Measure coating thickness early in your process.

Transcription

1 Measure coating thickness early in your process. Patented technology Control production. Detect and adjust deviations early in the process and avoid rejects and reworks. Document consistently. Continuous logging of your coating process for you and your customers. Save material. Reduce material consumption by up to 30 % in order to conserve your resources and protect our environment. Secure quality. Produce coatings with high accuracy and set new quality standards.

2 The coatmaster provides reliable results. Non-contact. Patented technology (Advanced Thermal Optics) for non-contact thickness measurement at a distance of up to 100 cm. In-line in real time. Measure on moving parts in the coating line for uninterrupted production. For complex-shaped parts. On curved surfaces, on inside faces as well as in corners and on edges. For all colours. Measure with or without calibration, matching your demands. Early in the process. Also suitable for wet and uncured coatings. Various substrate materials. Measure on metal, plastic, rubber, wood, CFRP, glass and many more materials. The coatmaster is versatile. Lubricant and polymer coatings. Lubricant coatings can be applied within a small tolerance range. Short measurement duration saves time and allows for continuous documentation. Powder coatings. The precise control of the coating thickness enables the consumption of powder paint to be reduced by up to 30 %. The thickness measurement early in the process saves time and reduces rejects. Wet paint coatings. Precise measurements even before curing. High repeatability is guaranteed, thus saving material and time whilst assuring quality. Thermal spray coatings. The thickness of thermal sprayed coatings is measured quickly and precisely on sprayed or mechanically processed surfaces. This saves time for quality control and also allows documentation even on delivered parts. Adhesives. Measure adhesives precisely and reliably in a soft state, even on rough surfaces. This assures that only the best quality is delivered. coatmaster by Winterthur Instruments AG Register for your personal webinar. Flugplatzstrasse 5 CH-8404 Winterthur phone info@winterthurinstruments.ch Industry partners

3 Data Sheet Inline Inline 500 Inline 1000 Inline 1500 Inline 2000 Energy 500 J 1000 J 1500 J 2000 J Measurement distance 5 cm 15 cm ** 5 cm 30 cm ** 5 cm 40 cm ** 5 cm 50 cm ** Measurement point ø2 20 mm * Ø 2 20 mm * Ø 2 20 mm * Ø 2 20 mm * Measurement range: Powder coating uncured Powder coating cured Powder coating pre-cured Wet paint µm µm Measurement duration 20 ms 2000 ms 20 ms 2000 ms 20 ms 2000 ms 20 ms 2000 ms Repetition rate 1 Hz 0.5 Hz 0.4 Hz 0.3 Hz Relative velocity of sample 50 m/min * 50 m/min * 50 m/min * 50 m/min * Tilt tolerance ±70 ±70 ±70 ±70 Power connection IEC 320-C14 IEC 320-C14 IEC 320-C14 IEC 320-C14 Supply voltage 230 V AC, 50 Hz 230 V AC, 50 Hz 230 V AC, 50 Hz 230 V AC, 50 Hz Fuse 10 A 10 A 10 A 10 A Power consumption max W max W max W max W Operating temperature measurement 5 C 50 C 5 C 50 C 5 C 50 C 5 C 50 C head Operating temperature cooling and generator unit 5 C 35 C 5 C 35 C 5 C 35 C 5 C 35 C Relative humidity < 80% < 80% < 80% < 80% Dimensions measurement head 204 x 254 x x 254 x x 254 x x 254 x 268 (mm) Dimensions cooling and generator unit 483 x x 418 (19 3 HE) 483 x x 418 (19 3 HE) 483 x x 418 (19 3 HE) 483 x x 418 (19 3 HE) Weight measurement head 5.3 kg 5.3 kg 5.3 kg 5.3 kg Weight cooling and generator 17.5 kg 17.5 kg 17.5 kg 17.5 kg unit Fixation guide rail guide rail guide rail guide rail Cable length between measurement max. 10 m max. 10 m max. 10 m max. 10 m head and cooling and gen- erator unit Height difference between max. 5 m max. 5 m max. 5 m max. 5 m measurement head and cooling and generator unit Interface: Ethernet Yes Yes * depending on distance / focal width ** depending on coating and substrate

4 Data Sheet Atline Energy 500 J 1000 J 1500 J 2000 J Measurement distance 5 cm 15 cm ** 5 cm 30 cm ** 5 cm 40 cm ** 5 cm 50 cm ** Measurement point Ø 2 20 mm * Ø 2 20 mm * Ø 2 20 mm * Ø 2 20 mm * Measurement range: Powder coating uncured Powder coating cured Pulverlack pre-cured Wet paint Measurement duration 20 ms 2000 ms 20 ms 2000 ms 20 ms 2000 ms 20 ms 2000 ms Repetition rate 1 Hz 0.5 Hz 0.4 Hz 0.3 Hz Relative velocity of sample 50 m/min 50 m/min 50 m/min 50 m/min Tilt tolerance ±70 ±70 ±70 ±70 Power connection IEC 320-C14 IEC 320-C14 IEC 320-C14 IEC 320-C14 Supply voltage 230 V AC, 50 Hz 230 V AC, 50 Hz 230V AC, 50 Hz 230V AC, 50 Hz Fuse 10 A 10 A 10 A 10 A Power consumption max W max W max W max W Operating temperature 5 C 35 C 5 C 30 C 5 C 30 C 5 C 30 C Relative humidity < 80 % < 80 % < 80 % < 80 % Dimensions (mm) 374 x 490 x x 490 x x 490 x x 490 x 196 Weight 16.8 kg 16.8 kg 16.8 kg 16.8 kg Fixation Guide rail Guide rail Guide rail Guide rail Interface: Ethernet WLAN External sensor * depending on distance / focal width ** depending on coating and substrate optional optional optional optional

5 Uncured powder coatings Process control of powder coatings by inline coating thickness measurement before curing Test measurements in the technical laboratory of J. Wagner in Markdorf, Germany, show, that the is well-suited for the inline process control of powder coatings in uncured state. The measurements are carried out on moving aluminum profiles with powder lacquer coating. As the is mounted directly at the exit of the powder coating booth, the measurement is performed immediately after the coating has been applied and before curing. Different profile types are hung in a frame and move at a speed of 1.8m/min on a belt. The measurement is triggered automatically by the signal of a light barrier sensor as soon as a profile passes by. The exact measuring positions are marked on the profiles, so that a comparative measurement is possible at the same positions after curing. The comparative measurement is carried out according to the inductive method with an Elcometer. From the graphic below a good correlation between the measurement before curing and the inductive contact measurement after curing can be seen. To test the reproducibility, the profile frame passes the several times. As the following graphic shows, also moving parts can be measured with a high reproducibility. Anschliessend wird der Profil-Rahmen wie The measurement results prove that the is well-suited for the inline coating thickness measurement of powder coatings before curing even on moving parts. Benefits for the user For manufacturers of industrial products with wet powder coatings, benefits include: Process control: A fast reaction to deviations in the process saves production time. Quality assurance: A full ducumenation of all parts is possible. Save coating material: Due to continuous process control, material savings of % can be achieved. J. Wagner GmbH Otto-Lilienthal-Strasse 18, D Markdorf Contact person: Patrik Studerus Elcometer (after curing) (µm) (before curing) (µm) Comparison of the measurement before curing and the inductive comparison measurement with the Elcomenter after curing. The correlation of the measurement values is r2 = 0,96, showing a very good correlation. The variation coefficient for repeated measurements with the is 1 % (measurement distance of 15 cm), those of the inductive measurement is 5 % (left); Comparison of repeated single measurements on six different moving profiles to test the reproducibility (MV=mean value, SD=standard deviation) (right) Coating thickness (µm) Sample number Application 6, 1401, 2014 Winterthur Instruments AG

6 Wet laser coating on plastic The predicts the coating thickness of dry laser paint by measuring the wet paint The continuous monitoring and control of coating processes can result in significant materials savings and cost reductions. The instrument from Winterthur Instruments enables such a control and the resulting benefits. In the application described in this document, the is used to determine the coating thickness of wet laser coatings on plastic, in a non-contact and non-destructive manner. Thickness of wet laser coatings A measurement series is carried out with the to measure the thickness of a wet laser coating (Mankiewicz dull matt black). The value displayed by the is a prediction of the coating thickness when the coating is dry. The laser coating is applied to plastic sheets in two different thicknesses by means of a scraper. One minute after application, Coat- Master measurements are carried out at six positions distributed over the coating. Five measurements are carried out at each position to determine the deviation. Then, the coating is dried for 20 minutes at 75 C and the coating thickness is measured at the same positions by means of the destructive wedge cut principle. Results The figure on the right-hand side shows the correlation of the measurement results from the and the wedge cut method. The mean difference between the two methods is 5 %, which is within the measurement tolerance. The optimal thickness of the laser coating is 25 µm. For this coating thickness the measurement has a standard deviation of 0.3 µm, and the wedge cut principle has a standard deviation of 3 µm. This investigation shows that the can reliably predict the thickness of laser coatings on plastic substrates. The measurements are carried out on the wet coating before drying. For manufacturers of industrial products with wet laser coatings, benefits include: Process safety: The coating process is controlled and protocolled continuously and objectively. Fewer coating defects: Deviations during the coating process are detected instantly, so corrective action can be taken immediately. Video documentation of the measurement series: v=4mm--cj7fwi. Links: The coating thickness of the wet laser coating can be measured with the in a precise and reproducible way (left). A destructive coating thickness measurement by means of the wedge cut principle serves as a comparison. Rechts: Based on the s measurement of the wet coating, the instrument generates a prediction for the coating thickness in dried state (orange). As a comparison, the coating thickness is measured in dried state by means of the wedge cut destructive method (blue). The two measurement methods have a good correlation within the measurement tolerance. The figure shows the mean values (dots, squares) as well as the dispersion of the measurement values (bars). Application 3, 1401, 2014 Winterthur Instruments AG

7 Wet paint on plastic The measures wet water-based paint on plastic without calibration Measurements performed by Winterthur Instruments together with AkzoNobel Coatings in Stuttgart show that the instrument is well-suited for measuring the coating thickness of wet, water-based paint on plastic. The measurements are carried out for the paint colors yellow uni, red uni, misan red and technical grey. For each paint two plastic sheets are coated with different thicknesses varying between 16 and 34 μm (dried state). As shown in the figure, there is a good correlation between the measurements of the samples with wet paint, and micrograph measurements of the same samples after drying. In other words, the can be used early in the coating process to measure the coating thickness of paint even while the paint is still wet. Depending on the process requirements and desired accuracy, the can be used without or with calibration. 35 No calibration relative measurement of coating thickness in % In this setup, the first measures the thickness of a reference coating, assigning it a value of 100 %, that serves as a comparison for subsequent measurements. For each subsequent measurement of coating thickness, the displays the deviation from this reference as a percentage e.g. 112 %, 93 %. No calibration is required. Calibration absolute measurement of coating thickness in μm To generate absolute values of coating thickness in μm, a comparative measurement is first taken, for example from a micrograph, to determine the thickness of the dried paint. The measurement results show that the is well-suited for the non-contact and non-destructive measurement of wet paint on plastic. Furthermore, the enables continuous control of the coating process, leading to significant materials savings and cost reductions. For manufacturers of industrial products with wet paint coatings, benefits include: Process control: The coating process is controlled and protocolled continuously and objectively. Fewer coating defects: Deviations during the coating process are detected instantly, so corrective action can be taken immediately. Shorter production time: Due to a continuous measurement of coating thickness, the coating process for a new production series can be set up and optimized more rapidly. Microscope (dry paint) (µm) (wet paint) (µm) Measurement of coating thickness of paint on plastic: Correlation of micrograph (dry paint) and (wet paint). Application 1, 1401, 2014 Winterthur Instruments AG

8 Wet zinc flake basecoats and topcoats Coating thickness measurement of wet DELTA-MKS basecoats and topcoats Tests at Dörken MKS-Systeme Germany show that the instrument is well-suited for measuring the coating thickness of wet zinc flake basecoats and topcoats. In the application described in this document, measurements are carried out on Dörken basecoats DELTA -TONE 9000 and DELTA-PROTEKT KL 101, as well as silver and black DELTA -SEAL topcoats. The thickness of the wet coatings (uncured) is measured with a Winterthur Instruments HP. The value displayed by the is a prediction of the coating thickness in μm after curing. Comparative measurements of the coating thickness are carried out on the same samples after curing, with a Fischer Dualscope MP40 instrument using the magnetic induction method. For each test sample, five consecutive measurements are carried out with each instrument. The correlation of the two sets of measurements is calculated via the vari- ation of the mean values. To estimate the accuracy of each method, the standard de- viation is calculated of the five consecutive measurements. Correlation of and magnetic induction thickness measurement results As shown in Figure 2, the thickness predictions based on measurements ofthe uncured coatings are in good agreement with the Dualscope inductive measurements after curing. The provides a high level of accuracy even with only one measurement (repeated measurements are not needed). To achieve a comparable level of accuracy with the magnetic inductive method, up to 170 repeated measurements are needed, depending on sample surface properties. The markers show the mean values of the measurements; the bars show the lowest and the highest measured values (from five measurements). The charts show the good correlation of the mean values of both measuring methods as well as the low dispersion of the values. For manufacturers of industrial products with wet paint coating, benefits include: Process control: By measuring the coating thickness of wet paint, one can react sooner to process deviations and make appropriate process improvements. Broad applications: Measurements without recalibration can be made on many substrate shapes and types of materials; objects with curves and edges can also be measured. Precise and reproducible: The reproducibility of the measurement is higher than that of the magneto-inductive method, and is not impaired by rough or uneven surfaces. Dörken MKS-Systeme GmbH & Co. KG Wetterstraße 58 D Herdecke Contact person: André Fackiner Comparison of thickness measurements of wet basecoats with (orange), and of basecoats after curing with Dualscope (gray): left DELTA -TONE 9000, right DELTA-PROTEKT KL 101. Application 2, 1401, 2014 Winterthur Instruments AG

9 Enamel powder coatings before curing Process control of enamel powder coatings by inline coating thickness measurement before curing Test measurements at the production site of Whirlpool Europe, Italy, in cooperation with Wagner Itep, Italy, show, that the is well-suited for the inline process control of enamel powder coatings in uncured state. The measurements are carried out on enamel powder coated cavities of baking ovens before curing. The is mounted upright on a profile rail at the position where the cavities are hung up by a robot to be lead through the drying oven. Here, they stand still for about 3 seconds. Now the measurement is carried out upwards into the inner back wall of the cavity with a distance of 60 cm. Each cavity is measured once. In a second measurement cycle the inner side walls of the cavities are measured with an angle of 45. The coating thickness within the cavities amounts to µm depending on the position. The measurement is triggered automatically by the signal of a sensor as soon as a cavitity reaches the measurement position. The comparative measurement is carried out according to the inductive method with a Fischerscope after curing. From the graphic below a good correlation between the measurement before curing and the inductive contact measurement after curing can be seen. The correlation coefficient is... (exact values and corresponding graphics below to be added). The measurement results prove that the is well-suited for the inline coating thickness measurement of enamel powder coatings before curing even with a large distance to the measurement object and with a large coating thickness. Benefits for the user For manufacturers of industrial products with enamel powder coatings, benefits include: Process control: A fast reaction to deviations in the process saves production time and renders expensive rework superfluous. Quality assurance: Coating thickness accuracy can be guaranteed and a full ducumenation of all parts is possible. Save coating material: Due to continuous process control, material savings of % can be achieved. Whirlpool Europe, Italy Contact person: Mr. Cristian Boem Elcometer (after curing) (µm) (before curing) (µm) Comparison of the measurement before curing and the inductive comparison measurement with the Fischerscope after curing. The correlation of the measurement values is r 2 = x, showing a very good correlation. The variation coefficient for repeated measurements with the is x % (measurement distance of 60 cm), those of the inductive measurement is x % (left); Comparison of repeated single measurements on six different cavities to test the reproducibility (right) Coating thickness (µm) Sample number Application 9, 1409, 2014 Winterthur Instruments AG

10 Enamel powder coatings before curing Process control of enamel powder coatings by inline coating thickness measurement before curing Test measurements at the production site of Whirlpool Europe, Italy, in cooperation with Wagner Itep, Italy, show, that the is well-suited for the inline process control of enamel powder coatings in uncured state. The measurements are carried out on enamel powder coated cavities of baking ovens before curing. The is mounted upright on a profile rail at the position where the cavities are hung up by a robot to be lead through the drying oven. Here, they stand still for about 3 seconds. Now the measurement is carried out upwards into the inner back wall of the cavity with a distance of 60 cm. Each cavity is measured once. In a second measurement cycle the inner side walls of the cavities are measured with an angle of 45. The coating thickness within the cavities amounts to µm depending on the position. The measurement is triggered automatically by the signal of a sensor as soon as a cavitity reaches the measurement position. The comparative measurement is carried out according to the inductive method with a Fischerscope after curing. From the graphic below a good correlation between the measurement before curing and the inductive contact measurement after curing can be seen. The correlation coefficient is... (exact values and corresponding graphics below to be added). The measurement results prove that the is well-suited for the inline coating thickness measurement of enamel powder coatings before curing even with a large distance to the measurement object and with a large coating thickness. Benefits for the user For manufacturers of industrial products with enamel powder coatings, benefits include: Process control: A fast reaction to deviations in the process saves production time and renders expensive rework superfluous. Quality assurance: Coating thickness accuracy can be guaranteed and a full ducumenation of all parts is possible. Save coating material: Due to continuous process control, material savings of % can be achieved. Whirlpool Europe, Italy Contact person: Mr. Cristian Boem Elcometer (after curing) (µm) (before curing) (µm) Comparison of the measurement before curing and the inductive comparison measurement with the Fischerscope after curing. The correlation of the measurement values is r 2 = x, showing a very good correlation. The variation coefficient for repeated measurements with the is x % (measurement distance of 60 cm), those of the inductive measurement is x % (left); Comparison of repeated single measurements on six different cavities to test the reproducibility (right) Coating thickness (µm) Sample number Application 9, 1409, 2014 Winterthur Instruments AG

11 Inline thickness measurement of resin coatings on foil Process control during the production of fiber-reinforced plastic Test measurements in the Polynt plant in Miehlen show, that the is well-suited for the inline process control of resin coatings on foil and helps to recognize process deviations at an early stage. Polynt is a manufacturer of glass- and fiber-reinforced semi-finished plastics, among others for the automobile industry. As the requirements for quality control increase continuously within this industry, the manufacturer strives to optimize his process control continuously as well. During the production process two foil-covered belts move along with a speed of several meters per minute. Above the belts a blade box with adjustable gap is located to apply the liquid resin to the foil. Up to know a radiometric measurement and the determination of the surface weight have been used to check the coating thickness. However, both methods entail some disadvantages. The radiometric measurement is very maintenance and thus cost-intensive and leads to a constant presence of radioactive radiation, whereas the surface weight determination is a destructive method, for which the process has to be interrupted. Thus, it cannot be applied continuously. During a production test run a test installation of the is performed for a continous process control. For this purpose, the is installed vertically at a cross-section profile 20 cm behind the doctor s knife with a distance of 10 cm to the surface of the resin surface. For calibration purposes the s measures the coating thickness for three different gaps (290, 340 und 390 µm) on the running belt. The measurements show a very good correlation of R 2 = 0.96 between the value and the gap. Now a continuous measurement on the running belt is carried out. As the figure below shows, there are repeated variations within the coating thickness when the blade box is refilled with resin (e.g. at 00:28). To avoid these deviations the resin is refilled slowly and continuously afterwards, which minimizes the resin movement and thus the different pressures within the blade box, so that the deviations disappear. Thanks to the findings by means of the measurements the coating thickness deviations during the production test run could be reduced significantly. The measurement results prove that the is well-suited for the inline coating thickness measurement of resin coatings on foil - even on the moving belt. For the manufacturers of fiber-reinforced plastic benefits include: More efficiency: The fast reaction to process deviations enables time savings within the production process and during the runin of new coating processes. Higher safety and profitability: Measuring without radioactive radiation sources leads to significant cost reduction and more safety for people and environment. Continuous process documentation: The coating parameters of the production charges are controlled and recorded continously and objectively. Polynt GmbH Kieselstrasse, D Miehlen Course of measurement during an inline measurement at a production test run. Apart from the setting of the doctor s knife gap, the thickness of the resin coating also depends on other factors like the filling level of the blade box, the environmental conditions, etc. In the course of the inline coating thickness measurement during the production it becomes obvious that strong coating thickness deviations occur, when the blade box is refilled with resin. Due to this finding, the resin is now added slowly and continuously, so that the coating thickness deviations are significantly reduced (from ca. 00:30 on) Application 8, 1401, 2014 Winterthur Instruments AG

12 Powder coatings on MDF panels Process control for powder coatings by inline coating thickness measurement before curing Test measurements in the Ramseier Woodcoat plant in Thun, Switzerland show, that the is well-suited for the inline process control of powder-coated MDF panels (medium density fibreboard) and helps to recognize process deviations at an early stage. For this test two measuring series are carried out. The first measuring series serves to verify the compliance of the measurement before curing with a destructive measurement with the Erichsen Paint Borer 518 MC after curing. MDF panels are coated with the primer lacquer and directly afterwards measured with the. The measuring positions are marked on the panels, so that a comparative measurement with the Paint Borer is possible at the same position after curing. The figure on the left shows a good correlation between measurement before curing and the comparative measurement after curing. Measurements are carried out on the front side of the MDF panels as well as on the edges, where a too thin coating leads to visible cracks. With the a coating thickness measurement is also possible on edges and curvatures. The edge width of the measured MDF panels is 19 mm. In the second measuring series both coatings of the MDF panels, the primer coating and the coating with the colored topcoat in different colors are measured inline directly after the coating application. The measurement is triggered automatically by the signal of a light barrier sensor as soon as a panel passes by. The belt moves with a speed of 1.8 m/min. The figure on the right shows that at the beginning the coating thickness of the topcoat is within the tolerance range but suddenly drops below it. An immediate check reveals that one of the powder guns is clogged. The gun is cleaned immediately and the coating thickness is back within the tolerance range. The measurement results prove that the is well-suited for the inline coating thickness measurement of powder coatings on MDF panels before curing even on moving parts. For manufacturers of coated MDF panels benefits include: Process control: A fast reaction to deviations in the process saves production time. Quality assurance: A full documentation of all parts is possible. The avoidance of an unsufficient coating thickness ensures the quality. Save coating material: Due to continuous process control, material savings of 10-30% can be achieved. Ramseier Woodcoat AG Tempelstrasse 10, CH-3608 Thun Comparison of the measurement before curing with the destructive Paint Borer comparative measurement after curing. The correlation coefficient R 2 is 0.95, showing that the two measuring methods have a very good correlation. The variation coefficient for repeated measurements with the is 3 %, the destructive measurement has a standard deviation of 7 μm (left); Measuring curve during an inline measurement. It is plain to see how the coating thickness drops below the tolerance limit and how this is corrected immediately (right). Application 7, 1401, 2014 Winterthur Instruments AG