Comparators

Comparators are used only for relative Measurement of dimension i.e. they give only dimensional difference in relation to a basic dimension. The comparator compares the unknown dimensions of a part with some standard or master setting which represents the basic size. The dimensional variations from the master setting are amplified and measured. Use of comparators is easier and not much skill is required to operate them. Calibration over full range is not required as the comparison is done with a standard end length. Various types of comparators are as follows. Mechanical Mechanical optical Electrical & electronics Pneumatic Fuel displacement etc. Comparators must have following features. Robust design and construction to take care of ordinary usage free from backlash, wear effect etc. Measurements should be compensated for temperature variation The scale should be linear. Comparators are used In mass production to check components at very fast rates. As laboratory standards from which gauges can be set or correlated. As working gauges to measure components while process is in progress. 1 In selective assemblies

Mechanical Comparators
In these comparators, magnification is obtained by mechanical linkages and other mechanical devices. Displacement amplification is achieved through Rack & Pinion : measuring spindle is integral with a rack, which engages with pinion. The pinion and further gear train amplify the movement further. Cam and gear train : In this case measuring spindle acts on a cam which transmits the motion to the amplifying gear train. 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. Compound levers : Here levers forming a couple with compound action are connected through segments and pinion to produce final pointer movement. 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 attached pointer. Lever combined with band wound around drum : The movement of measuring spindle tilts the hinged block, causing swing of fork which induces rotation of the drum Reeds combined with optical display : In this case parallelogram reeds are used which transfer measuring spindle movement to a deflecting reed whose extension carries a target utilised in optical path. Tilting mirror projecting light spots.

DBIT Pvt. circulation Notes by Prof.S.P.Sabnis

Mechanical Optical Comparators

In mechanical optical comparators small displacements of the measuring plunger are amplified first by mechanical system consisting of pivoted levers. The amplified mechanical movement is further amplified by a simple optical system involving the projection of an image. The usual arrangement is such that the mechanical system causes a plane reflector to tilt about an axix and the image of an index is projected on a scale on the inner surface of a ground glass screen. Optical magnification provides high degree of measuring precision due to reduction of moving members and better wear resistance qualities. Optical magnification is also free from friction, bending, wear etc.

In this system, Mechanical amplification = l2/l1 and Optical amplification = l4/l3x 2. It is multiplied by 2, because if mirror is tilted by an angle , then image will be tilted by 2 x . Thus overall magnification of this system = 2 x (l2/l1). (l4/l3)
DBIT Pvt. circulation Notes by Prof.S.P.Sabnis 3

Thus optical comparators are capable of giving a high degree of measuring precision owing to high magnification and the reduction of moving members to minimum. They possess better wear resistance qualities as the only wearing members are the plunger and its guide and the mirror pivot bearing. Another advantage of the optical comparators is that provision of an illuminated scale enables readings to be taken without regard to the room lighting conditions.

The mirror used must be of front reflection type and not of normal back reflection type. In normal back reflection type there are two reflected images, one each from front and back. Thus the reflected image is not well defined one, as one bright and other blurred image are observed. The front reflection type of mirror requires considerable care in its use to avoid damage to the reflecting surfaces.

DBIT Pvt. circulation Notes by Prof.S.P.Sabnis

Electrical & Electronic Comparators Electrical comparators: are also known as electromechanical measuring systems as these employ an electromechanical device which converts a mechanical displacement into electrical signal. Linear variable differential transformer (LVDT) is the most popular electro-mechanical device used to convert mechanical displacement into electrical signal. The Electronic Comparator: is based on the principle of application of frequency modulation or radio oscillation. A special radio oscillator is used which produces impulses of a definite value at a definite frequency. The frequency is controlled by the measuring head. When the measuring head is applied to the part to be measured the frequency of the instrument oscillator is modified because of the variation of the dimension from that of the preset standard. The modified frequency is negated by suitable controls to restore it back to the basic value. The measuring instrument dial is graduated directly in terms of the physical standards of length which compare with the electronic standards of wavelength. By using various adaptors to suit the work, the comparator can be put to many applications such as external and internal gauging, flatness, testing, thickness gauging, tube wall thickness, measurement of electro-plate coating, gauging on curved or flat surfaces etc., 5 to a very high limit of measuring precision.

Digital Comparators Incremental measuring system with optoelectronic reading of a grid line glass scale. Main features : Clear and high contrast digital display. Large measuring range and high resolution. Compact design with Universal power supply by choice of batteries or grid connection. Conveniently placed operating elements for the various measuring functions. Measuring spindle mounted in high precision ball bush guide, virtually friction free and without play. Advantages : Digital read-out High measuring accuracy Small dimensions Processing of measuring results Setting of tolerance limits Direction of counting reversible for outside and inside measurements Data transfer to computer

DBIT Pvt. circulation Notes by Prof.S.P.Sabnis