05 BYK-Mac Technology

BYK-mac with smart-chart The QC Solution for Effect Coatings

Sandra Weixel, BYK-Gardner GmbH 6th BYK-Gardner User Meeting, Dearborn – April 2011

Page 2, BYK-Gardner GmbH, BYK-mac Presentation

Surface quality

Color Effect

Orange Peel

Gloss Distinctness of Image


Effect Coatings 80% of todays automotive finishes are effect coatings

• Pearlescent coatings result in a more spectacular color effect: Color Flop

• Metallic coatings accentuate the curved profile: Light – Dark Flop

• Effect finishes with special glitter effect (XirallicsTM)

Photo: Courtesy of


Multi-angle Measurement Geometries Aspecular viewing angles


Traditional 5-angle

-120

-80

-40

40

80

120

-120 -80 -40 40 80 120 -a*

-b*

+b*

+a*

New: -15°

Color changes with Viewing Angles

Photos: Courtesy of


Surface quality

Color Effect

Orange Peel

Gloss Distinctness of Image


Visual Effect Judgement

Appearance of effect finishes depends on illumination conditions:

Sunny sky: Direct illumination • Color starts to sparkle

Cloudy sky: Diffused illumination • Fine versus grainy pattern


Visual Appearance of Effect Finishes under diffused lighting

Graininess: Texture – Structure – Coarseness – Salt & Pepper

Viewing conditions: • Diffused light • Close observation distance • Observation angle not important Potential causes of graininess: • Flake type – flake size • Disorientation of flakes • Agglomeration of particles

High Graininess

Low Graininess


Visual Appearance of Effect Finishes under direct illumniation

Sparkle: Micro brightness – Glints – Diamonds Viewing conditions: • Spotlight ~ direct sun light conditions • Observation angle critical:

Sparkle impression changes with illumination angle

Sparkle is generated by e.g.: • Reflectivity of the individual effect

pigment (alu flakes, mica, Xirallics®) • Amount of effect pigments • Size of the aluminum flakes • Flake orientation Sparkle 75°

High Sparkle

Low Sparkle


Flake Characterization Evaluation of the optical properties of effect particles

• Camera Analysis: The spatial resolution of the CCD chip correlates to the spatial resolution of the human eye.

• Camera pictures are taken

under different light conditions to simulate sunny sky and cloudy sky.

• The sparkling impression is

evaluated under 3-illumination angles: 15°- 45°-75°


Camera pictures characterize Sparkle and Graininess


Calculation of Sparkle and Graininess values

Analysis of the histograms

0 2000 4000 6000 8000

10000 12000 14000 16000 18000

1 84 167 250 333 416 499 582 665 748 831 914 997 Sparkle 15° Sparkle 45° Sparkle 75° Graininess

Lightness Grades

Cou

nt


Flake Characterization

Analysis of Sparkle Effect: • Sparkling area is detected Not size of the individual effect pigment

• Sparkling intensity is measured: How strong is the light flash of the effect pigment

• Total Sparkle Grade is determined as a

function of Sparkle area and Sparkle intensity


Analysis of Sparkle Effect

Sparkle Parameters Absolute: • 1-dimensional:

Sparkle Grade • 2-dimensional system:

Sparkle area – Sparkle intensity

Sparkle Grade = f (Sa; Si)

0

3

6

9

12

15

18

21

24

27

0 3 6 9 12 15 18 21 24 27Sparkle area 45°

Spa

rkle

inte

nsity

45°

1 2 3

4 5 6

7 8 9

Sparkle Grade


Analysis of Sparkle Effect

Sparkle Parameters Differences: • 2 -dimensional:

Δ Sparkle area – Δ Sparkle intensity

-3 -2 -1 0 1 2 3

-10 -5 0 5 10

d Sparkle area 15°

d S

park

le in

tens

ity 1

5°

Δ = Sample - Standard

What are visually acceptable tolerances for Sparkle differences?


Sparkle Tolerance Model

0

4

8

12

16

20

24

28

32

0 4 8 12 16 20 24 28 32

Tolerance for Grade: Tol_Gr = +/- 1 Visually the samples look very different within the marked tolerance range.

0

4

8

12

16

20

24

28

32

0 4 8 12 16 20 24 28 32

Tolerance within Grade: Tol_GF x Tol_Gr



Tolerance within Grade > Tol. Grade to Grade

Tol_GF x Tol_Gr = 2 x 1

-12 -10 -8 -6 -4 -2 0 2 4 6 8

10 12

-12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12

Δ S = Total Sparkle Difference

•  2 - dimensional distance to standard

•  Weighted with length of ellipse axis

Tol_S sets tolerance: ΔSparkle < Tol_S PASS ΔSparkle > Tol_S FAIL

2 S_a 2 1

⎥ ⎥ ⎦ ⎤

⎢ ⎢ ⎣ ⎡

+ ⎜ ⎝ ⎛ Δ

= S Δ f(Tol_Gr)

2

⎠ ⎞ ⎟

S_i

⎠ ⎞

⎜ ⎝ ⎛ Δ

f(Tol_GF x Tol_Gr) ⎟



d Sparkle area 45°

d S

park

le in

tens

ity 4

5°

Tol_Grade = 1 Tol_GF = 2

-12 -10 -8 -6 -4 -2 0 2 4 6 8

10 12

-12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12

ΔS = 1.07 ΔS = 0.66

Tol_S = 1

Tol_Grade = 1 Tol_GF = 2 Tol_S = 2

-12 -10 -8 -6 -4 -2 0 2 4 6 8

10 12

-12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12

ΔS = 1.07 ΔS = 0.66

Tol_Grade = 1 Tol_GF = 3 Tol_S = 1

-12 -10 -8 -6 -4 -2 0 2 4 6 8

10 12

-12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12

ΔS = 0.72 ΔS = 0.63


Flake Characterization

Analysis of Graininess Effect: • Uniformity of light/dark areas is

evaluated and summarized in a Graininess value

fine

grainy

4

8

2

6

12

10

15

14

0

• 1-dimensional scale: relative dimension

• Solid color (very uniform)

Graininess = 0

Page 20, BYK-Gardner GmbH, BYK-mac Presentation Page 20, BYK-Gardner GmbH, BYK-mac Presentation

Automotive - Exterior: Challenges

•  Different people have different views on what is acceptable: Paint shop <> QC department Customer <> Supplier

•  You cannot control what you can’t measure! •  Predictability: What happens if I change something?

•  Reliability: Supplier quality needs to be compared against objective criteria to determine PASS – FAIL

Standardized Quality Management is needed:

Figures and facts instead of feelings


Goals:   Complete solution: BYK-mac – wave-scan – cloud-runner

  Comprehensive „Standard Management General & customer specific color, appearance, mottling scales Definition of tolerances and limits

  Organizer definitions: Sample identification for data filtering

  Easy to use „Data Analysis Traffic light function in QC reports Process control charts

New smart-chart Software


NEW smart-chart Software QC management system for color & appearance


smart-chart Software: Standard Management

Define tolerances and limits

Define color families with common settings: ΔE equation, geometry, statistic

Set measurement geometries

Set Color difference method: dEc -- dEp


smart-chart Software: Standard Management

Define effect tolerances / limits

Set effect geometries


Color Measurement in Practice: Digital Standard

Design Master

Production of Working

Standards

“Master Master” standard is determined

Working Standards for visual control

“Master Master” is measured with

“Master BYK-mac”

Digital Master is distributed to supply

chain using smart-chart

No more limitations: Auto OEM maker & suppliers use same reference on a global basis


New BYK-mac - Economical and Reliable Advanced LED Technology

Excellent long-term repeatability: •  Stable, long term calibration – needed only every three months White tile: 500 readings – interval 60 seconds

ΔL*

-0.10 -0.05 0.00 0.05 0.10

1 101 201 301 401 -15 15° 25° 45° 75° 110°

Δa*

-0.10 -0.05 0.00 0.05 0.10

1 101 201 301 401

Δb*

-0.10 -0.05 0.00 0.05 0.10

1 101 201 301 401


New BYK-mac - Economical and Reliable Advanced LED Technology

Excellent temperature stability: Cyan Standard •  Temperature independent measurement results between 10 – 40°C

without calibration

ΔL*

-0.40 -0.20 0.00 0.20 0.40 0.60 0.80

10°C 20°C 30°C 40°C -15° 15° 25° 45° 75° 110°

Δa*

-0.40 -0.20 0.00 0.20 0.40 0.60 0.80

10°C 20°C 30°C 40°C

Δb*

-0.40 -0.20 0.00 0.20 0.40 0.60 0.80

10°C 20°C 30°C 40°C


BYK-mac inter-instrument agreement

100

0

L*

50

green beige black metallic white yellow green bright silver bright red solid blue dark red steel gray metallic dark silver green yellow yellow blue violet metallic

14 Colors: 6 panels per color – 6 readings per panel 2 BYK-mac

Test performed manually – Operator Influence


BYK-mac inter-instrument agreement Delta – Delta comparison: 15° and 25°angle

ΔL* Δb* Δa*

-1

-0,8

-0,6

-0,4

-0,2

0

0,2

0,4

0,6

0,8

1

-2,5 -1,5 -0,5 0,5 1,5 2,5

Δ BYK-mac

Δ B

YK-m

ac1

- Δ B

YK-m

ac2

-2

-1,5

-1

-0,5

0

0,5

1

1,5

2

-5 -3 -1 1 3 5

Δ BYK-mac

Δ B

YK-m

ac1

- Δ B

YK-m

ac2

-1

-0,8

-0,6

-0,4

-0,2

0

0,2

0,4

0,6

0,8

1

-2,5 -1,5 -0,5 0,5 1,5 2,5

Δ BYK-mac

Δ B

YK-m

ac1

- Δ B

YK-m

ac2

-2

-1,5

-1

-0,5

0

0,5

1

1,5

2

-5 -3 -1 1 3 5

Δ BYK-mac

Δ -

BYK-

mac

1- Δ

BYK

-mac

2

-1

-0,8

-0,6

-0,4

-0,2

0

0,2

0,4

0,6

0,8

1

-2,5 -1,5 -0,5 0,5 1,5 2,5

Δ BYK-mac

Δ B

YK-m

ac1

- Δ B

YK-m

ac2

-1

-0,8

-0,6

-0,4

-0,2

0

0,2

0,4

0,6

0,8

1

-2,5 -1,5 -0,5 0,5 1,5 2,5

Δ BYK-mac

Δ B

YK-m

ac1

- Δ B

YK-m

ac2

15°

25°


BYK-mac inter-instrument agreement Delta – Delta comparison: 45° angle

-2

-1,5

-1

-0,5

0

0,5

1

1,5

2

-5 -3 -1 1 3 5

Δ BYK-mac

Δ B

YK-m

ac1

- Δ B

YK-m

ac2

-1

-0,8

-0,6

-0,4

-0,2

0

0,2

0,4

0,6

0,8

1

-2,5 -1,5 -0,5 0,5 1,5 2,5

Δ BYK-mac

Δ B

YK-m

ac1

- Δ B

YK-m

ac2

-1

-0,8

-0,6

-0,4

-0,2

0

0,2

0,4

0,6

0,8

1

-2,5 -1,5 -0,5 0,5 1,5 2,5

Δ BYK-mac

Δ B

YK-m

ac1

- Δ B

YK-m

ac2

ΔL* Δb* Δa* 45°


BYK-mac inter-instrument agreement Delta – Delta comparison: 75° and 110° angle

-2

-1,5

-1

-0,5

0

0,5

1

1,5

2

-5 -3 -1 1 3 5

Δ BYK-mac

Δ B

YK-m

ac1

- Δ B

YK-m

ac2

-1

-0,8

-0,6

-0,4

-0,2

0

0,2

0,4

0,6

0,8

1

-2,5 -1,5 -0,5 0,5 1,5 2,5

Δ BYK-mac

Δ B

YK-m

ac - Δ

BYK

-mac

2-1

-0,8

-0,6

-0,4

-0,2

0

0,2

0,4

0,6

0,8

1

-2,5 -1,5 -0,5 0,5 1,5 2,5

Δ BYK-mac

Δ B

YK-m

ac1

- Δ B

YK-m

ac2

ΔL* Δb* Δa*

-2

-1,5

-1

-0,5

0

0,5

1

1,5

2

-5 -3 -1 1 3 5

Δ BYK-mac

Δ B

YK-m

ac1

- Δ B

YK-m

ac2

-1

-0,8

-0,6

-0,4

-0,2

0

0,2

0,4

0,6

0,8

1

-2,5 -1,5 -0,5 0,5 1,5 2,5

Δ BYK-mac

Δ B

YK-m

ac1

- Δ B

YK-m

ac2

-1

-0,8

-0,6

-0,4

-0,2

0

0,2

0,4

0,6

0,8

1

-2,5 -1,5 -0,5 0,5 1,5 2,5

Δ BYK-mac

Δ B

YK-m

ac1

- Δ B

YK-m

ac2

75°

110°


Key for standardized color managment

smart-chart Software: Digital Standard


NEW smart-chart Software for BYK-mac, wave-scan Family, cloud-runner


smart-chart Software: Organizer

Clear sample identification: Par 1: Models Par 2: Colors Par 3: Paint Booths


smart-chart Software: Organizer for BYK-mac

Menu guided operation:

Car schematics help to define sampling procedure


smart-chart Software: Organizer for BYK-mac Example: Color Harmony test procedure

•  Checkzone creation

•  Curvature per checkzone

•  Number of readings per checkzone

•  Definition of “Panel Matches”


NEW smart-chart Software for BYK-mac, wave-scan Family, cloud-runner

3 4


smart-chart Software: Data Analysis for BYK-mac

•  Filter database by: Status – Date – Model – Color – Paintline – Instrument

•  Click on “Refresh” List of all measured vehicles which “failed”

•  Click on individual vehicle for detailed report


smart-chart Software: Data Analysis for BYK-mac Single Car Analysis

•  Car schematic with traffic light symbols

•  Panel match with Pass/ Fail analysis

•  Match to standard with Pass/Fail

Documents

05 BYK-Mac Technology