Comparators

14 April 2025 17:03

Definition of Comparators :
• The Comparator is an indirect type of precision measurement because it will not measure the dimension, it will indicate the difference in
measurement between the given component and working standard, and another magnification instrument is needed to measure this
difference with accuracy.
• The comparator (which will have a dial indicator) will work along with the gauge blocks. Gauge blocks are also known as Slip Gauge.
Classification of Comparators
A wide variety of comparators are commercially available at present. They are classified according to the method used for amplifying and
recording the variations measured into the following types:
1.Mechanical comparators (It works on gears pinions, linkages, levers, springs, etc.)
a. Dial Indicator b. Read Type Mechanical Comparator c. Johansson Mikrokator d. Sigma Comparator
2.Optical comparators: (Optical comparator works by using lens, mirrors, light source, etc.)
3.Mechanical-Optical comparators
4.Electrical(Works by using step up, step down transformers.) and Electronics comparators(It works by using an amplifier, digital signal, etc.)
5.Pneumatic comparators (Pneumatic comparator works by using high-pressure air, valves, back pressure, etc.)
6.Fluid displacement comparators
7.Projection comparators
8.Multi check comparators
a. Electric Multi-check Comparator b. Air Multi-check Comparators c. Combination of Air-Electric
9.Automatic Gauging Machines
10.Electro-Mech. Comparators
In addition to above, comparators of particularly high sensitivity and magnification, used in standard rooms for calibration of gauges include:
1. The Brookes Level comparator
2. The Eden-Rolt ‘millionth’ comparator.
[NOTE- Combined Comparator: The combination of any two of the above types can give the best result.]
Uses Of Comparators
• They are used as Working Gauges to maintain the tolerance in all stages of manufacturing.
• Used in Laboratory Standards to co-relate the inspection gauges.
• For Final Inspection, comparators are used after production of parts before assembly.
• To check newly purchased Measuring Instruments.
• Can be used to inspect parts received from outside sources.
What is Mechanical Comparator?
A mechanical comparator is a measuring instrument that is made up of mechanical means like gears, levers, pinions & racks to get the
magnification. These kinds of means are mainly used for magnifying the means’ movement to enhance the precision of the instrument.
Working Principle
The working principle of a mechanical comparator is to use mechanical means for magnifying small deviations. The magnifying method of
the indicator’s small movement in all mechanical comparators is affected through gear train levers. These comparators have magnifications
that range from 300 to 1000. The mechanical comparator is also known as “microcator” which is used for linear measurements through the
relative contact technique.
Dial Indicators
A dial indicator is one type of simple mechanical comparator and it is a sensitive & versatile instrument. It uses a gear system jointly with a pinion & rack.
This kind of comparator works on the Rack & pinion system principle that is, the spindle’s linear movement is magnified through the arrangement of rack
& pinion.
The dial indicator mechanical comparator is used to determine the error in geometrical form like roundness, taper, ovality, etc. Determining the errors is
say alignment, surfaces, squareness, parallelism, etc.
• This comparator is used to compare two heights or distances in small limits.
• It is used for testing material’s compression & tension.
• It is used to verify the reality of milling machine arbors.
• It is used to verify the arrangement of lathe machine centers with a bar between centers.
Construction of a Dial Indicator:
Dial indicator is usually equipped with a sharply pointed stylus. Dial indicator consists of a calibrated dial that indicates the reading on the
scale, an adjusting screw for bringing the stylus in line with the required graduation, and generally three steel pointers marked.
Dial Indicator is a measuring device that can be used as a non-destructive testing tool. Dial indicator with its stylus at one end and dial at the
other end. Dial indicator with its stylus at one end and dial at the other end allows measurement of displacement, swarf thickness, or wear
limits.
A dial indicator typically moves by turning or twisting the outer dials or through sliding one of the two axes until contact is made with the
stationary boss. Contact is known as an “indication”. For linear scales, this typically requires additional locking onto a spring hook at specific
intervals using rubber-covered thumb screws.
In machining, the dimensional accuracy of a part is very important. Dial indicators are used by technicians to inspect all parts that have been
machined or manufactured before accepting them from the manufacturing plant. Dial indicators can also be used with fixtures and gauges if

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machined or manufactured before accepting them from the manufacturing plant. Dial indicators can also be used with fixtures and gauges if
it is necessary to measure the location of a small point on One of the most common uses for dial indicators is checking the objects.
Working Principle of Dial Indicator
Dial indicator’s working is based on the use of rack and pinion mechanism, the
idea behind its working is the multiplication of a very small upward movement
of the spindle at the contact point using the arrangements of gears & levers.
• When pressure is applied, the spindle moves upward, and the dial finger
indicates the reading on the dial face.
• Dial indicators consist of a body with a circular graded dial and a contact
point coupled by a spiral or gear train such that the hand on the dial face
indicates the amount of movement of the contact point.
• They are intended for use with a variety of conventional measuring
instruments, including dial indicator snap gauges, hand gauges, portal dials,
dial depth gauges, diameter gauges, dial box gauges, etc.

What is a Pneumatic Comparator?

A comparator that uses compressed air (or) pneumatic system as a means of magnification is known as a pneumatic comparator. The term
‘Pneumatic’ in pneumatic comparator means ‘air’. The main function of this comparator is to analyze the dimensional variation between the
standard workpiece & workpiece to be measured. So these comparators are extremely preferred in most cases over other types of
comparators due to many benefits.
Working Principle
The working principle of the Pneumatic comparator is the variation of
pressure generated within the airflow. When the air escapes under
stable pressure by flowing through the two orifices then the pressure
of air among them mainly depends on the cross-sectional regions of
the two orifices. So the dimension of one is kept consistent, and the
pressure of the remaining one changes based on its dimension.

Working Principle of Electrical Comparator

➢The electrical comparator works on the principle that the mechanical displacement
is converted into an electric signal. Hence they are known as an electro-mechanical
measuring system.
The principle of operation of an electrical comparator is shown in Fig. below an
armature supported on thin flexible steel strip is suspended between two coils C
and C. When the distance of the armature from two coils is equal, the Wheatstone
bridge is balanced and no current flows through the galvanometer.
➢ Little movement of the measuring plunger unbalances the bridge resulting in the
flow of current through the galvanometer. Galvanometer scale is calibrated to give
the movements of the plunger.
Optical Comparator Definition
Optical comparators, also called comparators or profile projectors, are measurement tools used in the manufacturing industry. Comparators
inspect, measure, and compare the dimensions of manufactured parts. These measurement tools function using the principles of optics by
utilizing illumination, lenses, and mirrors to project a magnified silhouette of a part upon a screen. Doing this compares the part to its
prescribed limits.
Working principle of Optical comparators:
The operating principle of this type, of the comparator, is based on the laws of light reflection and refraction. The magnification
system depends on the tilting of a mirror, deflects a beam of light, thus providing an optical lever.
Principle of the optical lever
If a beam of light AC is directed on to a mirror as shown in the figure, it will be reflected onto the screen at O as a dot.The angle
Ɵ at which the beam strikes the mirror is equal to the angle Ɵ at which the beam is reflected from the mirror. When the plunger
moves upwards vertically, causing the mirror to tilt by an angle „α‟ as shown in the figure.

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 principle of optical comparator

Then the reflected light beam moves through an angle “2α” which is twice the angle of tilt produced by the plunger movement.
The illuminated dot moves to “B” thus a linear movement “h” of the plunger produces a movement of the dot equivalent to the
distance OB on the screen. It also clear that as the distance (OC) of the screen from tilting mirror increases, greater will be the
magnification and is called the principle of enlarge image.
Characteristics of Good Comparators:
1. It should be compact.
2. It should be easy to handle.
3. It should give quick response or quick result.
4. It should be reliable, while in use.
5. There should be no effects of environment on the comparator.
6. Its weight must be less.
7. It must be cheaper.
8. It must be easily available in the market.
9. It should be sensitive as per the requirement.
10. The design should be robust.
11. It should be linear in scale so that it is easy to read and get uniform response.
12. It should have less maintenance.
13. It should have hard contact point, with long life.
14. It should be free from backlash and wear.

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