COMPARATORS

Introduction to comparators, ComparatorsCharacteristics & Classification Mechanical comparators, Sigma, Dial comparators Optical ComparatorsPrinciples, eiss ultra optimeter

!lectrical & !lectronic Comparator, "#DT, Pneumatic Comparator, $ac% pressure gauges Sole& Comparators Multi-Chec% comparators

COMPARATORS
The general principle of comparator is to indicate the differences in si'e (et)een the standard and the )or% (eing measured (* means of some pointer on a scale )ith sufficient magnification All comparators consist of three (asic features +,A sensing device )hich faithfull* senses the input signal -, A magnifying or amplifying system to increase the signal to suita(le magnitude. Mechanical, Optical, Pneumatic, h*draulic and electronic methods are used for this purpose. /, A display system (usually a scale and pointer) which utilizes the amplified signal to provide a

0eed for a comparator

A comparator is used in mass production to inspect the components to close tolerances )ith high degree of precision and speed. Ex: Piston 1se of line standards such as 2ernier and micrometer calipers re3uire considera(le s%ill Man* dimensions can (e chec%ed in a 2er* short time Comparators can be classified as +. Mechanical -. Optical /. !lectrical & !lectronic 4. Pneumatic 5. 6luid displacement comparators 7. Mechanical 8optical comparator 9. !lectro-mechanical comparator:. Multi-chec% comparator.

Design Consideration 1.Ability to record variation of at least 0.0025 mm 2.Linear recording scale 3.Variance free (Instr ment readings s!o ld not vary "!en re#eated meas rements of given $ antity are made %.&cale indicators clear and free from oscillations 5.'ree from bac(las!) nnecessary friction * clearances inertia s!o ld be lo". +.,eas ring #ress re s!o ld be lo" and constant -.& ##orting frame to be rigid and "it!stand reasonable ill sage "it!o t #ermanent damage ..Ca#able of meas ring "ide range.

Mechanical Comparators
In Mechanical t*pe, the re3uired magnification is o(tained (* using mechanical lin%ages, le2ers, gears and other mechanical de2ices. Magnification ;M,< It is the ratio (et)een the mo2ement of the plunger and the resultant mo2ement of the pointer M= P;pointer mo2ement,>p Plunger mo2ement

Mechanical comparators t*pes< +. Dial test indicator. -. ?ohansson mi%ro%ator. /. Sigma mechanical comparator

REED COMPARATOR

Scale Pointer

Fixed link

Reeds Movable link

Flexure strips

Spindle

Spindle displacement

R!!D COMPARATOR
As sho)n in fig, the mo2a(le lin% is constrained (* thin metal fle&ure strips to mo2e 2erticall* relati2e to fi&ed lin% attached to housing. The change of orientation of the fle&ure strips due to relati2e motion, the reeds pro2ide a large angular mo2ement of the pointer. The scale ma* (e cali(rated to indicate an* de2iation from an initial setting.

Light pointer

JOHANSSON MIKROKATER
Scale Twisted strip Spring elbow

Cantilever strip

Attachment screws

Slit washer

Plunger tip

Measuring plunger

?O@A0SSO0 MIAROAATOR
B It )or%s on the principle of a (utton spinning in a loop of string. B A t)isted thin metal strip carries a 2er* light pointer made of thin glass at the center of its length. B The t)o hal2es of the strip from the centre are t)isted in opposite directions so that an* pull on the strip )ill cause the centre to rotate. B One end of the strip is fi&ed to an adCusta(le cantile2er and the other is anchored to the spring el(o). B One arm of spring el(o) carries the measuring plunger.

?O@A0SSO0 MIAROAATOR ;contdD,

As the measuring plunger mo2es either up)ards or do)n)ards, the el(o) causes the t)isted strip to change its length thus ma%ing it to further t)ist or unt)ist. Thus the pointer at the center of the t)isted strip rotates (* an amount proportional to the change in length of the strip and hence to the plunger mo2ement. The strip is perforated along the center line to pre2ent e&cessi2e stress on the center portion. A slit )asher is used for lo)er mounting of the plunger.

?O@A0SSO0 MIAROAATOR ;contdD, The amplification of this comparator is gi2en (*

d L " where is the twist at the mid point o the strip dL n with respect to the ends! L is the length o the twisted strip measured along its neutral axis n is the number o turns

The ampli ication increases with the number o turns# The magni ication is o the order $%%%

The Mikrokator is an instrument for measuring differences in length The Mikrokator !rinci!le greatl" magnifies an" de#iation in si$e so that e#en small de#iations !roduce large deflections of the !ointer o#er the scale The transference of mo#ement from the measuring ti! to the !ointer is mechanical% com!letel" frictionless and free from &acklash The 'E Johansson Mikrokator (as introduced in )*+, and is still toda" the finest mechanical com!arator in the (orld A (ide range of models are a#aila&le% (hich gi#es graduations #ar"ing &et(een ---). / --0 mm1 and ----2. / ---) mm1 The uni3ue 4T(isted Stri!. !rinci!le on (hich all Mikrokators are &ased% !ro#ides man" features (hich are not a#aila&le on an" other measure instrument

SIEMA COMPARATOR
It has magnifications in the range of /FF to 5FFF. It has a plunger attached to a rectangular (ar )hich is supported at its upper and lo)er ends (* fle&ure plates. A %nife edge is fi&ed to the side of rectangular (ar )hich (ears on a mo2ing (loc%. The mo2ing (loc% and the fi&ed (loc% are connected (* fle&i(le strips at right angles to each other.

SIEMA COMPARATOR
Scale Flexure plate Flexible strips Pointer Fixed block &rum )ni e edge

Forked arm 'ron(e band

Flexure plate

Moving block Plunger

SIEMA COMPARATOR ;contdD,

If an e&ternal force is applied to the mo2ing (loc%, it )ould pi2ot a(out the hinge . A for%ed arm or G-arm attached to the mo2ing (loc% transmits the rotar* motion to the indicator dri2ing drum through a (ron'e (and )rapped around the drum. Magnification: If Y is the length of for%ed arm and X is the distance from the %nife edge to hinge, then first stage magnification is Y/X If the pointer length is R and the radius of the drum is r the second stage magnification is R/r such that the total magnification is ;Y/X)* (R/r)

DIA" I0DICATOR

DIA" I0DICATOR
&ial Scale Pointer Pinion Rack

Plunger C*lindrical component

Plunger

Pillar

'ase + block

DIA" I0DICATOR ;contd..,

It consists of a ro(ust (ase )hose surface is perfectl* flat and a pillar carr*ing a (rac%et. The (rac%et incorporates a spindle fitted )ith a pinion & dial scale. The linear mo2ement of the plunger is magnified (* means of a rac% & pinion arrangement into si'ea(le rotation of the pointer on the dial scale. The dial scale is set to 'ero (* use of slip gauges representing the (asic si'e of the part.

Ad2antages of Mechanical Comparators

The* are cheaper compared to other amplif*ing de2ices Do not re3uire electricit* or air and such the 2ariations in the outside sources do not affect the accurac*. The* ha2e a linear scale, ro(ust and eas* to handle.

Disad2antages of Mechanical Comparators

The* ha2e more lin%ages due to )hich friction is more and accurac* is less. Mechanisms used ha2e more inertia and hence the* (ecome sensiti2e to 2i(rations. An* )ear, (ac%lash, pla* or dimensional faults in the mechanical de2ices used )ill also (e magnified. The range of the instruments is limited as the pointer mo2es o2er a fi&ed scale. It is also difficult to incorporate arrangement for adCusting magnification.

OPTICAL COMPARATORS
Screen

Lamp A

Screen -ormal

, Mirror

Lamp A

"
l -orma , Mirror C

angle

o tilt

Pivot

Plunger

PRINCIPLE OF OPTICAL LEVER

OPTICA" COMPARATORS
An optical comparator )or%s on one of the follo)ing t)o main principles< +,1se of optical le2er -, 1se of enlarged image 5 If a (eam of light AC is directed on to a mirror as sho)n in fig, it )ill (e reflected onto the screen at O as a dot. The angle of incidence = angle of reflection 5 Hhen the plunger mo2es up, the mirror tilts (* . Then the reflected (eam mo2es through - . i.e. the illuminated dot mo2es to $. 5 Also the increase in distance CO of the screen from the tilting mirror )ill increase the magnification.

Mechanical0,ptical Comparator
Light source Screen with scale Collimating lens Pro.ection lens & Mecahnical lever /lass plate carr*ing index line Mirror Mirror pivot

L 4
Measuring Plunger Pivot

L 1

L 2

L 3

Mechanical Optical Comparator In this comparator, small displacements of the measuring plunger are first amplified (* a mechanical le2er. It is e3ual to ;"->"+, The amplified mechanical mo2ement is further amplified (* optical s*stem due to tilting of mirror (* . The reflected ra* D ;image of inde& line, )ill (e turned through an angle -, and hence optical amplification =-;"4>"/, The o2erall magnification = ;"->"+,I -;"4>"/,

eiss 1ltra Optimeter

Lamp

4*e piece

/reen Filter ,b.ective lens Fixed mirror M" Movable Mirror M1 Plunger 2ork piece Condenser 3ndex lens

eiss 1ltra Optimeter

The optical s*stem of this instrument in2ol2es dou(le reflection of light and hence gi2es higher degree of magnification. The green filter filters all ra*s e&cept green ;to reduce fatigue to e*e, and green light passes through a condenser. The light then passes through an inde& lens and the inde& mar% is proCected on to a mo2a(le mirror M +. It is then reflected on to another fi&ed mirror M - and then (ac% to the first mo2a(le mirror.

eiss 1ltra Optimeter ;contdD,

The o(Cecti2e lens (rings the reflected (eam from the mo2a(le mirror to focus at a transparent graticule. The graticule contains a precise scale )hich is 2ie)ed (* an e*e piece. The proCected image of the inde& line on the graticule can (e adCusted to set initial 'ero reading (* a scre). An* mo2ement of the plunger )ill tilt the mo2a(le mirror, )hich causes a shift in the reflected inde& line on the e*e piece graticule scale. This in turn measures the displacement of the plunger

 Ad2antages< +, 6e) mo2ing lin%ages and hence no friction & )ear. -, @igh range of measurements and no paralla& error /, Magnification is usuall* high. Disad2antages< +, @eat from the source of light, transformers etc., ma* cause the setting to drift. -, An electric suppl* is re3uired to operate these comparators. /, The si'e is large and costl*. 4, 1se of e*epiece to 2ie) is incon2enient for prolonged use. Also a dar% room is essential to ta%e readings.

Ad2antages & Disad2antages of Optical comparators

!lectrical& !lectronic Comparators

R1 R"

R5

R6

Coils Arm 'atter*

Coils

3ron Armature

Measuring Plunger

 These comparators depend on the principle of (alancing the Hheatstone (ridge, ;R+>R-, = ;R/>R4, applica(le for onl* to direct current o(tained from a (atter*. In actual instruments, one pair of inductances ta%es the form of a pair of coils in the measuring head of the instrument. An iron armature inside these coils mo2es along )ith the measuring plunger, and upsets the (alance of the circuit and causes the deflection of the pointer meter )hich is cali(rated directl* in linear units. Magnifications of the order of /F,FFF are possi(le.

!lectrical& !lectronic Comparators ;ContdD,

!lectrolimit gauge
Armature Spring A Thin steel strips

' Spring 4lectromagnetic coils Plunger

!lectrolimit gauge ;contdD,

6ig sho)s the principle of !lectrolimit gauge or measuring head. #ertical mo2ements of the plunger are transmitted to an armature, )hich in turn is suspended (* thin metal strips. At the left end, the armature (et)een t)o electromagnetic coils form the t)o arms of an AC (ridge circuit. An* mo2ement of the armature sets up out of (alance effects )hich are recorded (* a micrometer from )hich direct reading of plunger mo2ements can (e o(tained.

"inear #aria(le Differential Transformer "#DT is the most popular electro mechanical de2ice used to con2ert mechanical displacement into electrical signal. It is a differential transformer )hich pro2ides an A.C 2oltage output proportional to displacement of a core passing through the )indings. Of the three s*mmetricall* placed coils, the center coil is energi'ed from an A.C source and the t)o end coils connected together in phase opposition are used as pic% up coils.

"inear #aria(le Differential Transformer

,utput +oltage Fig#a displacement 3nput +oltage

3nput displacement

Fig#b

"inear #aria(le Differential Transformer ;contdD, $ased on the position of the core, a 2oltage is induced in each of the pic% up coils. A position of the core at )hich the 2oltages induced in the pic% up coils are same, (ut cancel each other due to phase opposition, is called the Jnull positionK. The fig sho)s the t*pical differential transformer characteristics o(tained (* plotting output 2oltages 2s. core displacements. All commercial de2ices are designed to operate onl* in the linear range and hence the name "#DT. Suppl* re3uirements 7./ # at 7F @', Range of displacement--5 mm.

"inear #aria(le Differential Transformer ;contdD,

,utput +oltage

Linear range

-ull position

Core &isplacement

Fig c

Commercial L+&Ts

Sectional +iew o L+&T

Ad2antages of "#DT It can (e used as a primar* detector transducer, as it does not re3uire assistance of another element such as a strain gauge to con2ert mechanical displacement into electrical 2oltage. The core is completel* separa(le from the rest of the e3uipment and hence no mechanical losses. It is insensiti2e to temperature changes. Pro2ides a comparati2el* high output and does not re3uire amplification. It is of reasona(le cost.

Disad2antages of "#DT +, It cannot (e used for d*namic measurements due to its apprecia(le mass compared to strain gauge. -, Re3uirement of 7F cps suppl* 2oltage (ecomes a limiting factor for d*namic measurements. /, The direction from the null point is to (e indicated )hich ma%es the circuit arrangement comple&.

Pneumatic comparators
In Pneumatic comparators air is used as a means of magnification and hence the* use principle of air Cet. A cham(er is fitted )ith control orifice C and a gauging orifice E through )hich air flo)s from a suppl* at a constant pressure P+. If the si'e of the control orifice C remains constant, an* 2ariation in si'e of E )ill cause alteration of pressure P- in the cham(er. This 2ariation is measured (* a suita(le pressure gauge graduated to read in linear units.

Air 9 constant Pr P1

C 7Control ori ice8 Chamber

Pressure P"

To pressure gauge

/ 7/auging ori ice8

2orkpiece

Principle o Pneumatic comparator

S*stems of Pneumatic comparators

$ased on the ph*sical phenomenon, Pneumatic comparators are classified asL ;a, 6lo) or 2elocit* t*pe ;(, $ac% pressure t*pe 6lo) t*pes operate (* sensing & indicating the momentar* rate of flo). Compressed air after filtering & pressure regulation flo)s through a glass tu(e )ith a small metal float. The air then passes through a plastic tu(e to the gauge head )ith t)o diametricall* opposite orifices for the air to escape.

Pneumatic comparators ;contdD,

Plastic tube 'ore to be measured

Scale Float Filter Pr regulator

Air suppl* /auging head

Flow or +elocit* t*pe Comparator

6lo) or 2elocit* t*pe ;contdD,

The position of the float depends upon the amount of air flo)ing through the gauging head, )hich in turn depends upon the clearance (et)een the (ore to measured and the gauging head. These t*pes )hen assem(led side (* side, can measure multiple inter related dimensions )ith great ease, accurac* & speed.

$ac% pressure t*pe Pneumatic Comparators

,c Constant pressure source P1 P" ,m To atmosphere

Principle o back pressure t*pe Pneumatic comparator Scale 'ourdon tube 2ork piece

Regulator Filter Air suppl*

'ack Pressure Circuit

Measuring head

$ac% pressure t*pe Pneumatic Comparators

The principle of (ac% pressure gauges is that )hen the orifice Om is (loc%ed, the upstream pressure P+ (ecomes e3ual to pressure P- (et)een the t)o orifices. Hhen the orifice opening Om is increased indefinitel*, the pressure P- tends to (ecome 'ero. In the (asic (ac% pressure unit sho)n in fig, a (ourdon tu(e deflects according to (ac% pressure changes (uilt up in the circuit )hen )or% piece is placed o2er the measuring head. The deflection is amplified (* gear & le2er and indicated on a dial.

Sole& Pneumatic gauge

Sole& t*pe of gauge emplo*s a )ater manometer for the indication of (ac% pressure. It consists of a )ater tan% filled up to a certain le2el and a dip tu(e immersed into it upto re3uired depth. Air, sent at higher pressure than re3uired, (u((les to the top of the )ater tan%. The air at the desired constant pressure then passes through the control orifice and escapes through the measuring Cets. The (ac% pressure in the circuit is indicated (* the head of )ater displaced in the manometer tu(e.

Sole& Pneumatic gauge

Air ilter Air Control ori ice

Scale 4xcess air bubbling at top &ip tube

Plug with measuring .aws

2ater tank Manometer workpiece

Solex Pneumatic gauge

Sole& Pneumatic gauge ;contdD,

The pressure in the manometer is regulated (* the relati2e rates of escape of air through the control orifice and the measuring Cets. The manometer tu(e is graduated linearl* to sho) changes in pressure resulting from changes in internal diameter of the )or% (eing measured. $* re2ol2ing the )or%piece around the measuring gauge, the roundness or concentricit* of the (ore can (e chec%ed. $* mo2ing the )or%piece along the length of the measuring gauge, taper of the (ore, if an*, can (e chec%ed. $est suited for chec%ing roundness and taper of c*linder (ores & gun (arrels.

Ad2antages & Disad2antages of Pneumatic Comparators

Ad2antages< ;+, 0o ph*sical contact (et)een gauge & )or% and hence practicall* no )ear ta%e place. ;-, @igh magnification & accurac* possi(le. ;/, Suita(le for chec%ing small (ores. ;4, Measuring pressure is 2er* small and Cet of air cleans the dust, if an*, from the )or%piece. Disad2antages< ;+, Re3uires ela(orate au&iliar* e3uipment such as pressure regulator, compressor, etc. ;-, Paralla& error in glass tu(es )hich is an indicating de2ice. ;/, Scale is generall* not linear and apparatus in not porta(le.

$roo%eMs le2el Comparator

'ubble Scale

Column

Spirit level

'all eet Spirit level

'racket

Rotatable disc 'ase

Levelling scews

$roo%eMs le2el Comparator

It is a mechanical comparator )hich uses a sensiti2e spirit le2el and a rotata(le disc. The rotata(le disc is mounted on a massi2e (ase )ith le2eling scre)s. A (rac%et supports the spirit le2el and allo)s it to (e raised or lo)ered along the main column of the instrument. The upper surface of the rotata(le disc is a plane lapped surface )hile the lo)er face has a lapped annular ring allo)ing eas* rotation of the (ase.

$roo%eMs le2el Comparator

7c8

7d8

$roo%eMs le2el Comparator ;ContdD,

In operation, the (u((le is first (rought to the center of the scale (* allo)ing the (all feet to rest on the surface of the rotata(le disc and adCusting the le2eling scre)s of the (ase. The standard S and the gauge to (e compared E are no) )rung to the disc, and the (all feet are made to rest on them as sho)n in fig. The position of the (u((le is noted, the spirit le2el is then raised, and disc rotated through +:FF. A second reading is ta%en in the position sho)n. The displacement of the (u((le along the scale represents t)ice the difference in height (et)een the t)o gauges. Thus, @= N;", )here @= difference in height (et)een gauges, " = (u((le dispalcement.