MEASUREMENTS

MEASUREMENTS

Lecture # 1

MEASUREMENTS Why we do measurements?

Measurements tell you if the part is worn or damaged
Measurements tell you if the parts are out of adjustment or out of specs and by how much.

Example: Measuring the bore or diameter of engine cylinder

MEASUREMENTS Measuring System

1. 2. 3. Metric System(M.K.S) S.I System Imperial and USC ( United State Customary)

MEASUREMENTS

Measuring System
Metric System
Meter(m) for length Kilogram (Kg) for mass Second (s) for Time

Prefixes
Kilo means 1000 Deci means 0.10 (one tenth) Centi (one hundredth) Milli means (one thousandth)

MEASUREMENTS Measuring System

Metric System
Examples: 1Km = 1000m 1Kg = 1000gm 1Liter = 1000ml

MEASUREMENTS Measuring System

SI System
The International System of Units (abbreviated SI from the French Systme international d'units) is the modern form of the metric system. It is the world's most widely used system of measurement, both in everyday commerce and in science

The SI was developed in 1960 from the old metre-kilogram-second system

SI prefixes

MEASUREMENTS

Measuring System
SI Prefixes
Prefix tera giga mega kilo hecto deca deci Symbol T G M k h da d 10n 1012 109 106 103 102 101 101 Decimal 1000000000000 1000000000 1000000 1000 100 10 0.1 Short scale Trillion Billion Million Thousand Hundred Ten Tenth

centi
milli micro nano pico

c
m n p

102
103 106 109 1012

0.01
0.001 0.000001 0.000000001

Hundredth
Thousandth Millionth Billionth

0.000000000001 Trillionth

MEASUREMENTS Measuring System

USC (United State Customary)
Foot (F) for length Pound (lb) for weight

Second (s) Time

Conversion 12inches = 1 foot 3feet = 1 yard 1760 yards = 1mile 16 ounces = 1 pound 2000pounds = 1tons

MEASUREMENTS Tools and Measurement Basics

Automotive repairs require the use of a variety of tools and measuring instruments. These tools are manufactured for use in a particular way, and accurate work and safety can only be assured if they are used correctly.

MEASUREMENTS
Basic concept for using tools and measuring instruments:
1. Learn the correct uses and functions:
Learn the correct uses and functions of each tool and measuring instrument. If used for any purpose other than that specified, the tool or measuring instrument damaged, and parts may be damaged or the quality of the job may be compromised.

2. Learn the correct way to use the instruments:

Each tool and measuring instrument has defined operation procedures. Make sure to correctly apply tools against workpieces, apply correct force to the tools, and adopt the proper work postures.

3. Select correctly:
There are various tools available for loosening bolts, depending on the size, position and other criteria. Always choose your tools to fit the shape of the part and the place in which the job is being carried out.

MEASUREMENTS
Basic concept for using tools and measuring instruments:
[Link] to keep organized
Tools and measuring instruments should be positioned so that they can be accessed easily when needed, and replaced in their correct locations once used.

5. Strict adherence to upkeep and management of tools.

Tools should be cleaned and where necessary oiled as soon as they have been used. Any necessary repairs should be carried out immediately, so that tools are always in perfect condition.

MEASUREMENTS
Basic concept for using tools and measuring instruments:
Points to check before measurement: 1. Clean the part to be measured and the measuring instrument
Waste products or oil can lead to errors in measurement values. Surfaces should be cleaned before measuring.

2. Choose a suitable measuring instrument

Select the measuring instrument according to the level of precision required. Bad example: Using a vernier caliper to measure the outer diameter of a piston. Measuring precision: 0.05mm Required precision: 0.01mm

MEASUREMENTS
Basic concept for using tools and measuring instruments:
Points to check before measurement: 3. Calibrate zero
Check that zero is aligned to its correct position. Zero is the basis for correct measurement.

4. Maintenance of measuring instrument

Maintenance and recalibration should be carried out regularly. Do not use if broken.

MEASUREMENTS
Basic concept for using tools and measuring instruments:
Points to be observed when measuring: 1. Fit the measuring Instrument to the part to be measured at a right angle.
Achieve a right angle by pressing the measuring Instrument while moving it against the part to be measured. (For details, refer to individual instructions for measuring Instruments.)

2. Use an appropriate range.

When measuring voltage or current, begin with a high range and adjust downwards. The measurement value should be read from a dial that is suitable for the range.

3. When reading the measurement value

Make sure your eye level is at a right angle to the dial and pointer.

MEASUREMENTS
Basic concept for using tools and measuring instruments:
Points to be observed when measuring: 1. Fit the measuring Instrument to the part to be measured at a right angle.
Achieve a right angle by pressing the measuring Instrument while moving it against the part to be measured. (For details, refer to individual instructions for measuring Instruments.)

2. Use an appropriate range.

When measuring voltage or current, begin with a high range and adjust downwards. The measurement value should be read from a dial that is suitable for the range.

3. When reading the measurement value

Make sure your eye level is at a right angle to the dial and pointer.

MEASUREMENTS
Basic concept for using tools and measuring instruments:
NOTICE: 1. Do not drop or strike, otherwise apply impact. These tools are precision instruments, and may damage the inside parts for construction. 2. Avoid using or storing in high temperatures or at high humidity. Errors in measurement values may occur from use at high temperature or humidity. The tool itself may deform if subjected to high temperatures. 3. Clean the tool after use, and put it away in its original condition. Put the tool away only after it has been cleaned of oil or waste products. All tools used must be returned in their original condition, and any equipment with a dedicated case must be put away in its case. Measuring tools must be stored in a defined place. If tools are to be stored for a long term, apply rust protection oil where necessary, and remove batteries.

MEASUREMENTS Measuring Instruments

Steel Scale

Inside and outside caliper

Vernier Caliper Micrometer Dial Gauge Feeler Gauge

Plasti Gauge
Wire Gauge Multimeter

MEASUREMENTS Measuring tools

Steel scale
Not accurate enough for most of the automotive work

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MEASUREMENTS Measuring tools

Inside Caliper
The inside calipers are used to measure the internal size of an object.

Outside Caliper
Outside calipers are used to measure the external size of an object.

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MEASUREMENTS

Lecture # 2

MEASUREMENTS Measuring tools

Vernier Caliper
Vernier Calipers can measure length, outside diameter, inside diameter and depth.

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MEASUREMENTS Measuring tools

Vernier Caliper
PARTS
1. 2. 3. 4. 5. 6. 7. Inside diameter of measuring jaws Outside diameter of measuring jaws Stop screw Vernier scale Main scale Depth measurement Depth rod

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MEASUREMENTS Measuring tools

Vernier Caliper
Examples of use
1. 2. 3. 4. Length measurement Inside diameter measurement Outside diameter measurement Depth measurement

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MEASUREMENTS Measuring tools

Vernier Caliper
Reading measurement STEP1
Read the main measuring scale, positioned to the left of the vernier 'zero'. Example A ) 45(mm)

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MEASUREMENTS Measuring tools

Vernier Caliper
Reading measurement STEP2
Read the point, which the scale on the vernier and main measuring scale become aligned. e.g.) 0.25(mm)

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MEASUREMENTS Measuring tools

Vernier Caliper
Reading measurement STEP3
A+B e.g.) 45+0.25=45.25(mm)

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MEASUREMENTS

Lecture # 3

MEASUREMENTS Measuring tools

Micrometer
Application Measures the external diameter / thickness of a part by calculating the proportionate rotation of the spindle in the shank direction.

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MEASUREMENTS Measuring tools Micrometer

Measuring (1) Apply the anvil against the item to be measured, and rotate the thimble until the spindle is touching the item gently. (2) Once the spindle touches gently the item to be measured, turn the ratcher stopper a few times and read the measurement. (3) The ratcher stopper unifies the pressure applied by the spindle, so when this pressure goes above the specified level it idles.
1. 2. NOTICE: The micrometer should be fixed on a stand when measuring small parts. Search for the position at which the correct diameter can be measured, by moving the micrometer.
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MEASUREMENTS Measuring tools Micrometer

STEP1:
Read the largest value, which is visible on the scale of sleeve. e.g.) A 55.5(mm)
1. 2. 3. 4. 5. Sleeve Thimble 1mm increments Base line on the sleeve 0.5mm increments

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MEASUREMENTS Measuring tools Micrometer

STEP2:
Read the point, which the scale on the thimble and the scale on the sleeve become aligned. e.g.) B 0.45(mm)
1. 2. 3. 4. 5. Sleeve Thimble 1mm increments Base line on the sleeve 0.5mm increments

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MEASUREMENTS Measuring tools Micrometer

STEP3:
A+B e.g.) 55.5+0.45=55.95(mm)
1. 2. 3. 4. 5. Sleeve Thimble 1mm increments Base line on the sleeve 0.5mm increments

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MEASUREMENTS Measuring tools

Inside micrometer

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MEASUREMENTS

Lecture # 4

MEASUREMENTS Measuring tools

Dial Gauge
Application
The up- down movement of the suspended measuring tip is converted into revolutions of long and short pointers. Used for measuring deviation or bends in shafts, and surface oscillation of flanges, etc.

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MEASUREMENTS Measuring tools

Dial Gauge
Application
Types of suspended measuring tip Long type: used to measure parts in a confined space Roller type: used to measure convex / concave patterns of tires etc. Seesaw type: used to measure parts that the pendulum cannot touch directly (vertical deviation of companion flanges) Flat plate type: used for measuring piston protrusion, etc.
1. 2. 3. 4. 5. Long pointer (0.01mm / dial increment) . Short pointer (1mm / dial increment) . Dial face (Rotate to set indication to zero). Spindle . Suspended measuring tip.

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MEASUREMENTS Measuring tools

Dial Gauge
Instructions 1. Measuring (1)Always use positioned on a magnetic stand. Adjust the dial gauge position and the item being measured, and set the pendulum so that it is at the center of its range of movement. (2)Rotate the item being measured, and read the deviation of the pointers.

2. Reading measurement value The dial shows a movement of 7 increments. Deviation range: 0.07mm

1. 2. 3. 4. 5.

Long pointer (0.01mm / dial increment) . Short pointer (1mm / dial increment) . Dial face (Rotate to set indication to zero). Spindle . Suspended measuring tip.

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MEASUREMENTS Measuring tools

Feeler Gauges
A feeler gauge is a simple tool used to measure gap widths

Feeler gauges are mostly used in engineering to measure the clearance between two parts.

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MEASUREMENTS Measuring tools

Feeler Gauges
NOTICE: (1) To avoid bending or damaging the tip of the gauge, do not force the gauge into the area to be measured. (2) Before putting the blades, away, clean the surfaces and apply oil to prevent them from rusting.

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MEASUREMENTS Measuring tools

Spark Plug Gap Gauge
Application
Used for measuring and adjusting the spark plug gap.

Each wires with different thickness are used for measuring the spark plug gap.
The ground electrode is bent by placing it in the groove of the gauge in order to adjust the gap.
[Link] [Link] plates [Link] plug gap

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MEASUREMENTS Measuring tools

Spark Plug Gap Gauge
Adjustment
Place the cut-out portion of the adjustment plate over the ground electrode of the spark plug, and bend the electrode to adjust. Do not interfere with the insulation or the center electrode. 1. Ground electrode 2. Center electrode 3. Insulation 4. Adjustment plate

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MEASUREMENTS

Lecture # 5

MEASUREMENTS Measuring tools

Plasti Gauge
Application
Used for measuring the oil clearance of the areas that are tightened with caps, such as the crankshaft journals and crankshaft pins

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MEASUREMENTS Measuring tools

Plasti Gauge
1. 2. 3. 4. 5. 6. 7. 8. Plastigage Torque wrench The widest portion of the Plastigage Crank shaft Connecting rod bearing Connecting rod cap Connecting rod Oil clearance

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MEASUREMENTS Measuring tools

Plasti Gauge
Plastigage is made of soft plastic, and comes in three colors, each indicating a different thickness Clearance measurement ranges: Green: 0.025 ~ 0.076mm Red: 0.051 ~ 0.152mm Blue: 0.102 ~ 0.229mm

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MEASUREMENTS Measuring tools

Plasti Gauge
Instructions (1) Clean the crankshaft pin and the bearing. (2) Cut the plastigauge sleeve with plastigauge to match the width of the bearing. (3) Place the plastigauge on the crankshaft pin as shown. (4) Place the bearing cap over the crankshaft pin and tighten it at the specified torque. Do not turn the crankshaft.

(5) Remove the bearing cap and use the scale on the plastigauge sleeve to determine the thickness of the flattened plastigauge. Measure the thickness at the widest portion of the plastigauge.

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MEASUREMENTS Measuring tools Multimeter

A multimeter or a multitester, also known as a volt/ohm meter or VOM, is an electronic measuring instrument that combines several measurement functions in one unit.

A typical multimeter may include features such as the ability to measure voltage, current and resistance.

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