COMPARATORS

BY GROUP 4
 GROUP MEMBERS
22/U/EME/08126/PE MPAMYA PAUSON 23/U/EMD/2158/PD MURIRU RAFSANJAN
24/U/EMD/18839/PD BISHISHA AINEPLAN TREVOR
24/U/EME/1254/PE MUCUNGUZI AMOS
22/U/EME1932/PE OKWARE WILLIAM 23/U/EME/15398/PE MUKAMA AMOS
24/U/EMD/1680/PD ONAI JAMES PETER 23/U/EME/14781/PE MURUNGI LAWRENCE
23/U/EME/2503/PE OTIM AUGUSTINE 24/U/FMD/1331/PDMUTAHI REAGAN DAVID
23/U/EME/12268/PE OWEMBABAZI ANTHONY 24/U/EMD/18861/PD EMOR STANELY BRIAN
24/U/EMD/1726/PD OYCRA STEPHEN 23/U/EME/14762/PE MAJEME KEMAN
23/U/EMD/2515/PD OYESIGYE DIDAS 24/U/EMD/1231/PDMASEREKA BENSON
23/U/EME/2092/PE LEMA JOEL
23/U/EME/14777/PE MUIUNI ANDREW KAGGWA
 OVERVIEW
• Appreciate the difference between direct measurement and
comparison measurement
• Understand the functional requirements of comparators
• Explain the basic principles of construction and operations of
various types of comparators such as mechanical, optical,
electrical and electronic comparators
• Describe the functions of various attachments that can be used
with different comparators to enhance their functional aspects
• Elucidate the basic measurement principles of comparators
• Discuss the applications and limitations of various comparators
 INTRODUCTION
• All measurement require the unknown quantity to be compared with a known
quantity called the standard
• A measurement is generally made with respect to time, mass and length
• In this case three elements are involved; the unknown, standard and the system for
comparing them
• Measurement instruments like verniers and micrometers enable us to directly
measure a linear dimension up to a given degree of accuracy
• On the other hand, comparison of the unknown with the standard is known as
comparison measurement and a device known as a comparator provides such
comparison.
• A comparator is a measurement instrument that evaluates an unknown dimension by
comparing it with a known standard rather than measuring an absolute value. In
other words, it produces a reading that reflects the deviation between the workpiece
and a pre-set reference or master standard.
DIRECT MEASUREMENT VERSUS
COMPARISON MEASUREMENT

A calibrated standard directly

gives the measured value incase
of direct measurement
On the other hand, a comparator
has to be set to a reference value
(usually zero setting) by
employing a standard. Once it is
set to this reference value, all
subsequent readings indicate
deviation from the standard
 ACCURACY OF DIRECT AND COMPARISON
MEASUREMENT DEPENDS ON
DIRECT MEASUREMENT COMPARISON MEASUREMENT
• The effect of instrument limitations can be partly
• Accuracy depends solely on the instrument’s
canceled out by comparing the sample with a
resolution. Any intrinsic imprecision, noise, reference. Differences are measured rather than
or drift directly shows up in the final reading. absolute values, so common errors may subtract
• Requires precise calibration to ensure that out if both are similarly affected

the instrument’s scale is accurate. Errors in • Depends on a highly accurate reference standard.
calibration immediately shift the absolute While calibration is still critical, systematic errors
may cancel out during the relative (often null)
measurement value,
comparison if both the unknown and the standard
• Highly sensitive to environmental factors share similar biases.
(e.g., temperature, humidity, pressure), • By measuring both the unknown and the reference
which can cause variations in the instrument under nearly identical environmental conditions
or sample dimensions and directly alter the (often concurrently), many environmental effects
measurement value. cancel out, thereby enhancing relative accuracy
 COMPRISON
DIRECT MEASUREMENTS MEASUREMENTS
• Susceptible to errors such as parallax, • Often employs methods (for example, null-
misreading, or misapplication of the detection or differential setups) that reduce
technique. Human error directly affects subjective interpretation. While errors in setup
can still occur, the relative nature of the method
the reported absolute value.
minimizes the impact of observer bias.
• A direct readout requires that the • The method allows for repetitive comparisons or
instrument’s response is quick and averaging techniques. By carefully timing the
stable. An inadequate response time or measurement of the sample and reference,
transient signals can distort the absolute transient errors are minimized, as the focus is on
the difference rather than the instantaneous
measurement if not timed correctly.
value.
•Typically, no external reference is involved
• The method is fundamentally based on the known
unless calibrating beforehand. The standard. Inaccuracies in the reference will
absolute reading is self-contained within directly affect the measurement, but if the
the instrument’s performance. reference is of very high quality, the
measurement can be more precise than a
standalone instrument readout.
 SUMMARY OF FACTORS

•Instrument Precision & Resolution

•Calibration and Standardization
•Environmental Influence
•Operator/Observer Errors
•Measurement Method and Timing
• Reliance on Reference Standards
 ACCURACY OF DIRECT AND COMPARISON
MEASUREMENT DEPENDS ON;
DIRECT MEASUREMENT COMARISON MEASUREMENT

Accuracy of the standard Accuracy of the standard used for setting the
comparator

Accuracy of the scale Least count of the standard

Least count of the scale Sensitivity of the comparator

Accuracy of reading the scale (human element) Accuracy of reading the scale
 FUNCTIONAL REQUIREMENTS

A comparator has to fulfill the many functional requirements in order

to be effective in the industry. The major requirements of a comparator
are as follows;
• A comparator should have a high degree of accuracy and precision
• The scale should be linear and have wide range. Since a
comparator, be it mechanical, pneumatic, or electrical, has means
of amplification of signals, linearity of the scale within the
measuring range should be assured.
• A comparator is required to have high amplification. It should be
able to amplify changes in the input value, so that the readings
can be taken and recorded accurately and with ease
 FUNCTIONAL REQUIREMENTS

• A comparator should have a good resolution, which is the least

possible unit of measurement that can be read on the display
device of the computer.
• There should be a provision incorporated to compensate for
temperature effects
• The comparator should be versatile. It should have provisions to
select different ranges, attachments, and other flexible means,
so that it can be put to various uses
 CLASSIFICATION OF COMPARATORS
With respect to the principle used for amplifying and recording
measurements, comparators are classified as follows;
• Mechanical comparators
• Mechanical-optical comparators
• Electrical and electronic comparators
• Pneumatic comparators
• Other types such as projection comparators and multi-check comparators.
Each of the above comparators has many variants, which provide flexibility to
the user to make an appropriate and economical selection for a particular
metrological application
 MECHANICAL COMPARATORS

• Mechanical comparators have a long history and have

been used for many centuries. They provide simple and
cost-effective solutions. The skills for fabrication and
using them can be learnt relatively easily compared to
other types of comparators. The following are some of
the important comparators in metrology;
• Dail indicator
• Johannson Mikrokator
• Sigma comparator
DIAL INDICATOR (DAIL GAUGE)

The basic features of a dial gauge

consist of a body with a circular
graduated dial, a contact point
connected to a gear train, and an
indicating hand that directly
indicates the linear displacement
of the contact point.
The scale of the dial indicator,
usually referred to as dial,
provides the required least count
for measurement, which normally
varies from 0.01 to 0.05 mm.
 DIAL INDICATOR

Dail indicator mounted on a

Standard contact points Working mechanism of a Dail
stand
indicator
 JOHANSSON MIKROKATOR

The basic element in this type of comparator is a

light pointer made of glass fixed to a thin
twisted metal strip.
It uses a principle of Abramson movement which
uses the principle in igneous manner to obtain
high mechanical magnification
The two halves of the thin metal strip, which
carries the light pointer, are twisted in opposite
directions. Therefore, any pull on the strip will
cause the pointer to rotate.
 SIGMA COMPARATOR

A linear displacement of a plunger is translated into

the movement of a pointer over a calibrated scale.
The plunger is the sensing element that is in contact
with the work part.
It moves on a slit washer, which provides frictionless
linear movement and also arrests rotation of plunger
about the axis.
A knife edge is screwed onto the plunger, which
bears upon the face of the moving member of a
cross-strip hinge
This unit comprises a fixed member and a moving
block, connected by thin flexible strips at right angles
to each other
 MECHANICAL-OPTICAL COMPARATOR

• This also termed as Cooke’s Optical Comparator. It combines mechanical and

optical systems to achieve high-precision measurements by amplifying small
displacements.
𝑙2
Mechanical amplification=
𝑙1

Optical amplification =
 PRINCIPLE OF OPERATION
• The plunger is spring loaded such that it is
biased to exert a downward force on the work
part.
• This bias 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 is introduced below the plunger
• This causes small displacement of the plunger,
which is amplified by the mechanical levers
• The amplified mechanical movement is further
amplified by optical system due to tilting of
 PRINCIPLE OF OPERATION
• 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 millimeters or fractions of a millimeter.
• Optical magnifications provide ahigh degree of precision in measurements
due to the reduction of moving members and better wear-resistance qualities
 ELECCTRICAL COMPARATORS
Electrical and electronic comparators are wide spread use because of their instantaneous
response and convenience in amplifying the input.
They generally depend on a Wheatstone bridge circuit measurement
 PRINCIPLE OF OPERATION

• A direct current (DC) circuit comprising 4 resistors, 2

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 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.
 PNEUMATIC COMPARATORS

• Pneumatic comparators use air as a means of

measurement
• The basic principle involved is that changes in
calibrated flow respond to changes in a calibrated flow
respond to changes in the part feature.
ADVANTAGES OF PNEUMATIC METROLOGY OR
COMPARATORS OVER OTHER COMPARATORS;
• Absence of metal contact
• Higher amplification
• Low cost
• Limited wear of the tool due to absence of metal to
metal contact
• Greater tool longevity
 FUNCTIONAL AND METROLOGICAL
FEATURES OF PNEUMATIC COMPARATORS
FUNCTIONAL FEATURES METROLOGICAL FEATURES
No wearing parts Non-contact inspection of work parts
Rapid response Minimum gauging force
Remote positioning Both variable inspection and attribute
inspection possible
Self-cleansing of heads and parts High range of amplification
No hysteresis Suited for varied inspections such as
length position, and surface topography
Scope for inspecting diverse part features
Compact size of gauge head
 PNEUMATIC COMPARATORS

• Free flow air gauge Back pressure gauge Solex pneumatic gauge
 FREE FLOW AIR GAUGE
• This uses a simple pneumatic circuit
• Compressed air with a pressure of 1.5 to 2 bar is passed through a tapered glass
column that contains a small metal float
• Then air passes through a rubber of plastic hose and exits to the atmosphere
through the orifice in the gauging head
• Since the gauging head is placed inside the workpiece being inspected, there is a
small clearance between the gauging head and work piece
• This results into a restriction in free air flow
• The restriction in air flow causes a change in position of the metal float in the
tapered glass
• The position of metal float is directly proportional to the clearance and the rate of air
flow
• Therefore the results of clearance can be read directly from the calibrated scale
 SOLEX PNEUMATIC GAUGE
• This is the commonly used pneumatic comparator
• The Solex pneumatic gauge is generally used for the inspection of internal
dimensions, although it is also used for external measurements with suitable
attachments.
OPERATION
• Compressed air is drawn from the factory supply line, filtered and regulated to a
pressure about 2 bar
• Air will now pass through a dip tube immersed in a glass water tank
• The position of the dip tube in terms of depth H will regulate the effective air
pressure in the system at the input side
• Extra air, by virtue of a slightly higher supply pressure, will leak out of the water
tank in the form of air bubbles and escape into the atmosphere
• This ensures that air moving towards the control orifice is at desired constant
pressure
 SOLEX PNEUMATIC GAUGE

• The air at reduced pressure passes the control

orifice and escapes from the measuring orifice in
the measuring head
• Basing on the clearance between the work part
and measuring head a back pressure is created
which results in displacement of water head in
the manometer tube
• Change in pressure varies with change internal
dimension
• Therefore the change in linear dimension can be
directly read from a linearly calibrated scale
 APPLICATIONS OF COMPARATORS
Mechanical Comparators:
•Dial Indicators: Widely used in checking roundness and
linear deviations.
•Johansson Mikrokator & Sigma Comparators: High
mechanical amplification for minute displacements. Useful in
bench-top precision inspections.
Mechanical–Optical Comparators:
•Optical Projection Systems: Project magnified images of
workpiece profiles for detailed inspection
i.e(gears, screws, contours).
Quick identification of dimensional devistions via clear
projected images
 APPLICATIONS OF COMPARATORS
Electrical/Electronic Comparators:
•Bridge-Based Systems & LVDTs: High-precision,
non-contact measurement of small displacements.
•Electronic Gauges (e.g., Sigma Electronic
Comparator): Rapid, automated measurements
(hundreds per minute) ideal for production lines.
Pneumatic Comparators:
•Air Gauging Systems: Measure internal features
(holes, bores, roundness) through flow/back pressure
changes.
•Solex Pneumatic Gauges:Provide uniform, rapid, and
operator-independent readings in production
environments.
 LIMITATIONS OF COMPARATORS
Mechanical Comparators:\
• Wear and Tear: Physical contact can lead to wear of plunger
and contact points.
• Limited Amplification: Mechanical systems may offer less
overall magnification compared to other methods.
• Operator Dependency: Readings can be affected by manual
handling and parallax error.

Electrical/Electronic Comparators:

•Power & Noise Sensitivity: Require stable electrical supply

and are sensitive to electromagnetic interference.
 LIMITATIONS OF COMPARATORS

•Calibration Complexity: High sensitivity may require frequent

recalibration.

•Inertia Effects: Components (like LVDT cores) may introduce errors

during high-speed dynamic measurements.
Mechanical–Optical Comparators:
• Setup & Alignment: Sensitive to proper lighting, stable mounting,
and precise alignment.
• Environmental Sensitivity:Performance affected by ambient light
and temperature.
• Dimensional Limitations: Essentially provide 2D profiles, which may
not capture complete 3D characteristics.
 LIMITATIONS OF COMPARATORS

Pneumatic Comparators:
•Measurement Range: Excel in small variations but have a limited
range for larger differences.

•Environmental Influences: Impacted by temperature, humidity,

and air pressure fluctuations.

•Precision Cost: Often require expensive, high-precision gauging

elements and strict conformity to master standards.

•Surface Finish Dependency: Variations in workpiece surface

conditions can influence air flow and measurement accuracy.