COMPARATORS

Introduction:
• Comparator is an instrument used for
comparing the dimensions of a component
with a standard of length
• Purpose of a comparator, in general, is to
detect & display the small differences b/w the
unknown linear dimension & length of the
standard

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COMPARATORS
Essential Parts of Comparators:
1. Fixed surface from which all measurements are taken
2. A very sensitive indicator which will show the
movement of a sliding piece usually terminating in an
anvil with curved surface
3. Some means of setting the curved face
Arrangement of above parts is used to measure the
difference b/w the length or diameter of a component &
a standard of length, usually made up of slip gauges

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COMPARATORS
The Important & essential function of the
instrument is to MAGNIFY or AMPLIFY the
small input displacements to that it is
displayed on an analogue scale

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COMPARATORS
Desirable Features of a Comparator:
1. It should at least be able to record variations of 0.0025mm
2. Recording scale should be linear
3. Maximum rigidity
4. Maximum compensation of temperature effect
5. Neither lag nor backlash in the movement of the plunger
& recording mechanism
6. Indicator should be constant in its return to zero
7. Measurement pressure should be low & constant
8. Instrument should be capable of a wide measuring range

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COMPARATORS
Uses of Comparators:
1. To inspect newly purchased gauges
2. In mass production, where components are
to be checked at a very fast rate
3. As laboratory standards from which working
or inspection gauges are set & correlated
4. As working, to prevent work spoilage & to
maintain required tolerance at all important
stages of manufacture
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COMPARATORS
Types of Comparators:
Most common commercially available comparators
can be classified into the following types:
1. Mechanical comparators
2. Optical comparators
3. Electrical & Electronic comparators
4. Fluid displacement comparators
5. Pneumatic comparators
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COMPARATORS
Types of Comparators:
A combination of magnifying principles has lead
to the development of a few more types of
comparators, which are:
6. Mechanical-Optical comparators
7. Electro-mechanical comparators
8. Multi-check comparators
The most interesting & important component on a
comparator is the indicating unit, & instruments are
made in which the operation for this unit depends
on mechanical, electrical or pneumatic principle

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 MECHANICAL COMPARATOR
• The mechanical comparators utilize
mechanical methods of magnifying, the
movement of the contact plunger; their
manufacture requires a high degree of skill &
accuracy.
• The usual magnifications of the mechanisms
range from about 250 to 1000.

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 MECHANICAL COMPARATOR
• Some of the comparator which belong to this
class are:
1. Dial indicator
2. Reed type comparator
3. Sigma Comparator
4. Johnson Mikrokrator
5. Eden Rolt Millionth Comparator

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MECHANICAL COMPARATOR
1. Dial Indicator:

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MECHANICAL COMPARATOR
1.Dial Indicator: (different uses)

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MECHANICAL COMPARATOR
1. Dial Indicator: (Various Uses)

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Reed Type Mechanical Comparator

In mechanical comparator, the gauging head is usually a sensitive, high quality,

dial indicator mounted on a base supported by a sturdy column. Fig shows the
reed type mechanical comparator. The reed mechanism is frictionless device for
magnifying small motions of spindle. It consists of a fixed block A which is rigidly
fastened to the gauge head case, and floating block B, which carries the gauging
spindle and is connected horizontally to the fixed block by reeds C. A vertical
reed is attached to each block with upper ends joined together. These vertical
reeds are shown in the figure by letter D.

Beyond this joint extends a pointer or target. A linear motion of the spindle
moves the free block vertically causing the vertical reed on the floating block to
slide past the vertical reed on the fixed block. How ever, as these vertical reeds
are joined at the upper end, instead of slipping, the movement causes both
reeds swing through an arc and as the target is merely an extension of the
vertical reeds, it swings through a much wider arc. The amount of target swing is
proportional to the distance the floating block has moved but of course very
much magnified. The scale may be calibrated by means of gauge block (slip
gauges) to indicate any deviation from an initial setting. Comparators using this
type of linkage have sensitivities of the order of 0.25 micron per scale division.
The mechanical amplification is usually less than 100, but it is multiplied by the
optical lens system. It is available in amplifications ranging from x 500 to x 1000.

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The Sigma Comparator
Fig shows the constructional details of the Sigma Mechanical Comparator.
The vertical beam is mounted on flat steel springs A connected to fixed
members, which in turn are screwed to a back plate. The assembly provides
a frictionless movement with a restraint from the springs. The shank B at the
base of the vertical beam is arranged to take a measuring contact, selecting
from the available range. The stop C is provided to restrict movement at the
lower extremity of the scale. Mounted on the fixed members, is the hinged
assembly D carrying the forked arms E. This assembly incorporates a
hardened fulcrum (provided with means for adjustment of controlling the ratio
of trans-mitted motion) operative on the face of a jeweled insert on the flexible
portion of the assembly. The metal ribboni, attached to the forked arms,
passes around the spindle G causing it to rotate in specially designed
miniature ball bearings. Damping action to the movement is affected by a
metal disc, mounted on the spindle, rotating in a magnetic field between a
permanent magnet and a steel plate. The indicating pointer H is secured to a
boss on the disc.

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