Comparator

It is a device that gives dimensional differences with

respect to a basic dimension.
It compares the unknown dimension of a part with some
standard or master setting and those dimensional
variations are amplified and measured.
They are generally used for linear measurements, and
they can be classified according to what principle they
use for amplifying and recording the variations
measured.

Characteristics of good
Comparators
Should be able to record variations of 0.0025 mm.
Should be of robust design and construction, so as to
withstand the effect of ordinary usage without damaging
its measuring accuracy.
Should be of light weight so as to minimize inertia.
The scale should be linear and straight.
Should have maximum versatility, i.e. its design must be
such that it can be used for a wide range of operations.

Applications
In mass production where components are to be
checked at a very fast rate.
As

laboratory

standards

from

which

working

or

inspection gauges are set and correlated.

Online inspection-Attached with some machines, they
can be used as working gauges to prevent work
spoilage and to maintain required tolerance at all
stages of manufacturing.

Classification:

Electrical Comparators
Mechanical
displacement

Electromechanical
transducer

Electric
al
signal

Signal
conditioning
Information
processing

Readout or
display
Information
output

Observ
er

Also known as the electro-mechanical measuring system,

these comparators employ an electro mechanical device
which converts a mechanical displacement into electrical
signal.
The most popular electro-mechanical device used is
Linear variable differential transformer (LVDT)

Linear variable differential

transformer
Unique features of
LVDT:

It works on the principle of

mutual inductance

Due to no physical contact b/w

the core and the coil its
mechanical components do not
wear out; as a result there is no
friction and true resolution is
obtained.
The small core mass and the
lack of friction enhance response
capabilities
for
dynamic
measurements
and
thus
it
becomes very suitable for taking
on-line
machining
measurements.

Advantages and
Disadvantages
AdvantagesSystem has a high magnification with small number of
moving parts.
Measurement unit can be small.
DisadvantagesThese comparators require an external agency to
operate, i.e. an a.c. supply. Thus the fluctuations in
voltage or frequency of electric supply may affect the
results.
More expensive than mechanical instruments.

Mechanical Comparators
These utilize mechanical methods of magnifying the
movement of the contact plunger.
Some of the mechanical comparators are:
Dial Indicator
Reed type comparator
Sigma comparator
Johansson Mikrokrator
Eden Rolt Millionth comparator

Dial Indicator

Checking out of roundness of a

cylindrical component using a dial
indicator and a V-block attachment

Advantages and
Disadvantages
AdvantagesUsually cheaper than electrical and pneumatic.
Do not require any external supply such as
electricity or air.
Robust and easy to handle.
DisadvantagesPosses more moving parts than other types and
hence the friction is more and less accuracy.
The range of the instrument is limited as the
pointer moves over a fixed scale.
The mechanism of these instruments has more
inertia and this may cause the instrument to be
sensitive to vibrations.

Checking out of roundness of a

cylindrical component using a dial
indicator and a V-block attachment

Pneumatic Comparators

Use of controlled air as an amplifying medium.

Can be used to measure diameter, length, squareness,
parallelism, concentricity, taper, etc.
Characteristics Independent of operator skill.
Very high amplifications are possible.
As no contact is made either with the setting gauge or the
part being measured, there is no loss of accuracy because
of gauge wear. Hence, they last very long.
Due to high pressure gauging, parts are cleansed which
helps to eliminate errors due to dirt.
It is accurate, flexible, reliable, universal and speedy device
foe inspecting parts in mass production.
Best suited for checking multiple dimensions or conditions
in least possible time.

Working of a Pneumatic
Comparator

 The air will now pass through the control jet at the full
controlled pressure and will reach the measuring jet S.
If this jet S cannot pass the full volume of the air from the
control jet, then a pressurewill tend to develop between
them.
This backpressure is instantly released through the opening
in the manometer tube where it willchange theheight of the
liquid, which indicates theamount ofbackpressure built up.
The
back
pressure
isthe
result
ofrestriction
at
themeasuringjet due to the effect of variations in the
dimension of the work being checked so that the variations
in the height of the liquid of the manometer are a measure
ofthe dimension variations.

Advantages and
Disadvantages
Advantages The gauging member does not come in contact with the part
to be measured and hence practically no wear takes place on
the gauging member.
Usually small no. of moving parts and in some cases none.
Thus the accuracy is more due to less friction and less inertia.
Jet of air helps in cleaning the dust on the work piece being
measured.
Disadvantages The scale is generally not uniform.
Requires elaborate auxiliary equipment such as accurate
pressure regulators.
The apparatus is not easily portable.