new structure space with balance chart analysis

1

New Structure Space with Balance Chart Analysis

BYK-Gardner GmbH, User Meeting 2010

Page 2, BYK-Gardner GmbH, Appearance of Automotive Finishes

Uniform Appearance = High Quality

Various substrates andcoating technologies

Stable process to guarantee

quality over time

Body vs Add-on parts

Online/off line painting

A real A real challenge

challenge

2


Appearance is influenced by ...

Waviness - Orange Peel

Brilliance - DOI


Focus on reflected Image

Gloss / Brilliance

Appearance Perception

Focus on Surface

Structures / Waves

3


wavy light / darkpattern

Visual Perception of Orange Peel


One sample SW: 17

40 cm 3 m

LW: 6

Appearance changes with Observing Distance

4


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3 m

ABCDEFGHIBCDEFGHIJCDEFGHIJKDEFGHIJKLEFGHIJKLMFGHIJKLMN

40 cm

Appearance changes with Observing Distance


wavelength (mm)

3m3m

0.1 1 10 1003030.3< 0.1

40cm40cm

20

40

60

80

100

Resolution of the human eye

Visibility of Structures

5


Optical Profile

scanning 10 cm

Laser

wave-scan: Measurement Principle


Optical Profile

0.1 mm 30 mm

Mathematical Filters

Expanded Range

LW splitted

Higher Resolution

Measurement Principle: wave-scan DOI

6


LW

0.1 1 10

wavelength

SW

3 300.3 mm

Classical scales:

Wa Wb Wc Wd We

Wavelength ranges - new separation into 5 ranges


Sample C

Sample D

0

5

10

15

20

25

1 - 3 3 - 10 10 - 300.3-10.1-0.3

wavelength (mm)

LW 7LW 12

Wc Wd WeWbWa

Structure - Spectrum

7


Appearance is influenced by ...

Contrast

Sharpness

Distinctness

Waviness + DOI


Good Poor

Contrast - Sharpness - Distinctness

What is DOI ?

8


Light scattering cause a contrast reduction

Small structures cause a distortionof outlines

20

40

60

80

100

1 10 1003030.3< 0.1 0.1

Influence of structure on DOI


Camera

20°

Scatter value

Scattering caused by structures < 0.1mm

Max= dullness

Measurement of light scattering (< 0.1 mm)

9


Independent of paintmaterial

Refractive index1.541.521.51 1.531.50

5

10

15

20

1 K 2 K du

Works on curvedsurfaces

flat curved

Dullness


< 0.1

dullness

0

5

10

15

20

25

1 - 3 3 - 10 10 - 300.3-10.1-0.3 mm

Wa Wb Wc Wd We

Complete Structure Spectrum

10


< 0.1

dullness

0

5

10

15

20

25

1 - 3 3 - 10 10 - 300.3-10.1-0.3 mm

Wa Wb Wc Wd We

Distinctness Of Image

91

84

DOI = f (du, Wa, Wb)


ProcessParameters

Substrate Quality

Paint Materials

•QC tool to document appearance and recognize changes early

•Measurement results help to improve quality

wave-scan - more than just an “Instrument“

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horizontalvertical

0

4

8

12

16

20

0.1-0.3Wa

0.3-1Wb

1- 3 Wc

3-10Wd

10-30We

< 0.1du

0

20

40

60

80

100

DOI

BYK

Influence of baking position on appearance


0

10

20

30

40

du <0.1 Wa 0.1-0.3 Wb 0.3-1 Wc 1-3 Wd 3-10 We 30-10 mm

16 µm

24 µm

30 µm

50 µm

2K Clearcoat

Influence of clear coat film build on appearance

12


5

10

15

20

5 10 15 20

0

Longwave

Hood

Sh

ort

wav

e

Flash-off:

9 min.

3 min.Door

Influence of flash-off time on appearance


< 0.1 1 - 3 3 - 10 10 - 300.3-10.1-0.3 mmdullness Wa Wb Wc Wd We

0

10

20

30

40

50

60

70

80

on smooth steel

on rough steel

Topcoat

Topcoat result on rough and smooth steel

< 0.1 1 - 3 3 - 10 10 - 300.3-10.1-0.3 mmdullness Wa Wb Wc Wd We

0

10

20

30

40

50

Topcoat

Significant Difference in Short Waves

Influence of steel quality on final appearance

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Topcoat on rough steel:SW dominates visual

Topcoat on smooth steelAppears smooth

Topcoat appearance observed at 40cm distance


Original: High Waviness

0

10

20

30

40

50

60

<0.1 0.1-0.3 0.3-1.0 1-3 3-10 10-30

0

10

20

30

40

50

60

<0.1 0.1-0.3 0.3-1.0 1-3 3-10 10-30

1. Step: Optimize CC Application

Improve appearance

14


0

10

20

30

40

50

60

<0.1 0.1-0.3 0.3-1.0 1-3 3-10 10-30

1.Step: Optimized Clear coat

2. Step: Sanding of primer

0

10

20

30

40

50

60

<0.1 0.1-0.3 0.3-1.0 1-3 3-10 10-30

Improve appearance


2. Step: Sanding of primer

0

10

20

30

40

50

60

<0.1 0.1-0.3 0.3-1.0 1-3 3-10 10-30

3. Step: Optimized primer / topcoat application

0

10

20

30

40

50

60

<0.1 0.1-0.3 0.3-1.0 1-3 3-10 10-30

Improve appearance

15


0

5

10

15

20

25

30

35

40

45

50

du Wa Wb Wc Wd We

Wd = 40 ; Wb = 41.9

Wd = 32 ; Wb = 37.9

Wd = 24 ; Wb = 33.4

Wd = 16 ; Wb = 28

Wd = 8 ; Wb = 21

Wd = 4 ; Wb = 16

Wd = 2 ; Wb = 12.5

Wd = 1 ; Wb = 10

Well Balanced Structure Spectrums developed by Orange Peel Workgroup


Well balanced ratio of “Wd”and “Wb”

4*6 += dbo WW Experimental Result:

•Wb minimum = 10

•Wb –Wd relation =

•BMW experience with N 1m

•Visual evaluation

dW*6

bo

bob

W

WWB

−= *10

16


Balance Chart - The Easy Way

for comprehensive and clear data visualisation

0

5

10

15

20

25

30

35

40

-10 -5 0 5 10

Balance B

Wa

vin

ess

Wd

less short waveslong waves get dominant

more short wavesshort waves get dominant

well balanced


0

5

10

15

20

25

30

35

40

45

-10 -8 -6 -4 -2 0 2 4 6 8 10B - Structure Balance

Wd

- W

av

ine

ss

0

5

10

15

20

25

30

35

40

45

-10 -8 -6 -4 -2 0 2 4 6 8 10B - Structure Balance

Wd

- W

avin

es

s

Balance Chart - The Easy Way

for comprehensive and clear data visualisation

17


0

5

10

15

20

25

30

35

40

du Wa Wb Wc Wd We

DL & rauh

neutral

neutral

DL & gla tt

Data InterpretationHow are the balance?

dominante short waves

0

5

10

15

20

25

30

35

40

-10 -5 0 5 10

Balance B

Wa

vin

ess

Wd


0

5

10

15

20

25

30

35

-10 -5 0 5 10

B - Structure Balance

Wd

- W

av

ines

s

Standard Prozess

FüllerloserProzess

Different paint process

conventional versus short paint process

Shortprocess

conventionalprocess

18


Prozess Control with Balance ChartOverview: All colors meet the specs (in average)


How stabil runs silber metallic?Compare car by car è normal variation

19


How stabil runs silber metallic?Check uniformity è very uniform within carbody


How stabil runs red solid?Compare car by car è significant variation on verticals

sandingline stop

20


How stabil runs red solid?Check uniformity è non uniform on verticals

New Structure Space with Balance Chart Analysis

BYK-Gardner GmbH, User Meeting 2010

new structure space with balance chart analysis

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