Introduction ORANGE PEEL / DOI. Structure size. Color Physical Properties Technical Service Index

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1 Introduction The total appearance and the visibility of structures depend on the structure size, the observing distance and the image forming quality. Structure size Surfaces with different structure sizes will appear visually different: Small structures Large structures The waviness of automotive paints is in a range of approx. 0.1 to 30 mm wavelength. These phenomena are often visually evaluated and subjective terms like degree of peel or texture are used as descriptions. Orange peel can be seen on high gloss surfaces as a wavy pattern of light and dark areas. Depending on the slope of the structure element the light is reflected in various directions. Only the elements reflecting the light in the direction of our eyes are perceived as light areas. ORANGE PEEL / DOI 33 Orange Appearance Peel / DOI Color Physical Properties Technical Service Index

2 Observing distance Visibility of structures is dependent on the observing distance. The greater the distance, the smaller objects will appear. Structures with a size of 10 to 30 mm can best be seen at a distance of approx. 3 m. Fine structures in a range of 0.1 to 1 mm can only be recognized at a close distance. Short distance: Shortwave Large distance: Longwave Resolution of our eyes The resolvable structure size is also dependent on the observing distance. Very fine structures that are below the human eye's resolution (approx. 0.1 mm) can no longer be recognized as a light / dark pattern, even at a close distance. The result is a reduction of the image forming quality (IFQ). At 3 m distance, structures between 1 3 mm can hardly be resolved as a waviness but influence the appearance. Image Forming Quality (IFQ) The higher contrast and sharpness of a reflected object, e.g. the edges of black and white lines, the better the image forming quality will be. Fine structures disturb the reflected image, consequently edges become blurry and are no longer sharp. Image Forming Quality at a close distance: Distinctness of Image (DOI) DOI can also be described with terms like brilliance, sharpness or clarity. DOI is diminished by very fine structures close to the human eye resolution (smaller than 0.3 mm). Image Forming Quality at a far distance: Wet Look At a distance of 3 m, the image forming quality is mainly influenced by structures between 1 3 mm. This effect is referred to as Wet Look. wave-scan dual see page

3 Simulation of the Visual Perception Waviness The wave-scan simulates visual perception. Like our eyes, the instrument optically scans the wavy light / dark pattern. A laser point light source illuminates the specimen at a 60 angle and a detector measures the reflected light intensity at the equal but opposite angle. The orange peel meter is rolled across the surface and measures point by point the optical profile of the surface across a defined distance. The wave-scan analyzes the structures according to their size. In order to simulate the human eye's resolution at various distances, the measurement signal is divided into several ranges using mathematical filter functions: Wa mm wavelength Wb mm wavelength Wc mm wavelength Wd mm wavelength We mm wavelength SW mm wavelength LW mm wavelength Dullness Structures smaller than 0.1 mm influence visual perception, therefore the wave-scan uses a CCD camera to measure the diffused light caused by these fine structures. This parameter is referred to as "dullness". Structure Spectrum The values of dullness and Wa to We form a "structure spectrum". This allows a detailed analysis of Orange Peel and its influencing factors, being material or application parameters. 20 Camera 35 Orange Appearance Peel / DOI Color Physical Properties Technical Service Index

4 wave-scan Scales The detailed information of the structure spectrum as well as LW and SW became the basis to correlate to customer specific scales and to the DOI as described in ASTM E430: DOI Rating: Tension-Scales: GM-Tension P-Tension H-Tension Ford Scales: Luster Sharpness Orange Peel Combined Daimler Chrysler Scales: Gloss DCA Dorigon DCA Orange Peel DCA Over All DCA BMW Scales: N1 Note 1 m N3 Note 3 m Function of du, Wa and Wb Correlation to ASTM E430, scaling is similar to 20 gloss Orange Peel based on ACT panels Leveling GM Specification Honda Specification Honda Specification A measurement for Gloss A measurement for DOI A measurement for Leveling An overall rating A measurement for Gloss A measurement for DOI A measurement for Leveling An overall rating A ranking note for 1m observation A ranking note for 3m observation Interpretation of Measurement Results Substrate Influence: In the following graph, the substrate roughness telegraphs through the clear coat and reduces the brilliance of the coating. Sample D is a lasertex panel with a specific texture resulting in lower SW values A: Glass B: Lab Panel C: Car Body Panel D: Lasertex A B C D SW LW Influence of Baking Position: In general, horizontal surfaces have shown better flow and leveling characteristics, i.e. in the values for the longer waves (Wc... We). The smaller waves are hardly influenced by the baking position. Influence of Film Thickness: The structure spectrum can help optimize the appearance, e.g. in determining the optimum film thickness. Increasing clear coat thickness improves flow and leveling. In the graph this can be seen in decreasing Wc and Wd values. 36

5 wave-scan dual Orange Peel and DOI measurement on high to semi gloss surfaces... appearance control is no longer limited to final topcoat inspection. The orange peel meter scans the optical profile of high gloss surfaces using a laser light source. An additional, infrared high energy LED allows measuring the same structure spectrum ( mm) on medium gloss surfaces. The dullness measurement is recorded with state-of-the-art CCD camera technology. It gives information on the image forming qualities of the surface caused by structures < 0.1mm. Close the appearance control loop for the entire paint process Thus, the surface quality after each paint process step can be objectively evaluated. No more guessing which substrate layer is influencing the final appearance. The wave-scan dual will help you to objectively analyze appearance problems and reduce the time necessary for trouble shooting. Example: Influence of Steel Quality on Final Appearance Step 1: Appearance Control after E-coat Same E-coat system was applied on rough and smooth steel. The influence of rougher steel can be seen in increased Wb and Wc-values. Step 2: Appearance Control after Primer Surfacer The primer surfacer was applied on both panels. The roughness of the steel quality can still be detected in increased Wb and Wc- values. This primer system could not completely cover the steel influence. Step 3: Appearance Control after Topcoat The final appearance shows higher shortwave values on the rougher steel panel. Therefore, the smooth panel will appear more brilliant. wave-scan dual a diagnostic tool for trouble shooting and optimizing appearance Now, you can establish appearance specifications for each paint layer to ensure the final appearance is always on target. 37 Orange Appearance Peel / DOI Color Physical Properties Technical Service Index

6 Objective and reliable appearance data Good correlation to wave-scan DOI on high gloss surfaces Good correlation to mechanical profilometer readings on medium gloss surfaces Easy to use with one hand For flat and curved areas Small and light weight Scroll wheel operation and multilingual menu Selectable scales and scan lengths Full statistics with saving in selectable memories USB port for data transfer to PC Software auto-chart: Organizer files for sample identification Data management with Access DB Standard QC Reports in Excel select mode... and measure Always ready The orange peel meter is operated with a rechargeable battery pack (Li-Ion). The docking station automatically charges the battery pack and transfers the measured data to the PC. Optionally, the instrument can be operated with 3 standard mignon alkaline or rechargeable batteries good for 1000 readings. 38

7 Ordering Information Cat. No. Description 4840 wave-scan dual Extended Warranty one year additional Comes complete with: Orange peel meter, Protective cover, Reference tile with certificate, Software auto-chart on CD, Docking station and interface cable, 2 rechargeable Li-Ion battery packs, Battery holder for AA batteries, 3 Batteries, Operating manual, Carrying case Training Free 1x preventive maintenance service during warranty period Hardware Requirements: Operating system: Windows 2000 or higher Excel version: 2002 or higher, incl. VBA Memory: min. 256 MB RAM (recommended 512 MB) Hard-disk space: min. 100 MB Monitor resolution: XGA (1024 x 768) or higher Disk drive: CD-ROM or DVD Interface: USB port Technical Specifications Application High to Semi Gloss Structure Spectrum du Wa Wb Wc Wd We ¹Standard deviation du < 65, linear range <0.1 mm 0.1 to 0.3 mm 0.3 to 1 mm 1 to 3 mm 3 to 10 mm 10 to 30 mm Repeatability¹ du < 40: 4% or > 0.4 du > 40: 6% or > 0.6 Reproducibility¹ du < 40: 6% or > 0.6 Object Curvature Min. Sample Size Scan Length Resolution Memory du > 40: 8% or > 0.8 radius > 500 mm 35 mm x 150 mm 5 / 10 / 20 cm 375 points/cm 1500 readings Interface USB 1.1 Languages Light Source English, French, German, Italian, Japanese, Portuguese, Spanish Laser diode, LED and IR-SLED Laser Energy < 1 mw (Laser class 2) Dimensions Weight Power Supply Temperature Range Rel. Humidity 150 x 110 x 55 mm (5.9 x 4.3 x 2.2 in.) 650 g (1.5 lbs) rechargeable battery pack or 3 alkaline AA Batteries, approx readings operation: +10 C to 40 C (+ 50 F to 104 F) storage: 0 C to 60 C (+ 32 F to 140 F) up to 85 % at 35 C (95 F) non-condensing Prices are subject to change without notice. 39 Orange Appearance Peel / DOI Color Physical Properties Technical Service Index

8 Training wave-scan dual BYK-Gardner offers you more than just an instrument. We assist you in operating the wave-scan system and understanding your appearance readings. As a result you will be able to use the orange peel meter to save time and money and at the same time improve your quality. Therefore, the instrument comes with a one day training course including: 1. Orange Peel and DOI Theory Visual perception and instrumental measurement of Orange Peel and DOI Data interpretation: How can the structure spectrum be used to optimize process / material parameters 2. Operation and Software Training Set-up of an Organizer to create a routine measurement procedure Programming of the instrument with organizer and measurement of several samples Direct data transfer to Excel for documentation of individual readings Data transfer to auto-chart software and saving in a database for routine QC Data analysis using standard QC-reports: Summary by lines to show at one glance how various colors are running at different paint lines Trend chart to show how specified zones perform over a defined time range SPC-chart for daily process control of your critical colors and highrunners: xr-chart Zone profile for trouble shooting using the structure spectrum Create your own reports in Excel Transfer data from the database to Excel Pivot function to define layout in Excel The training can be performed in one day or two half days. It is recommended to split the training into two half days: Day 1: Theory and basic operation (set-up organizer, taking readings and saving data in a database) Day 2: 3-4 weeks later to ensure readings were taken and in a database. Data analysis and standard QC reports can be explained using customer specific data. Ordering Information Accessories Cat. No. Description 4843 Reference Tile wave-scan dual To check performance of the orange peel meter, with certificate 4841 Docking Station Incl. USB interface cable, and recharger V self adapting 4842 Battery Pack Rechargeable battery for automatic charge in docking station 4809 auto-chart Software for analysis and professional documentation in Excel For Certification Services and Preventive Maintenance see pages Prices are subject to change without notice.

9 wave-scan II The specialist for high gloss surfaces Surface appearance changes with the size and distinctness of structures. The wave-scan II objectively evaluates orange peel as well as brilliance of topcoat finishes. Objective and reliable appearance data Excellent correlation to wave-scan DOI Classical Longwave and Shortwave Structure spectrum to analyze appearance changes Dullness and DOI measurement independent of the paint system Ideal size for the production line Easy handling even on the moving car body Small and light weight For flat and curved areas, radius > 50 cm Scroll wheel operation and multilingual menu Scales and scan lengths can be selected directly from menu Full statistics with saving in selectable memories Large memory for 1500 readings USB port for data transfer to PC auto-chart software: Organizer files for sample id Data management with Access DB Standard QC Reports in Excel select mode... and measure Always ready The orange peel meter is operated with a rechargeable battery pack (Li-Ion). The docking station automatically charges the battery pack and transfers the measured data to the PC. Optionally, the wave-scan II can be operated with 3 standard mignon alkaline or rechargeable batteries good for 1000 readings. 41 Orange Appearance Peel / DOI Color Physical Properties Technical Service Index

10 Ordering Information Cat. No. Description 4846 wave-scan II Extended Warranty one year additional Comes complete with: Orange peel & DOI meter with protective cover Reference tile with certificate auto-chart software on CD Docking station with interface cable 2 rechargeable Li-Ion battery packs Battery holder for AA alkaline batteries 3 Batteries, Operating manual Carrying case Training Free 1x preventive maintenance service during warranty period Hardware Requirements: Operating system: Windows 2000 or higher Excel version: 2002 or higher, incl. VBA Memory: min. 256 MB RAM (recommended 512 MB) Hard-disk space: min. 100 MB Monitor resolution: XGA (1024 x 768) or higher Disk drive: CD-ROM or DVD Interface: USB port Technical Specifications Application High Gloss Surfaces du < 40, linear range Structure Spectrum du Wa Wb Wc Wd We < 0.1 mm 0.1 to 0.3 mm 0.3 to 1 mm 1 to 3 mm 3 to 10 mm 10 to 30 mm Repeatability ¹ 4% or > 0.4 Reproducibility ¹ 6% or > 0.6 Object Curvature radius > 500 mm Min. Sample Size 35 mm x 150 mm Scan Length 5 / 10 / 20 cm Resolution 375 points/cm Memory 1500 readings Interface USB 1.1 Languages English, French, German, Italian, Japanese, Portuguese, Spanish Light Source Laser diode Laser Energy < 1 mw (Laser class 2) Dimensions 150 x 110 x 55 mm (5.9 x 4.3 x 2.2 in.) Weight 650 g (1.5 lbs) Power Supply rechargeable battery pack or 3 AA alkaline batteries approx readings Temperature Range operation: +10 C to 40 C (+50 F to 104 F) storage: 0 C to 60 C (+32 F to 140 F) Rel. Humidity up to 85% at 35 C (95 F), non-condensing ¹Standard deviation 42 Prices are subject to change without notice.

11 Training for wave-scan II BYK-Gardner offers you more than just an instrument. We assist you in operating the wave-scan system and understanding your appearance readings. As a result you will be able to use the orange peel meter to save time and money and at the same time improve your quality. Therefore, the instrument comes with a one day training course including: 1. Orange Peel and DOI Theory Visual perception and instrumental measurement of Orange Peel and DOI Data interpretation: How can the structure spectrum be used to optimize process and material parameters 2. Operation and Software Training Set-up of an Organizer to create a routine measurement procedure Programming of the instrument with organizer and measurement of several samples Direct data transfer to Excel for documentation of individual readings Data transfer to auto-chart software and saving in a database for routine QC Ordering Information Cat. No. Description Data analysis using standard QC-reports: Summary by lines to show at one glance how various colors are running at different paint lines Trend chart to show how specified zones perform over a defined time range SPC-chart for daily process control of your critical colors and highrunners: xr-chart Zone profile for trouble shooting using the structure spectrum Create your own reports in Excel Transfer data from the database to Excel Pivot function to define layout in Excel The training can be performed in one day or two half days. It is recommended to split the training into two half days: Day 1: Theory and basic operation (set-up organizer, taking readings and saving data in a database) Day 2: 3-4 weeks later to ensure readings were taken and saved in a database. Data analysis and standard QC reports can be explained using customer Accessories 4847 Reference Tile To check performance of the orange peel meter, with certificate 4841 Docking Station Incl. USB interface cable, and recharger V self adapting 4842 Battery Pack Rechargeable battery for automatic charge in docking station 4809 auto-chart Software for analysis and professional documentation in Excel For Certification Services and Preventive Maintenance see pages Prices are subject to change without notice. 43 Orange Appearance Peel / DOI Color Physical Properties Technical Service Index

12 micro-wave-scan Orange Peel and DOI measurement Now you can measure Orange Peel and DOI on small and curved surfaces: Automotive add-on parts like bumpers, gas tank doors, mirror housings, door handles, decorative trim or motorcycle parts....for curved and small parts Curvature > 300 mm Minimum sample size: 25 mm x 40 mm Selectable scan length 20, 10 or even 5 cm Measurement area: 4 mm x scan length DOI measurement possible without scanning the surface Good correlation to wave-scan DOI, the appearance standard in the automotive industry Fits in the palm of your hand Small and light weight, easy to operate with one hand New scroll wheel to select functions and operate button to take readings Large, multilingual display: complete statistics and name input directly at the orange peel meter Storage of 2000 readings in selectable memories Docking station for recharging battery pack and data transfer to PC Rechargeable battery pack or standard mignon batteries can be used auto-chart software for professional analysis, documentation and data management select mode... and measure Objective and reliable appearance data Structure spectrum gives detailed information about various structure size High correlation to the visual perception Cause of appearance changes can be analyzed DOI Distinctness of Image: objective measurement independent of paint system and curvature 44

13 Always ready The micro-wave-scan is operated with a rechargeable battery pack (Li-Ion). The docking station automatically charges the battery pack and transfers the measured data to the PC. Optionally, the orange peel meter can be operated with 2 standard AA alkaline or rechargeable batteries good for 1000 readings. Ordering Information Cat. No. Comes complete with: Orange peel meter, Protective cap, Reference tile with certificate, Software auto-chart on CD, Docking station and interface cable, 2 rechargeable Li-Ion battery packs, Battery holder for AA batteries, 2 Batteries, Operating manual, Carrying case and belt case Training For Certification Services and Preventive Maintenance see pages Description 4824 micro-wave-scan Extended Warranty one year additional Free 1x preventive maintenance service during warranty period Hardware Requirements: Operating system: Windows 2000 or higher Excel version: 2002 or higher, incl. VBA Memory: min. 256 MB RAM (recommended 512 MB) Hard-disk space: min. 100 MB Monitor resolution: XGA (1024 x 768) or higher Disk drive: CD-ROM or DVD Interface: serial or USB port Technical Specifications Application High Gloss Surfaces du < 40, linear range Structure Spectrum du: < 0.1 mm Wa: mm Wb: mm Wc: 1 3 mm Wd: 3 10 mm Scan length/ 20 cm: du, Wa...Wd, L, S, DOI Measurement scales 10 cm: du, Wa...Wd, L, S, DOI 5 cm: du, Wa...Wd, L, S, DOI 0 cm: du, Wa, Wb, DOI Repeatability¹ 8% or > 0.8 Reproducibility¹ 12% or > 1.2 Object Curvature radius > 300 mm Min. Sample Size 25 mm x 40 mm Measurement Area 4 mm x scan length Scan Length 5 / 10 / 20 cm Resolution 375 points/cm Memory 2000 readings Interface serial RS 232 Languages English, French, German, Italian, Japanese, Portuguese, Spanish Light Source Laser diode, LED Laser Energy < 1 mw (Laser class 2) Dimensions 70 x 120 x 40 mm (2.7 x 4.7 x 1.6 in) Weight 250 g (0.6 lbs) Power Supply rechargeable battery pack or 2 AA batteries, approx readings Temperature Range operation: +10 C 40 C (+50 F 104 F) storage: 0 C 60 C (+32 F 140 F) Relative Humidity up to 85% at 35 C (95 F) ¹ Standard deviation Prices are subject to change without notice. 45 Orange Appearance Peel / DOI Color Physical Properties Technical Service Index

14 Training for micro-wave-scan BYK-Gardner offers you more than just an instrument. We assist you in operation of the micro-wave-scan system and understanding your appearance readings. As a result you will be able to use the orange peel meter to save time and money and at the same time improve your quality. Therefore, the instrument comes with a one day training course including: 1. Orange Peel and DOI Theory Visual perception and instrumental measurement of Orange Peel and DOI Data interpretation: How can the structure spectrum be used to optimize process / material parameters 2. Operation and Software Training Set-up of an "organizer" to create a routine measurement procedure Programming of the instrument with "organizer" and measurement of several samples Direct data transfer to Excel for documentation of individual readings Data transfer to auto-chart software and saving in a database for routine QC Data analysis using standard QC-reports: Summary by lines to show at one glance how various colors are running at different paint lines Trend chart to show how specified zones perform over a defined time range SPC-chart for daily process control of your critical colors and highrunners: xr-chart Zone profile for trouble shooting using the structure spectrum Create your own reports in Excel Transfer data from the database to Excel Pivot function to define layout in Excel The training can be performed in one day or two half days. It is recommended to split the training into two half days: Day 1: Theory and basic operation (set-up organizer, taking readings and saving data in a database) Day 2: 3-4 weeks later to ensure readings were taken and saved in a database. Data analysis and standard QC reports can be explained using customer specific data. Ordering Information Accessories Cat. No. Description 4828 Docking Station Incl. serial interface cable 9-pin Sub-D and recharger V self adapting 4829 Reference Tile To check performance of the orange peel meter, with certificate 4401 USB-Adaptor For connection to USB-interface, incl. driver software 4827 Battery Pack Rechargeable battery for automatic charge in docking station 4809 auto-chart Software for analysis and professional documentation in Excel For Certification Services and Preventive Maintenance see pages Prices are subject to change without notice.

15 wave-scan ROBOTIC Automatic appearance control of topcoat finish at the line A stable running process is the key for uniform and consistent quality. Therefore, orange peel and DOI need to be measured on a routine basis in the production process and the measurement results shared with add-on suppliers. The new wave-scan ROBOTIC allows automated appearance control as it is mounted on a robotic arm. The robotic system ensures measurement on the same area and a high number of measured car bodies. Non-contact measurement Distance to surface 15 ± 2 mm Angle to perpendicular ± 2 Curvature > 500 mm radius Scan speed 50 to 150 mm/sec. Small and light weight Objective and reliable appearance data Excellent correlation to wave-scan DOI, the appearance standard in the automotive industry Structure spectrum gives detailed information about the surface quality Cause of appearance changes can be analyzed Orange Peel, DOI and customer specific scales available Stable process means consistent quality Automated appearance control provides complete and representative data for statistical process control wave-scan ROBOTIC builds up a valuable database for systematic process analysis and optimization 47 Orange Appearance Peel / DOI Color Physical Properties Technical Service Index

16 Training for wave-scan ROBOTIC BYK-Gardner offers you more than just an instrument, we assist you in operating the wave-scan system. Therefore, the orange peel meter comes with a two day training course including: Orange Peel & DOI: Theory and data interpretation. Support in integrating wave-scan ROBOTIC sensor into automated measurement system Data analysis using standard QC-reports including SPC-charts Ordering Information Cat. No. Description 4822 wave-scan ROBOTIC 4850 wave-scan dual ROBOTIC Extended Warranty one year additional Comes complete with: Orange peel meter Reference tile with certificate auto-chart software on CD, Communication software on CD Installation kit Operating manual Carrying case Training Free 1x preventive maintenance service during warranty period Hardware Requirements: Operating system: Windows 2000 or higher Excel version: 2002 or higher, incl. VBA Memory: min. 256 MB RAM (recommended 512 MB) Hard-disk space: min. 100 MB Monitor resolution: XGA (1024 x 768) or higher Disk drive: CD-ROM or DVD Interface: RS 422 Technical Specifications Application High Gloss Surfaces du < 40, linear range High to Semi Gloss du < 65, linear range Structure Spectrum du: < 0.1 mm Wa: 0.1 to 0.3 mm Wb: 0.3 to 1 mm Wc: 1 to 3 mm Wd: 3 to 10 mm We: 10 to 30 mm Repeatability¹ du < 40: 4% or > 0.4 du > 40: 6% or > 0.6 Reproducibility¹ du < 40: 6% or > 0.6 du > 40: 8% or > 0.8 Resolution 375 points/cm Distance to Surface 15 ± 2 mm Angle to Surface perpendicular ± 2 Object Curvature radius > 500 mm Min. Sample Size 35 mm x 150 mm Scan Length 5 / 10 / 20 cm Scan Speed 50 to 150 mm/sec Memory 100 readings Light Source Laser diode, LED Laser Energy < 1 mw (Laser class 2) Dimensions 112 x 115 x 60 mm (4.4 x 4.5 x 2.4 in) Weight 520 g (1.2 lbs) Power Supply external power supply 24 V DC, max. 0.5 A Interface RS 422 Robotic requirements Vibration-free operation Temperature Range operation: +10 C to 40 C (+50 F to 104 F) storage: 0 C to 60 C (+32 F to 140 F) Rel. Humidity up to 85% at 35 C (95 F) non-condensing ¹ Standard deviation Ordering Information Accessories Cat. No. Description 4833 Reference Tile ROBOTIC To check performance of the orange peel meter, with certificate 4851 Reference Tile ROBOTIC dual To check performance of the orange peel meter, with certificate 4809 auto-chart Software for analysis and professional documentation in Excel 48 Prices are subject to change without notice.

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