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BYK-mac with smart-chartThe QC Solution for Effect Coatings
Sandra Weixel, BYK-Gardner GmbH
9th BYK-Gardner User Meeting, Bad Tölz, Germany - November 2010
Page 2, BYK-Gardner GmbH, BYK-mac Presentation
Surface quality
Color
EffectOrange Peel
Gloss
Distinctness of Image
Page 3, BYK-Gardner GmbH, BYK-mac Presentation
Effect Coatings80% of todays automotive finishes are effect coatings
• Pearlescent coatings result in amore spectacular color effect:Color Flop
• Metallic coatingsaccentuate the curvedprofile: Light – Dark Flop
• Effect finishes with special glitter effect(XirallicsTM)
Photo: Courtesy of
Page 4, BYK-Gardner GmbH, BYK-mac Presentation
Multi-angle Measurement GeometriesAspecular viewing angles
Page 5, BYK-Gardner GmbH, BYK-mac Presentation
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
Page 6, BYK-Gardner GmbH, BYK-mac Presentation
Surface quality
Color
EffectOrange Peel
Gloss
Distinctness of Image
Page 7, BYK-Gardner GmbH, BYK-mac Presentation
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
Page 8, BYK-Gardner GmbH, BYK-mac Presentation
Visual Appearance of Effect Finishesunder 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
Page 9, BYK-Gardner GmbH, BYK-mac Presentation
Visual Appearance of Effect Finishesunder 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
Page 10, BYK-Gardner GmbH, BYK-mac Presentation
Flake CharacterizationEvaluation of the optical properties of effect particles
• Camera Analysis:The spatial resolution of the CCD chip correlates to the spatialresolution 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°
Page 12, BYK-Gardner GmbH, BYK-mac Presentation
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
Co
un
t
Page 13, BYK-Gardner GmbH, BYK-mac Presentation
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 afunction of Sparkle area and Sparkleintensity
Page 14, 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)
0
3
6
9
12
15
18
21
24
27
0 3 6 9 12 15 18 21 24 27Sparkle area 45°
Spark
le inte
nsity 4
5°
1
23
4
5
6
7
89
Sparkle Grade
Page 15, BYK-Gardner GmbH, BYK-mac Presentation
Analysis of Sparkle Effect
Sparkle Parameters Differences:
• 2 -dimensional:
Sparkle area – Sparkle intensity
-3
-2
-1
0
1
2
3
-10 -5 0 5 10
d Sparkle area 15°
d S
park
le inte
nsity 1
5°
= Sample - Standard
What are visually acceptable tolerances for Sparkle differences?
Page 16, BYK-Gardner GmbH, BYK-mac Presentation
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
Page 17, BYK-Gardner GmbH, BYK-mac Presentation
Sparkle Tolerance Model
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
S = Total Sparkle Difference
• 2 - dimensional distance to standard
• Weighted with length of ellipse axis
Tol_S sets tolerance: Sparkle < Tol_S PASS
Sparkle > Tol_S FAIL
2S_a21
+=Sf(Tol_Gr)
2 S_i
f(Tol_GF x Tol_Gr)
Page 18, BYK-Gardner GmbH, BYK-mac Presentation
Sparkle Tolerance Model
d Sparkle area 45°
d S
park
le inte
nsity 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
S = 1.07
S = 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
S = 1.07
S = 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
S = 0.72
S = 0.63
Page 19, BYK-Gardner GmbH, BYK-mac Presentation
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
NEW smart-chart Softwarefor BYK-mac, wave-scan Family, cloud-runner
Page 21, BYK-Gardner GmbH, BYK-mac Presentation
smart-chart Software: Standard Management
Define tolerances and limits
Define color families with
common settings:E equation, geometry, statistic
Set measurement geometries
Set Color difference method:
dEc -- dEp
Page 22, BYK-Gardner GmbH, BYK-mac Presentation
smart-chart Software: Standard Management
Define effect tolerances / limits
Set effect geometries
Page 23, BYK-Gardner GmbH, BYK-mac Presentation
NEW smart-chart Softwarefor BYK-mac, wave-scan Family, cloud-runner
Page 24, BYK-Gardner GmbH, BYK-mac Presentation
smart-chart Software: Organizer
Clear sample identification:
Par 1: Models
Par 2: Colors
Par 3: Paint Booths
Page 25, BYK-Gardner GmbH, BYK-mac Presentation
smart-chart Software: Organizer for BYK-mac
Menu guided operation:
Car schematics help to define sampling
procedure
Page 26, BYK-Gardner GmbH, BYK-mac Presentation
smart-chart Software: Organizer for BYK-macExample: Color Harmony test procedure
• Checkzone creation
• Curvature per checkzone
• Number of readings per checkzone
• Definition of “Panel Matches”
Page 27, BYK-Gardner GmbH, BYK-mac Presentation
NEW smart-chart Softwarefor BYK-mac, wave-scan Family, cloud-runner
3 4
Page 28, BYK-Gardner GmbH, BYK-mac Presentation
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
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