汽车表面外观控制

1、Start汽车涂层的表面外观汽车涂层的表面外观统一和谐的外观统一和谐的外观 = 质量质量水平区域水平区域垂直区域垂直区域加装部件加装部件Uniform Quality桔桔皮仪皮仪 DOI汽车汽车工业表面外观的标准工业表面外观的标准 wave-scan DOI 微型桔皮仪微型桔皮仪micro-wave-scan在现场作不同型号车之间的比较加装部件的涂装工艺控制整车质保中检查各部位间的一致性可解决小面积部件和弯曲面上的测量问题聚聚焦在表面焦在表面长长波波短波短波聚聚焦在反射影像焦在反射影像雾雾影影光泽光泽鲜鲜映性映性全面全面外观外观成成像质量像质量波波纹，桔皮纹，桔皮波波纹纹 桔桔皮皮明亮明亮度度

2、 - DOIApp. influenced by.表面表面外观受影响于外观受影响于 .聚焦在表面聚焦在表面表面结构表面结构 / 波纹波纹聚焦于反射影像聚焦于反射影像光泽光泽 / 明亮度明亮度表面表面外观的视觉感受外观的视觉感受 Focal Plane桔桔皮的视觉感受皮的视觉感受波纹波纹 亮亮/暗暗 模式模式 wavy pattern长长波波短短波波 Structure Size不同不同大小的波纹有不同的外观大小的波纹有不同的外观同一块样板 SW（短波）： 1740 cm3 mObserv. Distance不同不同的观察距离有不同的外观的观察距离有不同的外观 LW（长波）： 6ABCDEFGH

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19、 (mm)3m表面表面结构的可见度结构的可见度0.11101003030.3 0.140cm20406080100人眼的分辨率 Visibility桔桔皮仪皮仪: 测量测量原理原理光学光学轮廓轮廓扫描扫描 10 cm激光wsc Principle探头桔桔皮仪皮仪: 测量测量原理原理 scanning 1激光光源激光光源探头桔桔皮仪皮仪: 测量测量原理原理 scanning 2探头桔桔皮仪皮仪: 测量测量原理原理 scanning 3激光光源探头桔桔皮仪皮仪: 测量测量原理原理 scanning 4激光光源桔桔皮仪皮仪: 测量测量原理原理光学光学轮廓轮廓长长波波短波短波数学滤波器 Profile

20、 + Filter L/S信号分离信号分离信号信号0200400600800100012001400160018002000平均对比度 长波值长波长波0200400600800100012001400160018002000 Signal separation波波纹标尺：长波，短波纹标尺：长波，短波比较数值 208010004060平滑平滑差差 Scaling表面特征由长波和短波来表示表面特征由长波和短波来表示 sample A + B样品样品 A样品样品 B173115短波10长波3110仅用长波和短波来表示的局限性仅用长波和短波来表示的局限性新的油漆系统要求有更“高级”的测量步骤1212

21、sample C + D样品样品 C样品样品 D21短波7长波217测量测量原理原理: 桔桔皮仪皮仪 DOI光学光学轮廓轮廓0.1 mm30 mm数学滤波器扩大扩大测量的范围测量的范围将将长波细分长波细分更更高的分辨率高的分辨率Principle wscDOI波长范围波长范围长波0.1110波长短波3300.3mm经典的标尺WaWbWcWdWe new 5 ranges- 分割成分割成5个范围个范围结构结构 波段曲线波段曲线样品样品 C样品样品 D Struct. spectr C+D05101520251 - 33 - 1010 - 300.3-10.1-0.3波长 (mm)长波 7长波 1

22、2WcWdWeWbWa波纹 + 明亮度对比度对比度锐锐度度分辨分辨度度App. infl. by DOI表面表面外观受影响于外观受影响于 .探头镜镜向光泽测量向光泽测量测量全部反射光的强度 取决于曲率Specular Gloss: 光泽20例: 单组分和双组分反射指数1.541.521.511.531.5080859095单组分 双组分 视觉：视觉：同样同样明亮明亮 没有没有关联性关联性 取决于涂料的材料镜镜向光泽向光泽：什么是什么是DOI？好差对比度 锐度- 分辨度204060801001101003030.3 0.10.1表面表面结构对结构对DOI的影响的影响光线漫射引起影像对比度的降低光

23、线漫射引起影像对比度的降低小结构引起影像轮廓的模糊小结构引起影像轮廓的模糊测量测量光线漫射光线漫射 ( 0.1 mm)照相机20漫漫射值射值小于 0.1mm的结构引起的光线漫射最大最大= 晦涩度（晦涩度（dullness） Principle DOI晦涩度（晦涩度（du）与油漆材料无关反射指数1.541.521.511.531.505101520单组分 双组分du可用于弯曲的表面平面曲面 Dullness 0.1dullness05101520251 - 33 - 1010 - 300.3-10.1-0.3mmWaWbWcWdWe全部全部结构的波段曲线结构的波段曲线 Complette Str

24、uct.spectr. DOI DOI （鲜鲜映性）映性）05101520251 - 33 - 1010 - 300.3-10.1-0.3mm 5n Horizontal 7 Standards for comparison purposes to facilitate judgmentHigh peel1038156Smooth2479 Illumination & viewing conditions not defined Final judgment dependent on observerVisual Tools to assess Orange Peel1980R-wav

25、e-scanDOI 100010203040506070809012345678910123456789Visual Tools to assess Orange PeelR wave-scan: Function of (LW + SW)80% is based on LW 0.010.020.030.040.050.060.070.080.0dudullnessWa 0,1-0,3mmWb 0,3-1,0mmWc 1-3mmWd 3-10mmWe 10-30mmRating 1Rating 2Rating 3Rating 4Rating 5Rating 6Rating 7Rating 8R

26、ating 9Panel set: 1994 -BnDOI variesnNo real R8, R8=R9nR9=R10R-wave-scanDOI 100010203040506070809012345678910123456789Visual Tools to assess Orange PeelPanel set: 1994 - UnDOI varies nDifferences are not equalnNo real R5nR9 = R8, R10=R901020304050607080duWa Wb WcWd We R 1R 2R 3R 4R 5R 6R 7R 8R 9R 10

27、01020304050607080901001234567891010123456789R-wave-scanDOI Visual Tools to assess Orange Peel01020304050607080du Wa WbWc Wd We R 1R 2R 3R 4R 5R 6R 7R 8R 9R 10010203040506070809010012345678910Panel set: 1994 - AnDOI varies nDifferences are not equalnR4 better than R5nNo real R6nR8 = R9= R10R-wave-sca

28、nDOI 10123456789Visual Tools to assess Orange Peel Poor reproducibility between panel sets over the years0102030405060708090R 3R 4R 5R 6R 7R 8R 9R 10du Wa WbWc Wd We R-wave-scan0102030405060708090100345678910DOI 10123456789Panel set: 2002nVery different to 1994nPoor correlation to visualVisual Tools

29、 to assess Orange Peel桔皮仪桔皮仪 DOI 不仅仅是一台仪器不仅仅是一台仪器工艺工艺 底材底材油漆材料油漆材料l质保的工具使外观评估文件化并能及早地发现质量的变化l测量的结果帮助改善质量Influences: “More than instrument“ Substrate roughness磷化锌层 5 m电泳漆层18 25 m中涂层20 40 m面漆层15 20 m清漆层25 50 m车身底材底材质量影响表面外观底材质量影响表面外观 Steel type: Ford Study5055606570Combined QMSKawasaki Paint/Galv.USS

30、ETD/CRSZinc NickelKawasaki Paint/C.R.National Galv.Kawasaki Form/CRSBright SteelRouge Steel/Galv.Inland BonazincZinc XROXEffect of steel type on appearanceFord Study 1989短波短波长波长波玻璃ST 1405DIN 1624Lasertex1020300 Steel type: Merc.Benz钢板型号对外观的影响Mercedes Benz 研究于 1992 SMC glass fiber type051015202530354

31、045duWaWbWcWdWe686983C83M不同纤维的玻璃钢底材对外观的影响不同纤维的玻璃钢底材对外观的影响Owens Corning 玻璃钢外观研究 Courtesy of G. Montagna“粗糙粗糙”的中涂层对外观的影响的中涂层对外观的影响01020304050600.10.1-0.30.3-1.01-33-1010-30 Sanding primer砂磨中涂层 510152051015200长波长波前盖前盖短波短波晾晾干时间干时间: 9 min. 3 min.车门车门晾晾干时间对外观的影响干时间对外观的影响 Flash-Off time CC + Surface Tensio

32、n 50 m of clearcoat can level a wave of 500 m = 0.5mm in distance.What does this mean in wave-scan scales?lDullness 0.1 mmlWa: 0.1 to 0.3 mm lWb: 0.3 to 1 mm What substrate structures can we “level” with the clearcoat?Physics of surface tension leveling say that you can only level a wave that is, at

33、 most, 10 times wider than the depth of the liquid.lWc: 1 to 3 mm lWd: 3 to 10 mm lWe: 10 to 30 mm烘烘烤位置的不同会有什么影响？烤位置的不同会有什么影响？ 水平水平垂直垂直0481216200.1-0.3Wa0.3-1Wb 1- 3 Wc 3-10Wd10-30We 0.1du020406080100DOI BYK horiz./vertical CC film thickness010203040du 0.1 Wa 0.1-0.3 Wb 0.3-1 Wc 1-3 Wd 3-10 We 30-10

34、 mm16 m24 m30 m50 m双组分清漆清漆层的厚度会有什么影响？清漆层的厚度会有什么影响？Trouble shooting tool桔皮仪桔皮仪 DOI 极佳的诊断工具极佳的诊断工具l晦涩度（du）太高:清漆层可能太“混”: 由材料或者“太干”的喷涂引起的非常细小的表面结构lWa 太高:底材影响或者清漆喷涂“太干” lWb 太高:底材影响lWc太高: 清漆层厚度不够沙磨痕，底漆喷涂“太干”或漆雾颗粒太大 - 飞溅到下辆车上非常粗糙的底材lWd太高: 清漆层厚度不够非常粗糙的底材工艺工艺参数影响外观参数影响外观 流动流动 雾雾化状态化状态喷喷枪枪/旋杯旋杯- 距离距离温度，温度，湿度湿

35、度晾晾干时间干时间成成膜膜旋旋杯速度和杯速度和电压电压 溶剂挥发溶剂挥发助助剂剂组组分比率分比率 (双组分双组分) 如何使用结构波段曲线？如何使用结构波段曲线？Bild: BASF Coatings优化工艺和材料参数 How can we use .起初：起初： 波纹程度高波纹程度高01020304050600.10.1-0.3 0.3-1.01-33-1010-3001020304050600.10.1-0.30.3-1.01-33-1010-301. 优化面漆喷涂优化面漆喷涂 1. Step01020304050600.10.1-0.3 0.3-1.01-33-1010-301. 经过经过

36、优化的面漆喷涂优化的面漆喷涂2. 沙沙磨中涂层磨中涂层01020304050600.10.1-0.30.3-1.01-33-1010-30 2. Step2. 沙沙磨中涂层磨中涂层01020304050600.10.1-0.3 0.3-1.01-33-1010-303. 经过经过优化的中涂和面漆喷涂优化的中涂和面漆喷涂01020304050600.10.1-0.30.3-1.01-33-1010-30 3. Step不同结构范围间的比例不同结构范围间的比例 RatioL*a*b* 颜色空间颜色空间平滑平滑(玻璃板玻璃板)不良的湿性外观不良的湿性外观Wd/Wc 低低良好的湿性外观良好的湿性外观

37、Wd/Wc 高高波纹波纹对长波掩盖度低对长波掩盖度低Wb/Wd 低低能看到长波能看到长波对长波掩盖度高对长波掩盖度高Wb/Wd 高高能看到短波能看到短波模糊的外观模糊的外观湿性外观湿性外观Color Space结构结构 空间空间-100-75-50-250255075100-100 -75-50-250255075100Longwave CoverageWet LookSeries1Series2Series3Series4Series5Series6Series7Series8Series90102030405060708090100Waviness结构结构 图表图表Structur Spa

38、ce结构结构 空间空间-50-252550-50 -252550duWaWbWcWdWeduWaWbWcWdWeduWaWbWcWdWeduWaWbWcWdWeduWaWbWcWdWeduWaWbWcWdWe10305070duWaWbWcWdWe10305070duWaWbWcWdWe10305070duWaWbWcWdWe103050701030507010305070103050701030507010305070对对长波的掩盖度和湿性外观的计算长波的掩盖度和湿性外观的计算WdWbWdWbLC*100WcWdWcWdWL*100对对长波的掩盖度：长波的掩盖度：湿性外观湿性外观:calcu

39、lationduWaWbWcWdWeduWaWbWcWdWe检查检查涂装线工艺的稳定性涂装线工艺的稳定性不稳定的涂装线工艺不稳定的涂装线工艺检查检查加装部件与车身的一致性加装部件与车身的一致性质量不稳定的加装部件质量不稳定的加装部件强 “湿性外观” (+37)弱 “湿性外观” (+11)0510152025Wa 0,1-0,3mmWb 0,3-1,0mmWc 1-3mmWd 3-10mmWe 10-30mmLW 7LW 12结构结构 波段曲线波段曲线高 “对长波的掩盖度” (+42)0.010.020.030.040.050.060.070.0 300mml 最小样品尺寸: 25 x 40mm

40、l 可选扫描长度 5, 10, 20cml 不移动仪器可实现DOI 的测量用于小面积和有曲率的部件用于小面积和有曲率的部件 微型微型 桔皮仪桔皮和DOImws - fr kleine und gekrmmte Teilel 结构波段: du, Wa - Wdl 长波和短波l DOI用户定义的标尺:l Tensionl Ratingl QMS-Scales 微型微型桔皮仪102030duWaWbWcWd与汽车工业控制外观的标准-桔皮仪DOI之间有很好的一致性用于小面积和有曲率的部件用于小面积和有曲率的部件桔皮和DOI01020304050607080duWaWbWcWd试验组: 质量从好到差 与桔皮仪与桔皮仪DOI之间的一致性之间的一致性 与桔皮仪与桔皮仪DOI之间的一致性之间的一致性: 晦涩度（晦涩度（du）R2 = 0.98740.05.010.015.020.025.030.035.040.045.050.00.05.010.015.020.025.030.035.040.045.050.0桔皮仪桔皮仪DOI微型际皮仪微型际皮仪-12%+12%4.0 /4.815.8 / 14.627.6