METROLOGY

COMPARATORS
✓ In the context of metrology in mechanical engineering, comparators refer to precision
measuring instruments used to compare the dimensions or characteristics of a workpiece with
a known standard.
✓ These comparators are designed to ensure accuracy and consistency in dimensional
measurements and are commonly used in quality control, inspection, and precision
manufacturing processes.
Comparative Measurement in Metrology:
✓ Comparative measurement is a technique used in metrology, specifically in mechanical
engineering, to compare an unknown or variable quantity with a known or standard
reference.
✓ It involves the use of measuring instruments or devices to establish a quantitative relationship
between the unknown and reference quantity.
✓ The goal is to determine the difference or similarity between the two quantities being
compared.
✓ The comparative measurement process typically involves the following steps:
i. Selection of Reference: A suitable standard or reference is chosen against which the
unknown quantity will be compared. The reference should have a known and well-
defined value.
ii. Measurement Setup: The unknown and reference quantities are measured using
appropriate measuring instruments or devices. These instruments may include calipers,
micrometers, gauges, or other specialized tools.
iii. Comparison: The measurements of the unknown and reference quantities are compared to
determine the difference or similarity between them. This can be done visually,
numerically, or through graphical analysis.
iv. Error Analysis: The measurement errors associated with the instruments and the
comparative process are considered to assess the overall accuracy of the comparative
measurement. Error correction techniques may be applied to improve the measurement
accuracy.
Error Correction in Metrology:
✓ Error correction is a crucial aspect of metrology that involves identifying and compensating
for errors or inaccuracies in measurements.
✓ In mechanical engineering, error correction techniques are used to improve the accuracy and
reliability of measurement results.
✓ Several error correction methods are employed, including cosine correction, sine correction,
and parallax correction.
i. Cosine Correction: Cosine correction is applied in measurements where the angle of
incidence of the measuring device deviates from the normal direction of measurement.
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This occurs, for example, when using an instrument like an optical projector or a
coordinate measuring machine. The cosine correction factor is determined based on the
angle of incidence, and it is used to adjust the measured value to account for the
deviation. This correction ensures that the measurement accurately reflects the intended
dimension.
ii. Sine Correction: Sine correction is similar to cosine correction but applies when the angle
of measurement is inclined or deviates from the vertical direction. It compensates for the
measurement error caused by the angle of inclination. The sine correction factor is
determined based on the angle of inclination, and it is used to adjust the measured value
accordingly.
iii. Parallax Correction: Parallax is an error that occurs when the position of the observer
affects the measurement reading. It commonly occurs in measuring devices with a scale
or pointer that needs to be visually aligned. Parallax correction involves positioning the
observer's eye directly in line with the measurement scale to eliminate any apparent shift
in the reading. This correction ensures accurate readings by minimizing the parallax
error.
Classification of Comparators.
✓ Comparators are devices used to compare the dimensions or characteristics of two objects
and determine their relative differences.
✓ They can be categorized into mechanical and electrical types.
✓ In this response, we will provide detailed notes on each of the mentioned comparators.
Mechanical Comparators:
1. Dial Testing Indicator (DTI) (Plunger Type):
✓ DTI is a commonly used mechanical comparator in metrology.
✓ It consists of a spring-loaded plunger attached to a mechanical dial gauge.
✓ When the plunger is pressed against the surface being measured, the dial gauge
indicates the displacement or dimensional difference.
✓ DTIs are versatile and widely used for precision measurement in various industries,
including manufacturing, engineering, and inspection.
2. Sigma Comparator:
✓ The Sigma comparator is a high-precision mechanical comparator.
✓ It uses a differential mechanism to magnify small differences in dimensions.
✓ The comparator consists of two separate columns with scales and a differential screw
mechanism.
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✓ By adjusting the screw, the operator can find the difference between two dimensions
with high accuracy.
Sigma comparators are commonly used in precision workshops, laboratories, and
industries where high accuracy is required.
3. Johansson Mikrokator:
✓ Johansson Mikrokator is a mechanical comparator used for accurate linear
measurements.
✓ It consists of a probe with a measuring plunger and a dial gauge.
✓ The plunger moves in response to the displacement being measured, and the dial
gauge provides the reading.
✓ Mikrokators are known for their high precision and are commonly used in metrology
laboratories, tool rooms, and quality control departments.
Electrical Comparators:
1. Pneumatic Comparators:
✓ Pneumatic comparators use air pressure to compare dimensions or measurements.
They consist of a pneumatic amplifier, a pressure regulator, and a sensing element.
✓ The sensing element converts the displacement or dimension being measured into an
air pressure variation.
✓ The pressure is then compared with a reference pressure to determine the difference.
✓ Pneumatic comparators are used in industries where non-contact measurement, high
speed, and reliability are required.
2. Optical Comparators:
✓ Optical comparators use optical systems to measure dimensions or compare shapes.
✓ They utilize principles of optics, such as magnification, projection, and illumination.
✓ The object being measured is placed on a stage and magnified onto a screen or
viewed through an eyepiece.
✓ The operator can compare the dimensions or features of the object with a reference
pattern or overlay.
✓ Optical comparators are commonly used in industries like automotive, aerospace,
and tool manufacturing for fast and accurate measurements.
3. Mechanical Optical Comparators:
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✓ Mechanical optical comparators combine mechanical and optical principles for

measurements.
✓ They use a mechanical stage to position the object being measured and an optical
system for magnification and comparison.
✓ The operator can view the object's magnified image and compare it with a reference
scale or overlay.
✓ Mechanical optical comparators are used in industries where precise measurements
of small parts or features are required, such as in the manufacturing of electronic
components or precision instruments.
Working of Comparators
Electrical Comparators:
1. Measuring Head:
✓ In electrical comparators, the measuring head is the component that receives the input
signals to be compared.
✓ It typically consists of two input terminals: the non-inverting input and the inverting
input.
✓ The non-inverting input receives the reference signal or standard value, while the
inverting input receives the input signal to be compared.
✓ The measuring head compares the magnitudes of these input signals and produces an
output signal based on the comparison.
2. Magnification:
✓ Magnification refers to the amplification or gain provided by the electrical
comparator.
✓ It determines the sensitivity and resolution of the comparator.
✓ Higher magnification results in a smaller difference required between the input
signals to generate a noticeable output.
✓ The magnification of electrical comparators can often be adjusted to suit specific
measurement requirements.
Advantages of Electrical Comparators:
✓ High Accuracy: Electrical comparators can provide highly accurate measurements,
especially when used with precision components and calibration procedures.
✓ Wide Range of Applications: They can be used in various applications such as quality
control, metrology, scientific research, and industrial processes.
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✓ Fast Response: Electrical comparators can operate at high speeds, making them
suitable for time-critical measurements and dynamic systems.
✓ Flexibility: They can handle different types of signals, including voltage, current, and
frequency, allowing for versatile measurement capabilities.
✓ Integration: Electrical comparators can be easily integrated into electronic systems
and interfaced with other components for automation and data analysis.
Disadvantages of Electrical Comparators:
✓ External Power Requirements: Electrical comparators typically require a power
source to operate, which may limit their portability and increase complexity in certain
applications.
✓ Sensitivity to Noise: They can be sensitive to electrical noise, which may introduce
errors or affect the accuracy of measurements.
✓ Complexity and Cost: Depending on the specific implementation, electrical
comparators can be more complex and expensive compared to mechanical
comparators.
✓ Calibration and Maintenance: Regular calibration and maintenance are necessary to
ensure accurate and reliable measurements, adding to the overall cost and effort.
Mechanical Comparators:
1. Overview:
✓ Mechanical comparators are devices that use mechanical principles to compare the
dimensions of objects.
✓ They typically consist of a measuring element, a reference element, and a
mechanism that indicates the difference between the two elements.
✓ Mechanical comparators are often used in applications where high precision is
required but electronic solutions are not feasible or cost-effective.
2. Measuring Head:
✓ The measuring head in a mechanical comparator typically involves physical contact
between the object being measured and a stylus or probe.
✓ The stylus or probe transfers the dimensional information to the comparator
mechanism, which produces an output indicating the difference between the object
and the reference.
3. Magnification:
✓ Mechanical comparators often employ a mechanical amplification mechanism to
enhance the sensitivity and resolution of measurements.
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✓ The magnification is achieved by using levers, gears, or other mechanical

arrangements that amplify the displacement or movement of the measuring element.
Advantages of Mechanical Comparators:
✓ High Precision: Mechanical comparators can achieve high levels of precision,
making them suitable for applications where accuracy is critical.
✓ Robustness: They are generally robust and less susceptible to electrical noise or
environmental conditions, making them suitable for harsh industrial environments.
✓ Simple Operation: Mechanical comparators are often straightforward to operate,
requiring minimal training or expertise.
✓ Cost-Effective: Mechanical comparators can be more cost-effective compared to
their electrical counterparts, particularly for certain measurement tasks.
Disadvantages of Mechanical Comparators:
✓ Limited Speed: Mechanical comparators may have limitations in terms of
measurement speed due to the physical nature of their operation.
✓ Limited Measurement Range: They might have a limited measurement range
compared to electrical comparators, restricting their applicability in some cases.
✓ Mechanical Wear: The mechanical components of comparators may experience wear
over time, leading to reduced accuracy and the need for maintenance or replacement.
✓ Manual Operation: In many cases, mechanical comparators require manual
operation, which can be slower and less convenient compared to automated electrical
systems.