions within the
limits laid down.

The first application is very important when there is a requirement for precise measurement for e.g.
Checking or comparison of workshop slip gauges against inspection slip gauges. The second application
is used to indicate with a green light if a dimension is within the limits. A red lamp indicates an undersize
dimension; a yellow lamp indicates an oversize dimension. So the operator is not required to be aware
of the actual tolerances on the dimension. After setting the instrument correctly, all that needs to be
done is to place the component under the plunger of the gauging head. The signal lamps provide in
standard positive indication of the acceptability of the dimension under test

Advantages:

1. Measuring units can be remote from indicating units.

2. Variable sensitivity which can be adjusted as per requirement.

3. No moving parts, hence it can retain accuracy over long periods.

4. Higher magnification is possible as compared to mechanical comparator.

5. Compact sizes of probes arc available.

Disadvantages:

1. The accuracy of working of these comparators is likely to be affect due to temperature and humidity.

2. It is not a self contained unit; it needs stabilized power supply for its operation.

3. Heating of coils can cause zero drifts and it may alter calibration.

4. It is more expensive than mechanical comparator

Pneumatic Comparators (Solex Gauge):

Principle:

It works on the principle of pressure difference generated by the air flow. Air is supplied at constant
pressure through the orifice and the air escapes in the form of jets through a restricted space which
exerts a back pressure. The variation in the back pressure is then used to find the dimensions of a
component.

Working:
As shown in Figure (a) the air is compressed in the compressor at high pressure which is equal to Water
head H. The excess air escapes in the form of bubbles. Then the metric amount of air is passed through
the orifice at the constant pressure. Due to restricted area, at A1 position, the back pressure is
generated by the head of water displaced in the manometer tube. To determine the roundness of the
job, the job is rotated along the jet axis, if no variation in the pressure reading is obtained then we can
say that the job is perfectly circular at position A1. Then the same procedure is repeated at various
positions A2, A3, A4, position and variation in the pressure reading is found out. Also the diameter is
measured at position A1 corresponding to the portion against two jets and diameter is also measured at
various position along the length of the bore

Figure (A)

Any variation in the dimension changes the value of h, e.g. Change in dimension of 0.002 mm changes
the value of h from 3 to 20 mm. Moderate and constant supply pressure is required to have the high
sensitivity of the instrument.

Advantages:

1. It is cheaper, simple to operate and the cost is low.

2. It is free from mechanical hysteresis and wear.

3. The magnification can be obtained as high as 10,000 X.

4. The gauging member is not in direct contact with the work.

5. Indicating and measuring is done at two different places.

6. Tapers and ovality can be easily detected.

7. The method is self cleaning due to continuous flow of air through the jets and this makes the method
ideal to be used on shop floor for online controls.

Disadvantages:

1. They are very sensitive to temperature and humidity changes.

2. The accuracy may be influenced by the surface roughness of the component being checked.

3. Different gauging heads are needed for different jobs.

4. Auxiliary equipments such as air filters, pressure gauges and regulators are needed.

5. 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.