Comparators

Comparators are one form of linear measurement device which is quick and more
convenient for checking large number of identical dimensions. Comparators normally will
not show the actual dimensions of the work piece. They will be shown only the deviation
in size. i.e. During the measurement a comparator is able to give the deviation of the
dimension from the set dimension. It cannot be used as an absolute measuring device
but can only compare two dimensions.
The comparators are classified according to the principles used for obtaining
magnification The common types are:
1. Mechanical comparators
2. Electrical comparators
3. Optical comparators
4. Pneumatic comparators
MECHANICAL COMPARATORS
Mechanical comparator employs mechanical means for magnifying small
deviations. The method of magnifying small movement of the indicator in all mechanical
comparators are effected by means of levers, gear trains or a combination of these
elements. Mechanical comparators are available having magnific tions from 300 to 5000
to 1. These are mostly used for inspection of small parts machined to close limits.
Dial indicator
A dial indicator or dial gauge is used as a mechan cal comparator. The essential
parts of the instrument are like a small clock with a plu ger projecting at the bottom as
shown in fig. Very slight upward movement on the plu ger moves it upward and the
movement is indicated by the dial pointer. The di l is gr duated into 100 divisions. A full
revolution of the pointer about this scale corresponds to 1mm travel of the plunger. Thus,
a turn of the pointer b one scale division represents a plunger travel of 0.01mm.
Experimental setup
The whole setup consists of worktable,
dial indicator and vertical post. The dial
indicator is fitted to vertical post by on
adjusting screw as shown in fig. The vertical
post is fitted on the work table; the top surface
of the worktable is finely finished. The dial
gauge can be adjusted vertically and locked in
position by a screw.
Procedure
Let us assume that the required height of the component is 32.5mm. Initially this
height is built up with slip gauges. The slip gauge blocks are placed under the stem of the
dial gauge. The pointer in the dial gauge is adjusted to zero. The slip gauges are removed.
Now the component to be checked is introduced under the stem of the dial gauge. If there
is any deviation in the height of the component, it will be indicated by the po nter.
Mechanism
The stem has rack teeth. A set of gears engage with the rack. The pointer is
connected to a small pinion. The small pinion is independently hinged. I.e. it is not
connected to the stern. The vertical movement of the stem is tr nsmitted to the pointer
through a set of gears. A spring gives a constant downward pressure to the stem.

Advantages
1) It is usually robust, compact and easy to handle.
2) There is no external supply such as electricity, air required.
3) It has very simple mechanism and is cheaper when compared to other types
4) It is suitable for ordinary workshop and also easily portable.
Disadvantages
1.Accuracy of the comparator mainly depends on the accuracy of the rack and
pinion arrangement. Any slackness will reduce accuracy.
2. It has more moving parts and hence friction is more a d accuracy is less.
3. The range of the instrument is limited since pointer is moving over a fixed scale.
MECHANICAL–OPTICAL COMPARATOR
This is also termed as Cooke’s Optical Comparator. As the name of the comparator itself
suggests, this has a mechanical part and an optical part. Small displacements of a measuring
plunger are initially amplified by a lever mechanism pivoted about a point, as shown in Fig. The
mechanical system causes a plane reflector to tilt about its axis. This is followed by a simple optical
system wherein a pointed
image is projected onto a screen to facilitate
direct reading on a scale.
The plunger is spring loaded such that
it is biased to exert a downward force on
the work part. This bias also enables both
positive and negative readings, depending
on whether the plunger is moving up or
down. The scale is set to zero by inserting a
reference gauge below the plunger. Now, the
reference gauge is taken out and the work
part is introduced below the plunger. This
causes a small displacement of the plunger,
which is amplified by the mechanical levers.
The amplified mechanical movement is
further amplified by the optical system
due to the tilting of the plane reflector. A
condensed beam of light passes through an
index, which normally comprises a set of cross-wires. This image is projected by another lens
onto the plane mirror. The mirror, in turn, reflects this image onto the inner surface of a ground
glass screen, which has a scale. The difference in reading can be directly read on this calibrated
screen, which provides the linear difference in millimetres or fractions of a millimetre. Optical
magnifications provide a high degree of precision in measurements due to the reduction of
moving members and better wear-resistance qualities.

mechanical amplification = l2/l1 and optical amplification = 2 (l4/l3)

Electrical Comparators
Electrical and electronic comparators are in widespread use because of their instantaneous
response and convenience in amplifying the input. An electronic comparator, in particular, can
achieve an exceptionally high magnification of the order of 10 5:1 quite easily. Electrical and
electronic comparators mainly differ with respect to magnification and type of output. However,
both rely on mechanical contact with the work to be measured.
Electrical comparators generally depend on a Wheatstone bridge circuit for measurement.
A direct current (DC) circuit comprising four resistors, two on each arm, is balanced when
the ratios of the resistances in the two arms are equal. Displacement of the sensing element,
a plunger, results in an armature connected to one of the arms of the bridge circuit to cause
an imbalance in the circuit. This imbalance is registered as an output by a galvanometer, which is
calibrated to read in units of linear
movement of the plunger. Magnifications of
the order 104:1 are possible with electrical
systems. The block diagram given in Fig.
6.12 illustrates the main elements of an
electrical comparator.
The plunger is the sensing element, the
movement of which displaces an armature
inside a pair of coils. Movement of the
armature causes change in inductance in the two coils, resulting in a net change in inductance.
This change causes an imbalance in the bridge circuit, resulting in an output. The output display
device, whether analog or digital, is calibrated to show the readings in units of length, that is,
linear displacement.
A linear variable differential transformer (LVDT) is one of the most popular electromechanical
devices used to convert small mechanical displacements (of the order of a few millimetres or
fractions of a millimetre) into amplified electrical signals.

Electronic Comparator
While the
electronic comparator is more complex, advances in integrated circuits have reduced the size and power
consumption of the equipment. Electronic gauges are more accurate and reliable,
which has made them the preferred choice in many applications.
The most significant advantage offered by electronic comparators is the speed of response.
A measurement rate of 500 per minute is easily accomplished by an electronic comparator,
making it well suited for dynamic measurement. For example, the thickness of a strip coming
out of a rolling mill or deflection of a machine part under varying loads can be measured over a
given period of time. The following advantages make electronic comparators superior to other
types of comparators.
Advantages of electronic comparators
1. High accuracy and reliability
2. High sensitivity in all ranges
3. High speed of response
4. Easy provision for multiple amplification ranges
5. Versatility (a large number of measurement situations can be handled with standard accessories)
6. Easy integration into an automated system