Preface The glazing's optical reflection characteristics (the distortion of the mirror images of its surround‐ ings) affect the exterior aesthetics of vehicles and, under certain circumstances, vehicle functions such as how well windshields can be wiped.
Previous issues PV 8203: 2013-03
Changes The following changes have been made to PV 8203: 2013-03: – Section 3.4, text adapted – Appendix A, sample images revised
1 Scope This Test Specification (PV) describes measuring and evaluation methods that ensure the reprodu‐ cible quantitative evaluation of optical reflection characteristics. It applies to all types of vehicle win‐ dow glass. The specifications in this document are to be implemented in addition to those concerning optical reflection characteristics in PV 2501 and Technical Supply Specification TL 957.
2 Description Optical reflection characteristics test as per PV 8203
Always use the latest version of this standard.
This electronically generated standard is authentic and valid without signature. Page 1 of 12 The English translation is believed to be accurate. In case of discrepancies, the German version is alone authoritative and controlling.
Technical responsibility The Standards department
EKDV/4 Wolfgang Tiefenbach EKDV EGNM/G Dr. Boris Thielbeer Tel.: +49 5361 9 40212 Tel.: +49 5361 9 75357 Maik Gummert
3.1 Curvature Curvatures are the reciprocals of the radii of circles that follow the contour of the surface or of an intersection curve at the surface point being analyzed as tightly as possible. If the surface or the intersection curve at the point being analyzed is convex, the corresponding curvature (and the radi‐ us) will have a positive sign by definition. If it is concave, the curvature (and the radius) will be neg‐ ative. A curvature of zero describes an infinite radius, i.e., a perfectly flat point. In contrast, an infin‐ ite curvature would describe a radius of zero, i.e., a sharp point. The local curvature of a surface does not vary relative to the position or direction of observation or relative to the rotational position or displacement of the object being measured in space provided the object being measured is a rigid body.
3.2 Normal curvature CNORMAL
Curvatures that run in all possible tangential directions centered on a selected surface point are referred to as "normal curvatures" (all the curvatures centered on the normal vector). If the principal curvatures are known, they can be used to calculate any normal curvature for the corresponding surface point (normal curvature formula, Euler):
CNORMAL = Cmax cos2 α + Kmin sin2 α (1)
where α = angle between and
3.3 Principal curvatures
If one draws intersections in all possible tangential directions at a selected surface point, there will normally be exactly one intersection that has the smallest osculating circle and one intersection that has the largest osculating circle. These two intersections are perpendicular to each other and characterize the principal curvatures' contour. In other words, the surface's normal vector and the vectors corresponding to the two principal curvatures form a vector trihedron in which the vectors are orthogonal to each other. The two principal curvatures are called the "maximum curvature" and "minimum curvature" and, accordingly, are the normal curvature's extrema. The absolute values of these principal curvatures are always accompanied by the direction of curvature.
3.3.1 Maximum curvature Cmax
The maximum curvature at a point is characterized by the fact that the smallest possible osculating circle (minimum radius) is located at the intersection curve – for this surface point – on the plane defined by the surface's normal vector and the tangential vector (the direction vector of the maxi‐ mum curvature). In other words, the maximum curvature corresponds to the minimum radius. Page 3 PV 8203: 2014-03
3.3.2 Minimum curvature Cmin
The minimum curvature at a point is characterized by the fact that the largest possible osculating circle (maximum radius) is located at the intersection curve – for this surface point – on the plane defined by the surface's normal vector and the tangential vector (the direction vector of the mini‐ mum curvature). In other words, the minimum curvature corresponds to the maximum radius.
3.4 Derived curvatures, principal direction of bend, and transverse direction of bend The Gaussian curvature and mean curvature can be calculated on the basis of the principal curva‐ tures and are independent of direction. However, under certain circumstances, parts found in the individual principal curvatures may be neutralized by the method used to calculate a Gaussian or mean curvature on their basis. Because of this, an analysis in two separate directions of curvature is preferred as a basis for evaluation. Instead of analyzing the Gaussian and mean curvatures, the local principal curvatures are used to‐ gether with the normal curvature formula to calculate a globally horizontally oriented curvature and a globally vertically oriented curvature. These two global directions are referred to as the principal direction of bend and the transverse direction of bend. The principal direction of bend is oriented along the coordinate axis, together with which the mean direction of all maximum curvature vectors encloses the smallest solid angle. The corresponding local curvatures are labeled as CMAJOR (princi‐ pal direction of bend) and CMINOR (transverse direction of bend).
If sets of raw curvature data for a window glass and a reference window glass are available, curva‐ ture differences can be computed in order to determine the differences between the two data sets (for a reference specification, see section 6.3). When the difference is computed, the local direction of curvature must be taken into account and adapted to the principal direction of bend and the transverse direction of bend. One data set de‐ fines the TARGET characteristic (reference), while the other defines the ACTUAL characteristic. The following calculation convention is agreed upon so that the sign will be clearly defined when calculating the curvature difference CDIFF:
CDIFF = CACTUAL - CTARGET (2)
In addition, a standardized curvature difference CMEANDIFF is calculated by dividing the curvature dif‐ ference CDIFF by the absolute value of the local mean TARGET curvature. This ensures that devia‐ tions in flat areas will be weighted more than deviations in areas that are more curved:
(3)
3.6 Deflectometry "Deflectometry" refers to the measuring method used to measure curvatures on reflective surfaces. This measuring method obtains the raw curvature data that is processed as per this PV. Page 4 PV 8203: 2014-03
4 Requirements
4.1 Measuring system requirements related to the object being measured
Window glass dimensions that the system At least 1 500 mm × 1 000 mm × 300 mm can handle Variation of surface normals Maximum ± 90° in all directions (hemisphere)
4.2 Vehicle window glass setup and position
Since vehicle window glass is normally not stable enough by itself, it must be mounted or stabilized in such a way that it will match the as-installed position in the vehicle during the measurement. It must be possible to adjust the measuring fixture in such a way that the window glass can be set up in its as-installed position (vehicle coordinate system) without the mount producing additional cur‐ vatures in the window glass that will not exist when the window glass is installed in the vehicle (in‐ herent load, warping).
4.3 Requirements for the raw data being obtained
The distance between measuring points is ≤ 1 mm. This measuring point distance must be main‐ tained across the window glass' entire surface (all the way to the edge, i.e., the distance between the point and the edge is ≤ 1 mm). Ideally, the measuring points will be distributed in an approxi‐ mately equidistant grid. At least the following information must be provided for each measuring point, in a readable ASCII format: – X-axis, Y-axis, and Z-axis coordinates, in mm, in the vehicle coordinate system [expanded measurement uncertainty (k = 2) for the X-axis, Y-axis, Z-axis coordinates: ± 1.0 mm] – Surface normal direction (X-axis, Y-axis, Z-axis coordinates in the vehicle coordinate system; absolute value = 1) – Maximum and minimum curvature in m-1 [expanded measurement uncertainty (k = 2) for the curvature data: ± 0.05 m-1] – Direction of maximum curvature (X-axis, Y-axis, Z-axis coordinates in the vehicle coordinate system; absolute value = 1)
5 Measuring and providing raw curvature data
5.1 Measuring a window glass
The surface curvature is measured with a deflectometric measuring system that meets the require‐ ments described in section 4. The window glass' entire surface (normally the one corresponding to the vehicle exterior or the one corresponding to the vehicle interior as well) must be recorded in the vehicle coordinate system. If the window glass cannot be recorded in one single view, the individu‐ al views must be combined in such a way that exactly one single data set that meets the require‐ ments in section 4.3 is produced for each window glass (normally the side corresponding to the vehicle exterior or the side corresponding to the vehicle interior as well). Page 5 PV 8203: 2014-03
5.2 Reconstructing curvature data on the basis of CAD surface descriptions
Surface data (CAD) available in CATIA or IGES format must be prepared in such a way that exact‐ ly one single data set that meets the requirements in section 4.3 is produced for each window glass (normally the side corresponding to the vehicle exterior or the side corresponding to the vehi‐ cle interior as well).
6 Evaluation
6.1 Graphic representation formats
Curvatures and curvature differences must be represented both as grayscale and pseudo-color two-dimensional images (or as isolines instead of as a pseudo-color image). The limits are adjusta‐ ble. The pseudo-colors comprise eleven colors (see 8-bit RGB values in table 1). The grayscale is continuous. Page 6 PV 8203: 2014-03
Table 1 Pseudo-color image Grayscale image
R G B Description Color Description
0 0 127 Concave outside Blue Concave outside limit limit 0 0 255 Concave, major deviation Black Concave, major deviation 0 127 255 0 242 242 Concave, deviation Dark gray Concave, deviation 0 204 127 0 178 0 No deviation = 0.0 Standard gray No deviation = 0.0 153 204 0 247 247 0 Convex, deviation Bright gray Convex, deviation 255 127 0 255 0 0 Convex, major deviation White Convex, major deviation 127 0 0 Convex outside Red Convex outside limit limit
The limits and the intermediate values between the color limits/isolines must be specified on a scale. The percentage of measuring points that fall within the selected limits and the percentage of measuring points that fall outside must be specified. The distribution of measuring points must be represented in a bar graph. For more graphic representation formats for analysis, see appendix A.
6.2 Graphically representing the absolute curvature, curvature difference, and standardized curvature difference Curvatures must always be compared relative to a reference (for the reference specification, see section 6.3). Curvatures and curvature differences must always be represented in the principal direction of bend and transverse direction of bend. The corresponding curvatures CMAJOR (principal direction of bend) and CMINOR (transverse direction of bend) are always calculated with the normal curvature formula: Page 7 PV 8203: 2014-03
CMAJOR = Cmax cos2 α + Cmin sin2 α (4)
The curvature in the transverse direction of bend CMINOR is orthogonal to it (tangential to the sur‐ face).
Table 2 Principal direction of bend Transverse direction of bend Absolute curvatures CMAJOR, TARGET CMINOR, TARGET in the TARGET data set (reference) Absolute curvatures CMAJOR, ACTUAL CMINOR, ACTUAL in the ACTUAL data set Curvature differences CMAJOR, DIFF = CMAJOR, ACTUAL - CMAJOR, CMINOR, DIFF = CMINOR, ACTUAL - CMINOR, TARGET TARGET
Standardized curvature differences
The variables listed in table 2 must be documented in the measurement report. Appendix A shows examples of graphic representations.
6.3 Limits and reference specification
For each window glass, Volkswagen and the window glass manufacturer will jointly define a sur‐ face data set as a reference for comparing curvatures and for calculating the curvature difference. Normally, this reference data set will match the window glass' CAD data set. In exceptional cases, a reference surface data set may be derived from a window glass evaluated as being OK. The maximum permissible curvature difference relative to the reference is 0.2 m-1 at any point on the window glass. The maximum permissible standardized curvature difference relative to the reference is 0.75 at any point on the window glass. For areas with extremely little curvature that have a mean target curvature below the measuring system's measurement uncertainty of ± 0.05 m-1 (radii with an absolute value ≥ 20 m), standar‐ dized curvature differences greater than 0.75 are permissible. These areas must be marked in the reference data.
7 Applicable documents The following documents cited in this standard are necessary to its application. Some of the cited documents are translations from the German original. The translations of Ger‐ man terms in such documents may differ from those used in this standard, resulting in terminologi‐ cal inconsistency. Standards whose titles are given in German may be available only in German. Editions in other languages may be available from the institution issuing the standard. Page 8 PV 8203: 2014-03
Table A.1 Principal direction of bend Transverse direction of bend
A.1.2 Absolute ACTUAL curvature
Table A.2 Principal direction of bend Transverse direction of bend Page 10 PV 8203: 2014-03
A.1.3 Curvature difference
Table A.3 Principal direction of bend Transverse direction of bend Page 11 PV 8203: 2014-03
A.1.4 Standardized curvature difference
Table A.4 Principal direction of bend Transverse direction of bend Page 12 PV 8203: 2014-03
A.2 Additional graphic representation formats
A.2.1 Cross-sectional view
Table A.5
A.2.2 Representation of the radii at a point
Table A.6
Example of a curvature difference limit in the principal direction of bend = ± 0.2 m-1: At point X = +594.3 mm; Y = -567.2 mm; Z = +901.4 mm The TARGET radius is = +2.645 m The limit for the radius in the convex direction is = +1.730 m The limit for the radius in the concave direction is = +5.616 m And the ACTUAL radius is = +1.333 m. Accordingly, the ACTUAL radius at this point is located outside the convex limit.
