汽車表面外觀控制

1、Start汽車涂層的表面外觀汽車涂層的表面外觀統(tǒng)一和諧的外觀統(tǒng)一和諧的外觀 = 質(zhì)量質(zhì)量水平區(qū)域水平區(qū)域垂直區(qū)域垂直區(qū)域加裝部件加裝部件Uniform Quality桔桔皮儀皮儀 DOI汽車汽車工業(yè)表面外觀的標(biāo)準(zhǔn)工業(yè)表面外觀的標(biāo)準(zhǔn) wave-scan DOI 微型桔皮儀微型桔皮儀micro-wave-scan在現(xiàn)場(chǎng)作不同型號(hào)車之間的比較加裝部件的涂裝工藝控制整車質(zhì)保中檢查各部位間的一致性可解決小面積部件和彎曲面上的測(cè)量問(wèn)題聚聚焦在表面焦在表面長(zhǎng)長(zhǎng)波波短波短波聚聚焦在反射影像焦在反射影像霧霧影影光澤光澤鮮鮮映性映性全面全面外觀外觀成成像質(zhì)量像質(zhì)量波波紋，桔皮紋，桔皮波波紋紋 桔桔皮皮明亮明亮度度

2、 - DOIApp. influenced by.表面表面外觀受影響于外觀受影響于 .聚焦在表面聚焦在表面表面結(jié)構(gòu)表面結(jié)構(gòu) / 波紋波紋聚焦于反射影像聚焦于反射影像光澤光澤 / 明亮度明亮度表面表面外觀的視覺(jué)感受外觀的視覺(jué)感受 Focal Plane桔桔皮的視覺(jué)感受皮的視覺(jué)感受波紋波紋 亮亮/暗暗 模式模式 wavy pattern長(zhǎng)長(zhǎng)波波短短波波 Structure Size不同不同大小的波紋有不同的外觀大小的波紋有不同的外觀同一塊樣板 SW（短波）： 1740 cm3 mObserv. Distance不同不同的觀察距離有不同的外觀的觀察距離有不同的外觀 LW（長(zhǎng)波）： 6ABCDEFGH

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19、 (mm)3m表面表面結(jié)構(gòu)的可見(jiàn)度結(jié)構(gòu)的可見(jiàn)度0.11101003030.3 0.140cm20406080100人眼的分辨率 Visibility桔桔皮儀皮儀: 測(cè)量測(cè)量原理原理光學(xué)光學(xué)輪廓輪廓掃描掃描 10 cm激光wsc Principle探頭桔桔皮儀皮儀: 測(cè)量測(cè)量原理原理 scanning 1激光光源激光光源探頭桔桔皮儀皮儀: 測(cè)量測(cè)量原理原理 scanning 2探頭桔桔皮儀皮儀: 測(cè)量測(cè)量原理原理 scanning 3激光光源探頭桔桔皮儀皮儀: 測(cè)量測(cè)量原理原理 scanning 4激光光源桔桔皮儀皮儀: 測(cè)量測(cè)量原理原理光學(xué)光學(xué)輪廓輪廓長(zhǎng)長(zhǎng)波波短波短波數(shù)學(xué)濾波器 Profile

20、 + Filter L/S信號(hào)分離信號(hào)分離信號(hào)信號(hào)0200400600800100012001400160018002000平均對(duì)比度 長(zhǎng)波值長(zhǎng)波長(zhǎng)波0200400600800100012001400160018002000 Signal separation波波紋標(biāo)尺：長(zhǎng)波，短波紋標(biāo)尺：長(zhǎng)波，短波比較數(shù)值 208010004060平滑平滑差差 Scaling表面特征由長(zhǎng)波和短波來(lái)表示表面特征由長(zhǎng)波和短波來(lái)表示 sample A + B樣品樣品 A樣品樣品 B173115短波10長(zhǎng)波3110僅用長(zhǎng)波和短波來(lái)表示的局限性僅用長(zhǎng)波和短波來(lái)表示的局限性新的油漆系統(tǒng)要求有更“高級(jí)”的測(cè)量步驟1212

21、sample C + D樣品樣品 C樣品樣品 D21短波7長(zhǎng)波217測(cè)量測(cè)量原理原理: 桔桔皮儀皮儀 DOI光學(xué)光學(xué)輪廓輪廓0.1 mm30 mm數(shù)學(xué)濾波器擴(kuò)大擴(kuò)大測(cè)量的范圍測(cè)量的范圍將將長(zhǎng)波細(xì)分長(zhǎng)波細(xì)分更更高的分辨率高的分辨率Principle wscDOI波長(zhǎng)范圍波長(zhǎng)范圍長(zhǎng)波0.1110波長(zhǎng)短波3300.3mm經(jīng)典的標(biāo)尺WaWbWcWdWe new 5 ranges- 分割成分割成5個(gè)范圍個(gè)范圍結(jié)構(gòu)結(jié)構(gòu) 波段曲線波段曲線樣品樣品 C樣品樣品 D Struct. spectr C+D05101520251 - 33 - 1010 - 300.3-10.1-0.3波長(zhǎng) (mm)長(zhǎng)波 7長(zhǎng)波 1

22、2WcWdWeWbWa波紋 + 明亮度對(duì)比度對(duì)比度銳銳度度分辨分辨度度App. infl. by DOI表面表面外觀受影響于外觀受影響于 .探頭鏡鏡向光澤測(cè)量向光澤測(cè)量測(cè)量全部反射光的強(qiáng)度 取決于曲率Specular Gloss: 光澤20例: 單組分和雙組分反射指數(shù)1.541.521.511.531.5080859095單組分 雙組分 視覺(jué)：視覺(jué)：同樣同樣明亮明亮 沒(méi)有沒(méi)有關(guān)聯(lián)性關(guān)聯(lián)性 取決于涂料的材料鏡鏡向光澤向光澤：什么是什么是DOI？好差對(duì)比度 銳度- 分辨度204060801001101003030.3 0.10.1表面表面結(jié)構(gòu)對(duì)結(jié)構(gòu)對(duì)DOI的影響的影響光線漫射引起影像對(duì)比度的降低光

23、線漫射引起影像對(duì)比度的降低小結(jié)構(gòu)引起影像輪廓的模糊小結(jié)構(gòu)引起影像輪廓的模糊測(cè)量測(cè)量光線漫射光線漫射 ( 0.1 mm)照相機(jī)20漫漫射值射值小于 0.1mm的結(jié)構(gòu)引起的光線漫射最大最大= 晦澀度（晦澀度（dullness） Principle DOI晦澀度（晦澀度（du）與油漆材料無(wú)關(guān)反射指數(shù)1.541.521.511.531.505101520單組分 雙組分du可用于彎曲的表面平面曲面 Dullness 0.1dullness05101520251 - 33 - 1010 - 300.3-10.1-0.3mmWaWbWcWdWe全部全部結(jié)構(gòu)的波段曲線結(jié)構(gòu)的波段曲線 Complette Str

24、uct.spectr. DOI DOI （鮮鮮映性）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桔皮儀桔皮儀 DOI 不僅僅是一臺(tái)儀器不僅僅是一臺(tái)儀器工藝工藝 底材底材油漆材料油漆材料l質(zhì)保的工具使外觀評(píng)估文件化并能及早地發(fā)現(xiàn)質(zhì)量的變化l測(cè)量的結(jié)果幫助改善質(zhì)量Influences: “More than instrument“ Substrate roughness磷化鋅層 5 m電泳漆層18 25 m中涂層20 40 m面漆層15 20 m清漆層25 50 m車身底材底材質(zhì)量影響表面外觀底材質(zhì)量影響表面外觀 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短波短波長(zhǎng)波長(zhǎng)波玻璃ST 1405DIN 1624Lasertex1020300 Steel type: Merc.Benz鋼板型號(hào)對(duì)外觀的影響Mercedes Benz 研究于 1992 SMC glass fiber type051015202530354

31、045duWaWbWcWdWe686983C83M不同纖維的玻璃鋼底材對(duì)外觀的影響不同纖維的玻璃鋼底材對(duì)外觀的影響Owens Corning 玻璃鋼外觀研究 Courtesy of G. Montagna“粗糙粗糙”的中涂層對(duì)外觀的影響的中涂層對(duì)外觀的影響01020304050600.10.1-0.30.3-1.01-33-1010-30 Sanding primer砂磨中涂層 510152051015200長(zhǎng)波長(zhǎng)波前蓋前蓋短波短波晾晾干時(shí)間干時(shí)間: 9 min. 3 min.車門車門晾晾干時(shí)間對(duì)外觀的影響干時(shí)間對(duì)外觀的影響 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 “l(fā)evel” 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烘烘烤位置的不同會(huì)有什么影響？烤位置的不同會(huì)有什么影響？ 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雙組分清漆清漆層的厚度會(huì)有什么影響？清漆層的厚度會(huì)有什么影響？Trouble shooting tool桔皮儀桔皮儀 DOI 極佳的診斷工具極佳的診斷工具l晦澀度（du）太高:清漆層可能太“混”: 由材料或者“太干”的噴涂引起的非常細(xì)小的表面結(jié)構(gòu)lWa 太高:底材影響或者清漆噴涂“太干” lWb 太高:底材影響lWc太高: 清漆層厚度不夠沙磨痕，底漆噴涂“太干”或漆霧顆粒太大 - 飛濺到下輛車上非常粗糙的底材lWd太高: 清漆層厚度不夠非常粗糙的底材工藝工藝參數(shù)影響外觀參數(shù)影響外觀 流動(dòng)流動(dòng) 霧霧化狀態(tài)化狀態(tài)噴噴槍槍/旋杯旋杯- 距離距離溫度，溫度，濕度濕

35、度晾晾干時(shí)間干時(shí)間成成膜膜旋旋杯速度和杯速度和電壓電壓 溶劑揮發(fā)溶劑揮發(fā)助助劑劑組組分比率分比率 (雙組分雙組分) 如何使用結(jié)構(gòu)波段曲線？如何使用結(jié)構(gòu)波段曲線？Bild: BASF Coatings優(yōu)化工藝和材料參數(shù) How can we use .起初：起初： 波紋程度高波紋程度高01020304050600.10.1-0.3 0.3-1.01-33-1010-3001020304050600.10.1-0.30.3-1.01-33-1010-301. 優(yōu)化面漆噴涂?jī)?yōu)化面漆噴涂 1. Step01020304050600.10.1-0.3 0.3-1.01-33-1010-301. 經(jīng)過(guò)經(jīng)過(guò)

36、優(yōu)化的面漆噴涂?jī)?yōu)化的面漆噴涂2. 沙沙磨中涂層磨中涂層01020304050600.10.1-0.30.3-1.01-33-1010-30 2. Step2. 沙沙磨中涂層磨中涂層01020304050600.10.1-0.3 0.3-1.01-33-1010-303. 經(jīng)過(guò)經(jīng)過(guò)優(yōu)化的中涂和面漆噴涂?jī)?yōu)化的中涂和面漆噴涂01020304050600.10.1-0.30.3-1.01-33-1010-30 3. Step不同結(jié)構(gòu)范圍間的比例不同結(jié)構(gòu)范圍間的比例 RatioL*a*b* 顏色空間顏色空間平滑平滑(玻璃板玻璃板)不良的濕性外觀不良的濕性外觀Wd/Wc 低低良好的濕性外觀良好的濕性外觀

37、Wd/Wc 高高波紋波紋對(duì)長(zhǎng)波掩蓋度低對(duì)長(zhǎng)波掩蓋度低Wb/Wd 低低能看到長(zhǎng)波能看到長(zhǎng)波對(duì)長(zhǎng)波掩蓋度高對(duì)長(zhǎng)波掩蓋度高Wb/Wd 高高能看到短波能看到短波模糊的外觀模糊的外觀濕性外觀濕性外觀Color Space結(jié)構(gòu)結(jié)構(gòu) 空間空間-100-75-50-250255075100-100 -75-50-250255075100Longwave CoverageWet LookSeries1Series2Series3Series4Series5Series6Series7Series8Series90102030405060708090100Waviness結(jié)構(gòu)結(jié)構(gòu) 圖表圖表Structur Spa

38、ce結(jié)構(gòu)結(jié)構(gòu) 空間空間-50-252550-50 -252550duWaWbWcWdWeduWaWbWcWdWeduWaWbWcWdWeduWaWbWcWdWeduWaWbWcWdWeduWaWbWcWdWe10305070duWaWbWcWdWe10305070duWaWbWcWdWe10305070duWaWbWcWdWe103050701030507010305070103050701030507010305070對(duì)對(duì)長(zhǎng)波的掩蓋度和濕性外觀的計(jì)算長(zhǎng)波的掩蓋度和濕性外觀的計(jì)算WdWbWdWbLC*100WcWdWcWdWL*100對(duì)對(duì)長(zhǎng)波的掩蓋度：長(zhǎng)波的掩蓋度：濕性外觀濕性外觀:calcu

39、lationduWaWbWcWdWeduWaWbWcWdWe檢查檢查涂裝線工藝的穩(wěn)定性涂裝線工藝的穩(wěn)定性不穩(wěn)定的涂裝線工藝不穩(wěn)定的涂裝線工藝檢查檢查加裝部件與車身的一致性加裝部件與車身的一致性質(zhì)量不穩(wěn)定的加裝部件質(zhì)量不穩(wěn)定的加裝部件強(qiáng) “濕性外觀” (+37)弱 “濕性外觀” (+11)0510152025Wa 0,1-0,3mmWb 0,3-1,0mmWc 1-3mmWd 3-10mmWe 10-30mmLW 7LW 12結(jié)構(gòu)結(jié)構(gòu) 波段曲線波段曲線高 “對(duì)長(zhǎng)波的掩蓋度” (+42)0.010.020.030.040.050.060.070.0 300mml 最小樣品尺寸: 25 x 40mm

40、l 可選掃描長(zhǎng)度 5, 10, 20cml 不移動(dòng)儀器可實(shí)現(xiàn)DOI 的測(cè)量用于小面積和有曲率的部件用于小面積和有曲率的部件 微型微型 桔皮儀桔皮和DOImws - fr kleine und gekrmmte Teilel 結(jié)構(gòu)波段: du, Wa - Wdl 長(zhǎng)波和短波l DOI用戶定義的標(biāo)尺:l Tensionl Ratingl QMS-Scales 微型微型桔皮儀102030duWaWbWcWd與汽車工業(yè)控制外觀的標(biāo)準(zhǔn)-桔皮儀DOI之間有很好的一致性用于小面積和有曲率的部件用于小面積和有曲率的部件桔皮和DOI01020304050607080duWaWbWcWd試驗(yàn)組: 質(zhì)量從好到差 與桔皮儀與桔皮儀DOI之間的一致性之間的一致性 與桔皮儀與桔皮儀DOI之間的一致性之間的一致性: 晦澀度（晦澀度（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桔皮儀桔皮儀DOI微型際皮儀微型際皮儀-12%+12%4.0 /4.815.8 / 14.627.6