DJH Designs Phaeton Online Coating Thickness Measurement System
| Brand | DJH Designs |
|---|---|
| Origin | Canada |
| Manufacturer Type | Authorized Distributor |
| Origin Category | Imported |
| Model | Phaeton |
| Pricing | Available Upon Request |
Overview
The DJH Designs Phaeton Online Coating Thickness Measurement System is a non-contact, real-time optical metrology platform engineered for precise, in-line and laboratory-based measurement of dry and wet organic coating films on continuous metal substrates—primarily used in coil coating (pre-painted metal), automotive primer/finish lines, and architectural sheet metal production. Utilizing advanced multi-wavelength reflectometry combined with calibrated spectral analysis, the Phaeton system determines film thickness by quantifying interference patterns generated at the air-coating and coating-substrate interfaces. This principle enables sub-micron resolution without physical contact, eliminating risk of surface damage or measurement drift caused by mechanical wear. Designed for integration into high-speed production environments (up to 200 m/min line speed), the system delivers stable, temperature-compensated readings under ambient factory conditions—including variable lighting, humidity, and substrate vibration.
Key Features
- Real-time, non-destructive measurement of single- and multi-layer organic coatings (e.g., polyester, PVDF, epoxy, acrylic) on steel, aluminum, and galvanized substrates
- Simultaneous dual-point scanning capability for cross-web thickness profiling (standard configuration); optional triple-point for enhanced lateral uniformity mapping
- Integrated thermal stabilization module ensures <±0.1 °C sensor head temperature control, minimizing drift during extended operation
- Ruggedized IP65-rated enclosure with passive cooling—suitable for installation directly above production lines or in QC laboratories
- Auto-calibration routine using certified NIST-traceable reference standards; calibration verification logs stored with full audit trail
- Modular signal processing unit supports Ethernet/IP and Modbus TCP protocols for seamless PLC and MES integration
Sample Compatibility & Compliance
The Phaeton system accommodates substrates ranging from 0.15 mm to 3.0 mm in thickness and widths up to 1,800 mm. It is validated for use with matte, glossy, textured, and embossed finishes—compensating for surface scatter via adaptive illumination geometry. All hardware and firmware comply with IEC 61000-6-2 (EMC immunity) and IEC 61000-6-4 (EMC emissions) standards. Measurement traceability follows ISO/IEC 17025 requirements when operated under documented calibration and environmental control procedures. The system supports GLP-compliant data handling, including electronic signatures, user access levels, and 21 CFR Part 11–ready audit logs for regulated manufacturing environments.
Software & Data Management
Phaeton Control Suite v4.2 provides intuitive operator interface with real-time thickness trend visualization, SPC charting (X̄-R, Cpk), and automated alarm thresholds based on user-defined specification limits. All raw spectral data, metadata (timestamp, line speed, zone ID), and processed results are stored in an encrypted SQLite database with configurable retention policies. Export formats include CSV, PDF reports, and OPC UA-compatible structured data streams. Remote diagnostics and firmware updates are supported via secure TLS-encrypted connection. Audit trails record every parameter change, calibration event, and user login—retained for minimum 36 months per internal QA policy.
Applications
- Coil coating line end-of-line quality gate: immediate detection of thickness excursions before packaging or shipment
- Process optimization in R&D labs—correlating formulation viscosity, roller gap settings, and final film build
- Root cause analysis of orange peel, pinholing, or edge thinning through spatial thickness gradient mapping
- Supplier qualification audits requiring objective, instrument-based thickness verification against ASTM D7091 (Standard Practice for Nondestructive Measurement of Dry Film Thickness of Nonmagnetic Coatings Applied to Ferrous Metals) and ISO 2808 (Paints and Varnishes — Determination of Film Thickness)
- Supporting IATF 16949 clause 8.5.1.1 (Control of Production Process) through automated process capability reporting
FAQ
Does the Phaeton system require daily recalibration?
No—routine calibration is performed weekly using certified reference standards; however, the system executes self-diagnostic checks at startup and every 4 hours during operation.
Can it measure transparent or low-contrast coatings?
Yes—multi-spectral reflectance analysis allows reliable measurement of clear coats, UV-curable inks, and anti-fingerprint layers where conventional eddy-current or beta-backscatter methods fail.
Is offline data analysis possible without the host PC?
Yes—the embedded processing unit stores full spectral datasets locally; exported files can be analyzed post-hoc using Phaeton Analysis Toolkit (standalone Windows application).
What substrate temperature range is supported?
The system operates continuously across substrate temperatures from –20 °C to +80 °C, with automatic emissivity compensation for hot-dip galvanized or annealed coils.
How is measurement uncertainty reported?
Uncertainty budgets (k=2) are provided per ISO/IEC Guide 98-3 and include contributions from spectral noise, substrate flatness deviation, and environmental thermal gradients—typically ±0.3 µm for 10–50 µm polyester films on cold-rolled steel.
