SIGMA COMPARATOR
INTRODUCTION
Sigma comparator was developed by a company named Sigma Instrument
Company, USA. Its magnification* ranges from 300 to 5000. It has a least count of
up to 0.25 microns. It is widely used in selective assembly** and automation. It is
also used as an inspection tool in mass production.
WORKING PRINCIPLE
A linear displacement of a plunger is translated into the movement of a pointer
over a calibrated scale.
DIAGRAM
CONSTRUCTION
A Sigma Comparator is constructed by the following components
1 Plunger
It is the sensing unit of the comparator. This part is in contact with the
surface and senses any unevenness in the surface that is analyzed.
2 Knife Edge
The plunger has a groove to which knife edge is connected. This knife is
attached to the plunger with the help of screws.
3. Adjustable Screws
Adjustable screws are used to adjust the height or keeping the contact of
the knife edge with the movable block.
4. Slit diaphragm (or) Slit washer
It helps in mounting the plunger and results in a frictionless linear
displacement. They are placed on both sides of the plunger at the bottom.
5. Movable Block
Moving block is a part which is directly in contact with the knife-edge. It is
present at the bottom part of the cross strip.
6. Fixed Block
Fixed block is present at the upper part of the cross strip and cannot move
i.e. it is stationary.
7. Cross Strip
Cross Strip is a pivoted portion of the fixed block and moving block. This
strip is made up of elastic material so that when the force is applied this
strip will get deformed and when the forces are removed it will return back
to its original position.
8. Y-arm
Y-arm is a Y shaped armed which is connected to the movable block. This
Y-arm is in contact with driving drum or driving pulley. This Y-arm is made
of Phosphorus Bronze alloy.
9. Driving Drum
The driving drum is used to connect the Y-arm to the pointer with the help
of pointer spindle.
10. Pointer Spindle
Pointer spindle is used to connect the pointer to the driving drum.
11. Pointer
A pointer is used for pointing the measured value on the scale.
12. Scale
The scale of the sigma comparator can be linear or circular in shape and
contains the reading of the comparator. The pointer points at the measured
reading on this scale.
WORKING
The plunger is the sensing element that is in contact with the work part. It moves
on the slit washer, which provides frictionless linear movement and also arrests
rotation of the plunger about its 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. Whenever the plunger moves up or down, the knife
edge drives the moving member of the cross-strip hinge assembly. This deflects
an arm, which divides into a ‘Y’ form. The extreme ends of this Y-arm are
connected to a driving drum by means of phosphor-bronze strips. The movement
of the Y-arm rotates the driving drum and, in turn, the pointer spindle. This causes
the movement of the pointer over a calibrated scale.
MAGNIFICATION
The magnification of the instrument is obtained in two stages.
In the first stage, if the effective length of Y-arm is L and the distance from the
hinge pivot to the knife edge is x, then magnification is L/x.
The second stage of magnification is obtained with respect to the pointer length
R and driving drum radius r. The magnification is given by R/r.
Therefore, overall magnification is given by (L/x) × (R/r).
Thus, the desired magnification can be obtained by adjusting the distance x by
operating the two screws that hold the knife edge to the plunger.
In addition, the second level of magnification can be adjusted by using driving
drums of different radii (r).
ANIMATION VIDEO
Sigma Comparator Animation
*(The output result from a measuring device to be magnified many times to make
it more readable, called Magnification.)
** (The selective assembly can be referred to as a concept where the
subcomponents are assembled to form a proper final assembly which will in
return provide the highest tolerance specification.)
