New Structure Space with Balance Chart Analysis
Transcript of New Structure Space with Balance Chart Analysis
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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
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Page 3, BYK-Gardner GmbH, Appearance of Automotive Finishes
Appearance is influenced by ...
Waviness - Orange Peel
Brilliance - DOI
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Focus on reflected Image
Gloss / Brilliance
Appearance Perception
Focus on Surface
Structures / Waves
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Page 5, BYK-Gardner GmbH, Appearance of Automotive Finishes
wavy light / darkpattern
Visual Perception of Orange Peel
Page 6, BYK-Gardner GmbH, Appearance of Automotive Finishes
One sample SW: 17
40 cm 3 m
LW: 6
Appearance changes with Observing Distance
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Page 7, BYK-Gardner GmbH, Appearance of Automotive Finishes
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3 m
ABCDEFGHIBCDEFGHIJCDEFGHIJKDEFGHIJKLEFGHIJKLMFGHIJKLMN
40 cm
Appearance changes with Observing Distance
Page 8, BYK-Gardner GmbH, Appearance of Automotive Finishes
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
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Optical Profile
scanning 10 cm
Laser
wave-scan: Measurement Principle
Page 10, BYK-Gardner GmbH, Appearance of Automotive Finishes
Optical Profile
0.1 mm 30 mm
Mathematical Filters
Expanded Range
LW splitted
Higher Resolution
Measurement Principle: wave-scan DOI
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Page 11, BYK-Gardner GmbH, Appearance of Automotive Finishes
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
Page 12, BYK-Gardner GmbH, Appearance of Automotive Finishes
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
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Appearance is influenced by ...
Contrast
Sharpness
Distinctness
Waviness + DOI
Page 14, BYK-Gardner GmbH, Appearance of Automotive Finishes
Good Poor
Contrast - Sharpness - Distinctness
What is DOI ?
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Page 15, BYK-Gardner GmbH, Appearance of Automotive Finishes
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
Page 16, BYK-Gardner GmbH, Appearance of Automotive Finishes
Camera
20°
Scatter value
Scattering caused by structures < 0.1mm
Max= dullness
Measurement of light scattering (< 0.1 mm)
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Page 17, BYK-Gardner GmbH, Appearance of Automotive Finishes
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
Page 18, BYK-Gardner GmbH, Appearance of Automotive Finishes
< 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
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Page 19, BYK-Gardner GmbH, Appearance of Automotive Finishes
< 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)
Page 20, BYK-Gardner GmbH, Appearance of Automotive Finishes
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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Page 21, BYK-Gardner GmbH, Appearance of Automotive Finishes
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
Page 22, BYK-Gardner GmbH, Appearance of Automotive Finishes
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
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Page 23, BYK-Gardner GmbH, Appearance of Automotive Finishes
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
Page 24, BYK-Gardner GmbH, Appearance of Automotive Finishes
< 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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Page 25, BYK-Gardner GmbH, Appearance of Automotive Finishes
Topcoat on rough steel:SW dominates visual
Topcoat on smooth steelAppears smooth
Topcoat appearance observed at 40cm distance
Page 26, BYK-Gardner GmbH, Appearance of Automotive Finishes
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
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Page 27, BYK-Gardner GmbH, Appearance of Automotive Finishes
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
Page 28, BYK-Gardner GmbH, Appearance of Automotive Finishes
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
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Page 29, BYK-Gardner GmbH, Appearance of Automotive Finishes
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
Page 30, BYK-Gardner GmbH, Appearance of Automotive Finishes
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
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Page 31, BYK-Gardner GmbH, Appearance of Automotive Finishes
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
Page 32, BYK-Gardner GmbH, Appearance of Automotive Finishes
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
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Page 33, BYK-Gardner GmbH, Appearance of Automotive Finishes
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
Page 34, BYK-Gardner GmbH, Appearance of Automotive Finishes
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
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Page 35, BYK-Gardner GmbH, Appearance of Automotive Finishes
Prozess Control with Balance ChartOverview: All colors meet the specs (in average)
Page 36, BYK-Gardner GmbH, Appearance of Automotive Finishes
How stabil runs silber metallic?Compare car by car è normal variation
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Page 37, BYK-Gardner GmbH, Appearance of Automotive Finishes
How stabil runs silber metallic?Check uniformity è very uniform within carbody
Page 38, BYK-Gardner GmbH, Appearance of Automotive Finishes
How stabil runs red solid?Compare car by car è significant variation on verticals
sandingline stop