EXPERIMENT NO: 03

EXPERIMENT : Measurement of Different parameters Of a Machine Component Using the Optical Comparator

AIMS
Identify and familiarizes with the Optical Comparator by measuring of different parameters of a
complex shaped machine component within a small time.

OBJECTIVES
To measure,
1. The distance between two points
2. Skew calibration
3. Radius and center location
4. Angle and vertex location

INTRODUCTION
An optical comparator is a device that applies the principles of optics to the inspection of
manufactured parts and this is a versatile, non-contact, precision measuring system. In an optical
comparator, the magnified silhouette of a part is projected upon the screen, and the dimensions
and geometry of the part are measured against prescribed limits. This device can be used to
measure such as distance, radii, angle and etc.

THEORY
Optical comparators are based on the principle of projection of image. An optical comparator is a
device that applies the principles of optics to the inspection of manufactured parts. In a
comparator, the magnified silhouette of a part is projected upon the screen, and the dimensions
and geometry of the part are measured against prescribed limits.
A way of measuring the distances is that various points on the silhouette are lined up with the
reticle at the centerpoint of the screen, one after another, by moving the stage on which the part
sits, and a digital read out reports how far the stage moved to reach those points.

APPARATUS

Optical comparator
Gauge blocks
A machine part of complex shape

PROCEDURE
Before taking any readings initially the optical comparator was set to zero at a particular point
where we needed to start our measurings.
Then firstly the basic measurement of distance between two points were measured.
There after the skew calibration was made.
Using Skew method distance between two points were measured.
Then radius and the location of a center were measured for different kinds of curvatures.
Finally the angle between two separate edges were found by entering the vertex locations.

a) The distance between two points

1) The device was powered on and machine part was moved to position 1, then set Zero
reset.
2) After that moved to position 2 and measured a, b and c, d were measured by pressing
polar conversion button.
3) Values were converted from mm to inch by pressing metric button.

b) Skew calibration
1) Moved to 1 and set zero
2) Then moved to 2 and measured a, b and set position 2 as the calibration point by
pressing Skew Cal button.
3) The moved to 3 and measured c, d and set position 3 as the second calibration point.
4) Skew mode went on automatically and measured g.
5) Now moved to 4 and measured h and pressed f for viewing Skew Calibration factor
6) Angle was measured by pressing skew mode.

c) Radius & Center location

1)
2)
3)
4)
5)

Reference point was set.

Radius button was pressed and moved to 1 and after pressed Enter display button.
Moved to 2 and again pressed Enter display button.
Moved to 3 and pressed Enter display button.
F button was pressed to measure radius and distance was measured by pressing Dia2
button.
6) Center or radius was measured by pressing Ctr/Ver button.

d) Angle & Vertex location

1) Moved to 1 after pressed Angle button, then measured coordinates and pressed
Enter Display button.
2) Moved to 2 then measured coordinates and pressed Enter Display button.
3) Moved to 3 then measured coordinates and pressed Enter Display button.
4) Moved to 4 then measured coordinates and pressed Enter Display button measured
angle.
5) F button was pressed to get Angle and Ctr/Vet button was pressed to get vertex
distance.

DISCUSSION
Classical Measuring Techniques
Block Gauge
Micrometer
Profile Projector
Coordinate Measurement Machine

New Dimensional Measurements

Mechanical Methods
Optical Methods
Pneumatic Methods
Ultrasonic Methods
Optical Comparator is one device which helps us to measure the dimensions using the image
projection. There are several other ways also to full fill the need. For complex items we could use
the some other instruments too.
Such instruments are
Mechanical Comparators
1. Mechanical comparators.
a) Dial-indicator.
b) Johnson mikrokator.
c) Read-type mech. comparators.
d) Sigma comparators.
2. Mechanical Optical Comparators
3. Electrical and Electronic Comparator
4. Pneumatic Comparator
5. Fluid displacement comparator
There are some other classical techniques also can be used to measure the parameters of a
machine component

VERNIER CALIPER
An ordinary Vernier caliper has jaws you can place around an object, and on the other side jaws
made to fit inside an object. These secondary jaws are for measuring the inside diameter of an
object. Also, a stiff bar extends from the caliper as you open it that can be used to measure
depth.

MICROMETER SCREW GAUGE

Micrometer screw gauge is used to measure even smaller dimensions than the Vernier calipers.
The micrometer screw gauge also uses an auxiliary scale (measuring hundredths of a millimeter)
which is marked on a rotary thimble. Basically it is a screw with an accurately constant pitch (the
amount by which the thimble moves forward or backward for one complete revolution). The
micrometers in our laboratory have a pitch of 0.50 mm (two full turns are required to close the
jaws by 1.00 mm). The rotating thimble is subdivided into 50 equal divisions. The thimble passes
through a frame that carries a millimeter scale graduated to 0.5 mm. The jaws can be adjusted
by rotating the thimble using the small ratchet knob. This includes a friction clutch which
prevents too much tension being applied. The thimble must be rotated through two revolutions
to open the jaws by 1 mm.

Optical Comparator
The optical comparator projecs the shadow of an object onto a glass screen. Can measure
features such as angles, radii and distances of the projeced image.

To measure these features the comparators edge detector defines an edge by the difference in
light and dark light intensities.
Optical comparators provide a cost effective solution for non-contact measurement. Optical
Comparators are found in shop and lab environments that is often related to product
manufacturing activity. An optical comparator is used for a wide range of dimensional inspection
applications. Optical Comparator horizontal models work good with parts that need to be fixed,
held in a vise, or on centers. Optical Comparator vertical models provide accuracy and are ideal
for parts that are placed on the glass insert of the work stage. Optical Comparator vertical
systems work well when the parts to be measured are flexible or soft.

Optical comparators are inspection machines that project magnified images of parts onto a glass
screen using illumination sources, lenses and mirrors for the primary purpose of making 2-D
measurements. Optical Comparators have been used for more than 50 years and remain a
versatile and cost-effective technology for the monitoring and the the processes and quality of a
broad range of manufactured parts. An Optical Comparator Originates from static overhead
projectors that displayed magnified images of screw threads onto a wall for manual
measurement, optical comparators have evolved into full-featured machines that use modern
mechanical, electrical and optical technology to minimize inspection time and maximize cost
savings.

Advantages

Optical comparators are easy measurement instruments to use. In less than a couple of
hours, users with only a little amount of gaging experience can make accurate measurements
using an optical comparator. Because an optical comparator displays the part's 2-D image onscreen, the image can be easily associated with the part's 2-D CAD drawing. This simplifies
the process of developing measurement procedures for parts from drawings and minimizes
the subjectivity of more complex measuring methods.

o Magnification accuracy is not affected by part geometry or configuration.

o Magnification stays the same regardless of different operators focusing the
instrument in slightly different places.
o When coupled with relay lenses, coaxial or through-the-lens surface illumination is
possible.
o Coaxial surface illumination provides brighter and more even illumination.
o Depth of field is increased.
Using optical comparators we could get more information than the usual dimensions. For
example length and width measurements of the part can be quickly obtained from two separate
measurements by using a micrometer. But the scratches and defections of the object may affect
the readings. Such imperfections are best detected on a comparator. In addition, a comparator's
screen can be simultaneously viewed by more than one person and provide a medium for
discussion.

 Disadvantages

Depends on availability on external power supply.

Apparatus is usually expensive.
When scale is projected on screen, Instrument has to be used in dark room
Inconvenient for continuous use because scale is viewed through eye piece.
As the instrument has high magnification, heat from the lamp, transformer etc. may cause
the setting to drift.

Practical Errors and improving methods

At times we get negative values for dimensions cause of the image projection. This could be
solved by setting up the zero position properly and intentionally.
When projecting the shadow of the image we should adjust the sharpness of the shadow and
get a clear view of it so that the exact position could be pointed out and accurate values
could be taken.
When we move the bed of the comparator which holds the object, it should not disturb the
position of the object so that the object stays still.
When finding out the radius of several curvatures we should input the exact three points
which will represent the arc of the circle which it belongs to, or else we would get a totally
wrong value. This could occur due to human errors which emphasises the complexness of the
object and its appearance.
Finding the angle corresponding to the edges might give us a wrong value as the edges of the
machine part or the object might have some deffects. So it is better to input four points from
the part of the edges which appears to be straight.