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
Surface quality
Gloss Distinctness of Image Orange Peel
Color Effect
Page 2, BYK-Gardner GmbH, BYK-mac Presentation
Effect Coatings 80% of todays automotive finishes are effect coatings
Metallic coatings accentuate the curved profile: Light Dark Flop Pearlescent coatings result in a more spectacular color effect: Color Flop
Effect finishes with special glitter effect (Xirallics )

TM
Photo: Courtesy of
Multi-angle Measurement Geometries Aspecular viewing angles
Color changes with Viewing Angles

+b*
120 80
40
-a*
-120
-80
-40 -40
40
80 New: -15
120
+a*
-80 -120
-b*
Traditional 5-angle Photos: Courtesy of
Surface quality
Gloss Distinctness of Image Orange Peel
Color Effect
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

18000 16000 14000 12000
Count
10000 8000 6000 4000 2000 0 1 84 167 250 333 416 499 582 665 748 831 914 997 Sparkle 15 Sparkle 45 Sparkle 75 Graininess
Lightness Grades
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

Sparkle intensity 45
27 24 21 18 15 12 9 6 3 0 0 3 6 9 12 15 18 21 24 27 Sparkle area 45
2-dimensional system: Sparkle area Sparkle intensity
Sparkle Grade = f (Sa; Si)
Sparkle Grade
1 2 3
4 5 6
7 8 9
Analysis of Sparkle Effect
d Sparkle intensity 15
Sparkle Parameters Differences: 2 -dimensional: Sparkle area Sparkle intensity = Sample - Standard
-10
-5
10
-1
-2
-3
d Sparkle area 15
What are visually acceptable tolerances for Sparkle differences?
Sparkle Tolerance Model

32 28 24 20 16 12 8 4 0 0 4 8 12 16 20 24 28 32 32 28 24 20 16 12 8 4 0 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.
Tolerance within Grade: Tol_GF x Tol_Gr

Tolerance within Grade > Tol. Grade to Grade
12 10 8 6 4 2 0 -12 -10 -8 -6 -4 -2 -2 -4 -6 -8 -10 -12 0 2 4 6 8 10 12
S = Total Sparkle Difference

2 S_i S_a 2 = f(Tol_Gr) + f(Tol_GF x Tol_Gr) 12
2 - dimensional distance to standard Weighted with length of ellipse axis
Tol_GF x Tol_Gr = 2 x 1
Tol_S sets tolerance:
Sparkle < Tol_S Sparkle > Tol_S
PASS FAIL

12 10 8
12
12 10 8 6 4 2 0
0 2 4 6 8 10 12
10 8
d Sparkle intensity 45
6 4 2 0 -12 -10 -8 -6 -4 -2 -2 -4 -6 -8 -10 -12 0 2 4 6 8 10 12

-12 -10 -8 -6 -4 -2
6 4
2 0
-12
-10
-8
-6
-4
-2 -2 -4 -6 -8 -10 -12
10
12
-2 -4
-6 -8
-10 -12
d Sparkle area 45
Tol_Grade = 1 Tol_GF = 2 Tol_S = 1 S = 1.07 S = 0.66
Flake Characterization
Analysis of Graininess Effect: Uniformity of light/dark areas is evaluated and summarized in a Graininess value 1-dimensional scale: relative dimension Solid color (very uniform) Graininess = 0
15 14 12 10 8 6 4 2 0
grainy
fine
Automotive - Exterior: Challenges Standardized Quality Management is needed:

Different people have different views on what is acceptable: Paint shop <> QC department Customer <> Supplier You cannot control what you cant measure! Predictability: What happens if I change something? Reliability: Supplier quality needs to be compared against objective criteria to determine PASS FAIL
Figures and facts instead of feelings

New smart-chart Software
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
QC management system for color & appearance
smart-chart Software: Standard Management
Set Color difference method: dEc -- dEp Set measurement geometries Define tolerances and limits Define color families with common settings:
E equation, geometry, statistic
smart-chart Software: Standard Management
Set effect geometries
Define effect tolerances / limits
Color Measurement in Practice: Digital Standard
Design Master
Production of Working Standards
Master Master standard is determined
Master Master is measured with Master BYK-mac
Working Standards for visual control
No more limitations: Auto OEM maker & suppliers use same reference on a global basis
Digital Master is distributed to supply chain using smart-chart
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
0.10 L* 0.05 0.00 -0.05 -0.10 1 101 201 301 401 -15 15 25 45 75 110
0.10 a* 0.05 0.00 -0.05 -0.10 1 101 201 301 401
0.10 b* 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 40C without calibration
0.80 0.60 0.40 0.20 0.00 10C -0.20 -0.40 0.80 0.60 0.40 0.20 0.00 10C -0.20 -0.40 20C 30C 40C 0.80 0.60 0.40 0.20 0.00 -0.20 -0.40 10C 20C 30C 40C 20C 30C 40C -15 15 25 45 75 110
L*
a*
b*
BYK-mac inter-instrument agreement

14 Colors: 6 panels per color 6 readings per panel 2 BYK-mac Test performed manually Operator Influence
100 L* 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
50
BYK-mac inter-instrument agreement Delta Delta comparison: 15 and 25angle

L*
- BYK-mac1- BYK-mac2
a*
2 1,5 1 0,8
b*
1 0,8 0,6 0,4 0,2
15
BYK-mac1 - BYK-mac2
BYK-mac1 - BYK-mac2
1 0,5 0 -5 -3 -1 -0,5 -1 -1,5 -2 2 BYK-m ac 1 3 5
0,6 0,4 0,2 -2,5 -1,5 0 -0,5 -0,2 -0,4 -0,6 -0,8 -1 1 BYK-m ac 0,8 0,5 1,5 2,5
-2,5
-1,5
0 -0,5 -0,2 -0,4 -0,6 -0,8
0,5
1,5
2,5
BYK-mac1 - BYK-mac2
BYK-mac1 - BYK-mac2
BYK-mac1 - BYK-mac2
1,5 1 0,5 0 -5 -3 -1 -0,5 -1 -1,5 -2 BYK-m ac 1 3 5
-1 1 BYK-m ac 0,8 0,6 0,4 0,2 -2,5 -1,5 0 -0,5 -0,2 -0,4 -0,6 -0,8 -1 BYK-m ac 0,5 1,5 2,5
25
0,6 0,4 0,2 -2,5 -1,5 0 -0,5 -0,2 -0,4 -0,6 -0,8 -1 BYK-m ac 0,5 1,5 2,5
BYK-mac inter-instrument agreement Delta Delta comparison: 45 angle

L*
2
a*
1 0,8
b*
1 0,8 0,6 0,4 0,2
45
BYK-mac1 - BYK-mac2
BYK-mac1 - BYK-mac2
1,5 1 0,5 0 -5 -3 -1 -0,5 -1 -1,5 -2 BYK-m ac 1 3 5
BYK-mac1 - BYK-mac2
0,6 0,4 0,2 -2,5 -1,5 0 -0,5 -0,2 -0,4 -0,6 -0,8 -1 BYK-m ac 0,5 1,5 2,5
-2,5
-1,5
0 -0,5 -0,2 -0,4 -0,6 -0,8 -1
0,5
1,5
2,5
BYK-m ac
BYK-mac inter-instrument agreement Delta Delta comparison: 75 and 110 angle

L*
2 1,5
a*
1 0,8
b*
1 0,8
75
BYK-mac1 - BYK-mac2
BYK-mac1 - BYK-mac2
1 0,5 0 -5 -3 -1 -0,5 -1 -1,5 -2 2 BYK-m ac 1 3 5
BYK-mac - BYK-mac2
0,6 0,4 0,2 -2,5 -1,5 0 -0,5 -0,2 -0,4 -0,6 -0,8 -1 1 BYK-m ac 0,8 0,5 1,5 2,5
0,6 0,4 0,2 -2,5 -1,5 0 -0,5 -0,2 -0,4 -0,6 -0,8 -1 1 BYK-m ac 0,8 0,5 1,5 2,5
110
BYK-mac1 - BYK-mac2
BYK-mac1 - BYK-mac2
1,5
BYK-mac1 - BYK-mac2
0,6 0,4 0,2 -2,5 -1,5 0 -0,5 -0,2 -0,4 -0,6 -0,8 -1 BYK-m ac 0,5 1,5 2,5
0,6 0,4 0,2 -2,5 -1,5 0 -0,5 -0,2 -0,4 -0,6 -0,8 -1 BYK-m ac 0,5 1,5 2,5
1 0,5 0 -1 -0,5 -1 -1,5 -2 BYK-m ac
-5
-3
smart-chart Software: Digital Standard

Key for standardized color managment
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
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

05 BYK-Mac Technology

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05 BYK-Mac Technology

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

Gloss Distinctness of Image Orange Peel

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

Effect Coatings 80% of todays automotive finishes are effect coatings

Effect finishes with special glitter effect (Xirallics )

Multi-angle Measurement Geometries Aspecular viewing angles

Page 4, BYK-Gardner GmbH, BYK-mac Presentation

Color changes with Viewing Angles

Page 5, BYK-Gardner GmbH, BYK-mac Presentation

Gloss Distinctness of Image Orange Peel

Page 6, BYK-Gardner GmbH, BYK-mac Presentation

Visual Effect Judgement

Cloudy sky: Diffused illumination Fine versus grainy pattern

Page 7, BYK-Gardner GmbH, BYK-mac Presentation

Flake Characterization Evaluation of the optical properties of effect particles

Page 10, BYK-Gardner GmbH, BYK-mac Presentation

Camera pictures characterize Sparkle and Graininess

Page 11, BYK-Gardner GmbH, BYK-mac Presentation

Calculation of Sparkle and Graininess values

Analysis of the histograms

Page 12, BYK-Gardner GmbH, BYK-mac Presentation

Analysis of Sparkle Effect

Sparkle Parameters Absolute: 1-dimensional: Sparkle Grade

2-dimensional system: Sparkle area Sparkle intensity

Sparkle Grade = f (Sa; Si)

Page 14, BYK-Gardner GmbH, BYK-mac Presentation

Analysis of Sparkle Effect

What are visually acceptable tolerances for Sparkle differences?

Page 15, BYK-Gardner GmbH, BYK-mac Presentation

Sparkle Tolerance Model

Tolerance within Grade: Tol_GF x Tol_Gr

Page 16, BYK-Gardner GmbH, BYK-mac Presentation

Sparkle Tolerance Model

S = Total Sparkle Difference

2 - dimensional distance to standard Weighted with length of ellipse axis

Tol_S sets tolerance:

Sparkle < Tol_S Sparkle > Tol_S

Page 17, BYK-Gardner GmbH, BYK-mac Presentation

Sparkle Tolerance Model

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

Tol_Grade = 1 Tol_GF = 2 Tol_S = 1 S = 1.07 S = 0.66

Tol_Grade = 1 Tol_GF = 2 Tol_S = 2 S = 1.07 S = 0.66

Tol_Grade = 1 Tol_GF = 3 Tol_S = 1 S = 0.72 S = 0.63

Page 18, BYK-Gardner GmbH, BYK-mac Presentation

Page 19, BYK-Gardner GmbH, BYK-mac Presentation

Automotive - Exterior: Challenges Standardized Quality Management is needed:

Figures and facts instead of feelings

New smart-chart Software

Page 21, BYK-Gardner GmbH, BYK-mac Presentation

NEW smart-chart Software

QC management system for color & appearance

Page 22, BYK-Gardner GmbH, BYK-mac Presentation

smart-chart Software: Standard Management

Page 23, BYK-Gardner GmbH, BYK-mac Presentation

smart-chart Software: Standard Management

Set effect geometries

Define effect tolerances / limits

Page 24, BYK-Gardner GmbH, BYK-mac Presentation

Color Measurement in Practice: Digital Standard

Production of Working Standards

Master Master standard is determined

Master Master is measured with Master BYK-mac

Working Standards for visual control

Digital Master is distributed to supply chain using smart-chart