Abstract:
A method and system are provided for generating vehicle alignment reports. Preferred aspects of the present invention comprise receiving at a computer a plurality of alignment characteristics in an electronic format directly from a vehicle alignment auditing machine, receiving at the computer alignment session information, and outputting the alignment characteristics and alignment session information via computer network to a central alignment data repository remote from the computer. An additional aspect of the present invention comprises downloading historical vehicle alignment characteristics, historical alignment session information and predefined alignment specification information via computer network from the central alignment data repository and generating at least one historical alignment report based on the downloaded data.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    This invention relates generally to computer software and computer systems and, more particularly, to an online system and method for generating vehicle alignment reports.  
           [0002]    Conventionally, the automotive industry utilizes statistical process control (SPC) data charts for globally reporting vehicle alignment data to a central management location. To report the data, vehicle alignment auditing machine operators manually input vehicle alignment characteristics and alignment session information into an SPC terminal.  
           [0003]    An improved methodology may provide for automatically reporting vehicle alignment data as it is output from alignment auditing machines at a plurality of distributed alignment centers. In addition, the methodology might relieve the alignment audit equipment operators of the menial task of reporting SPC alignment data thereby increasing the operator&#39;s overall daily efficiency.  
           [0004]    The following patents disclose technology that, although related to the present invention, do not provide the effective solution to the prior art problems in the manner disclosed by the present invention.  
           [0005]    U.S. Pat. No. 6,064,927 (&#39;927) to Molbach et al. discloses a computerized system for facilitating the replacement of alignment components such as bushings or shims based on an assessment of a vehicle&#39;s alignment characteristics. Utilizing information provided by the patented system, a vehicle alignment technician can more accurately determine the proper alignment adjustment. This invention is an improvement over the prior art method of having to remove a vehicle wheel assembly more than once during the adjustment. What the Molbach system lacks, however, is an automated system in accord with the present invention for reporting and tracking vehicle alignment characteristics collected at a plurality of distributed vehicle alignment centers.  
           [0006]    U.S. Pat. No. 5,948,024 (&#39;024) to O&#39;Mahony et al. discloses a computerized apparatus and method for diagnosing a vehicle&#39;s current alignment characteristics and outputting the difference between those characteristics and predefined alignment specifications for the vehicle. Based on the output, a vehicle alignment technician can more accurately adjust the vehicle&#39;s alignment to an acceptable state. Similar to the &#39;927 patent to Molbach, as well as other prior art methods and systems, the &#39;024 patent lacks an automated system in accord with the present invention for reporting and tracking vehicle alignment characteristics from a plurality of distributed vehicle alignment centers.  
         SUMMARY OF THE INVENTION  
         [0007]    One aspect of the present invention comprises a system for generating vehicle alignment reports. The system comprises at least one computer having input/output capabilities, the at least one computer being configured to receive electronically a plurality of vehicle alignment characteristics directly from a vehicle alignment auditing machine, receive alignment session information, and upload the alignment characteristics and alignment session information via computer network to a central alignment data repository remote from the at least one computer. The computer is additionally configured to download historical vehicle alignment characteristics, historical alignment session information and predefined alignment specification information via computer network from the central alignment data repository and generate at least one historical alignment report based on the downloaded data.  
           [0008]    Another aspect of the present invention comprises a method for generating vehicle alignment reports. The method comprises the steps of receiving at a computer a plurality of alignment characteristics in an electronic format directly from a vehicle alignment auditing machine, receiving at the computer alignment session information, and outputting the alignment characteristics and alignment session information via computer network to a central alignment data repository remote from the computer.  
           [0009]    The method additionally comprises the steps of downloading historical vehicle alignment characteristics, historical alignment session information and predefined alignment specification information via computer network from the central alignment data repository and generating at least one historical alignment report based on the downloaded data. 
       
    
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0010]    [0010]FIG. 1 illustrates a preferred system for implementing the present invention;  
         [0011]    [0011]FIG. 2 is a graphical user interface (GVI) containing a form  50  for inputting and receiving alignment audit data in accord with the present invention;  
         [0012]    [0012]FIG. 3 illustrates an example “Daily Shift Report” generated by the ADM application report generation utility in accord with the present invention;  
         [0013]    [0013]FIG. 4 illustrates an example “Individual/Moving Range Characteristic” report generated by the ADM application report generation utility in accord with the present invention;  
         [0014]    [0014]FIG. 5 illustrates an example “Alignment Health” report generated by the ADM application report generation utility in accord with the present invention;  
         [0015]    [0015]FIG. 6 illustrates an example “Health Factor Trending” chart generated by the ADM application report generation utility in accord with the present invention;  
         [0016]    [0016]FIG. 7 illustrates a GUI for uploading alignment specification data for a particular vehicle type to the central alignment data repository in accord with the present invention; and  
         [0017]    [0017]FIG. 8 illustrates a GUI for reviewing and updating alignment characteristic control limit values in accord with the present invention. 
     
    
     DETAILED DESCRIPTION  
       [0018]    [0018]FIG. 1 illustrates a system in accord with a preferred embodiment of the present invention. The system comprises a plurality of distributed vehicle alignment centers (VAC)(e.g. VAC “A” 12 , VAC “B” 14 , VAC “n” 16 , etc.), and remote system users (e.g. field personnel  37 , corporate management  39 , etc.) operably linked via computer network  38  to a central data repository  24 . As illustrated in VAC “A” (block  12 ), each distributed VAC generally comprises a personal computer (FACPC)  18  operably linked to a barcode scanner  28 , a vehicle alignment auditing machine (VAAM)  26 , and a printer  34 .  
         [0019]    The central data repository  24  comprises a server computer  22  operably configured to write data to and a read data from at least one database  36 .  
         [0020]    The computer network  38  interconnects the distributed components of the present invention (i.e., VACs, the central data repository, remote field personnel and management, etc.) for operable communication among the distributed components. The computer network includes but is not limited to one or any operable combination of the following: a local area network (LAN), a wide-area network (WAN), or the Internet including the World Wide Web.  
         [0021]    In accord with a preferred embodiment of the present invention, vehicle alignment characteristics are generated and electronically output from the VAAM  26  to the VACPC  18  during or subsequent to a vehicle alignment audit session.  
         [0022]    Vehicle alignment characteristics electronically output by the VAAM  26  include, but are not limited to, left and right caster for front and rear wheels, front toe, clear vision, thrust, right and left rear camber, and right and left rear toe.  
         [0023]    In further accord with the preferred embodiment, an alignment data management (ADM) software application is installed and running on the VACPC  18 .  
         [0024]    The ADM application is operably configured to, interalia, receive the vehicle alignment characteristic data output from the VAAM  26  during a vehicle alignment audit session and report the data via the computer network  38  to the central alignment data repository  24  for storage and, as discussed in more detail infra, subsequent retrieval for report generation purposes.  
         [0025]    [0025]FIG. 2 is a graphical user interface illustrating a form  50  for inputting and receiving alignment audit data. During or subsequent to a vehicle alignment audit, alignment data electronically output from the VAAM is received by the ADM application and automatically input into alignment data field  66 .  
         [0026]    Additional information  65  collected and input into the form  50  during an audit session includes the type of vehicle being audited, the date, time, shift, and plant of audit, the vehicle identification number (VIN), rotation number, clear vision value, and alignment pin number.  
         [0027]    Preferably, the vehicle type and VIN are automatically input to the data form  50  via the RF barcode scanner (illustrated in FIG. 1). As a new vehicle is mounted for audit by the VAAM, the VAAM operator utilizes the RF barcode scanner to scan the vehicle&#39;s identification barcode. The VIN and vehicle type data encoded within the barcode is output to the VACPC  18  and automatically input into the corresponding data input fields illustrated in FIG. 2.  
         [0028]    Notably, a VAAM operator can select the “Bypass” button  70  to manually enter or bypass any data automatically input into the alignment audit session data form. The “Bypass” function is most helpful where a vehicle cannot be audited by the VAAM due to mechanical vehicle problems (e.g., incorrect springs, etc.). Additionally, the operator may input notes or comments corresponding to the current auditing session within the “Notes/Comments” data entry field  64 .  
         [0029]    Once all of the appropriate information for the current audit session has been input into the data form  50 , the VAAM operator selects the “Submit” button  68 . In response to this selection, the ADM application causes the collected audit session data to be output from the VACPC  18  and transmitted via the computer network  38  to the central alignment data repository  24  for storage within an SQL alignment information database  36 .  
         [0030]    Alignment information input into the SQL database  36  is stored within a plurality of data tables. Table 1 contains a listing of example data tables with corresponding descriptions and contents in accord with the present invention.  
                       TABLE 1                       Data Table   Description   Contents                   Alignment   Alignment date for   Time of AuditVehicle       Data   new vehicles   ModeIVINAlignment               CharacteristicsShift               #Rotation #Alignment PIN               #CommentsPlant Name       Repair Data   Alignment data for   Time of RepairVehicle           used vehicles   ModeIVINAlignment               CharacteristicsShift               #Rotation #Alignment PIN               #CommentsPlant Name       Vehicle   Vehicle model   Listing of all vehicle model       Models   alternatives   alternatives       Vehicle Types   Vehicle type   Listing of all vehicle type           alternatives   alternatives       Control Limits   control limits with   Lower Control LimitCenter           respect to the   Line Control LimitUpper           alignment   Control Limit           characteristics           (individual and           moving range data)       Alignment   Alignment   Lower Alignment       Specifications   specifications with   Spec.Nominal Alignment           respect to the   Spec.Upper Alignment Spec.           alignment           characteristics       Assembly   Plant where the   Assembly Plant       Plant   alignment audit is           being conducted       Adjustment   Adjustable and non-   Adjustable and non-       Flags   adjustable parameters   adjustable parameters                  
 
         [0031]    Another aspect of the ADM application comprises a report generation utility. The report generation utility is configured to generate reports based on historical, specification, and control limit information uploaded to the central data repository  24 . In accord with a preferred embodiment of the present invention, the report utility is configured to generate reports including but not limited to daily alignment session shift reports, individual and moving range alignment characteristic reports, an alignment health report, and an alignment health factor trending report.  
         [0032]    [0032]FIG. 3 illustrates an example “Daily Shift Report” generated by the ADM application report generation utility. The Daily Shift Report comprises a listing of the vehicles that were audited for a selected operator shift  75  along with the corresponding historical alignment characteristics uploaded to the central alignment data repository  24  during that shift. A color indicator  74  alerts viewers if a data point falls outside a predefined specification or control range. Specification and control range definition is discussed in more detail infra .  
         [0033]    [0033]FIG. 4 illustrates an example “Individual/Moving Range Characteristic” report generated by the ADM application report generation utility. The Individual Characteristic report  76  is a chart plotting historical alignment characteristics  86  (i.e., clear vision) for a particular vehicle type  84  over a particular data range  80  or date range  82 . The Moving Range Characteristics report  78  is a chart plotting a moving range of a particular alignment characteristic. The moving range is calculated based on the absolute value of a current characteristic minus the immediately preceding historical value for a particular vehicle type  84  (i.e., Taurus/Sable Sedan).  
         [0034]    For each series plotted on the Individual/Moving Range Characteristic report, two data range options are provided. The first option  80  is to plot the last  50  data points. The second option  82  is to plot the data points collected over a particular date range. To generate a plot, the user chooses the vehicle type  84 , the characteristic  86  and the plot option  80  or  82 . Next, the user selects the “Submit” button  88  and the plots  76  and  78  are automatically generated based on the appropriate historical alignment data previously uploaded to the central alignment data repository  24 . Notably, Cp, Cpk and LSL values  83  are calculated with respect to the plotted characteristic  86 . The upper  90 , lower  92 , and center line  94  control and specification limits for the selected characteristic are also shown on the graph.  
         [0035]    An indicator  96  appears around a data point if the data point falls outside of the predefined specification or control limits.  
         [0036]    [0036]FIG. 5 illustrates an example “Alignment Health” report generated by the ADM application report generation utility. This chart quantitatively summarizes how far the overall alignment for a selected vehicle type  100  falls outside of predefined specification or control limits for a given time period  102  (i.e., week of Aug.  13 ,  2000 ).  
         [0037]    To calculate an alignment characteristic factor  104 , the actual Cpk  106  of a particular alignment characteristic is subtracted from a target Cpk (approximately 1.33). If the actual Cp exceeds the target Cpk, then the factor is zero. As illustrated in data field  110 , the factors of each characteristic of alignment are summed to define an overall Alignment Health Factor. Preferably, the factors for each alignment characteristic are color coded to show their respective level of compliance with the corporate target Cpk. An example color coding scheme is as follows: Green: Cpk≧1.33, Yellow 1.33 &gt;Cpk&gt;1.00, and Red: Cpk &lt;1.00.  
         [0038]    [0038]FIG. 6 illustrates an example “Health Factor Trending” chart generated by the ADM application report generation utility. The Health Factor Trending chart graphically illustrates the trend of alignment Health Factors (as described in FIG. 5) by vehicle type  112 . The chart demonstrates how a particular vehicle&#39;s historical alignment health factors have changed over a particular date range  114 . In addition, the chart plots regression lines (not shown) for each data series  112 .  
         [0039]    Yet another aspect of the ADM application comprises an alignment specification data management interface. FIG. 7 illustrates a GUI for uploading alignment specification data for a particular vehicle type to the central alignment data repository. Specification data includes but is not limited to an upper, lower, and nominal valve for left front caster and camber, right front caster and camber, overall front caster cross, camber cross and toe total, left rear camber and toe, right rear camber and toe, and overall rear camber cross and total toe.  
         [0040]    To input alignment specification data for a new vehicle type, an authorized user selects the “Add New Type” button  120 , enters a vehicle type code  122 , a description  124 , and enters the corresponding specification limits  126  for the vehicle. To edit alignment specification data for an existing vehicle type, an authorized user selects the “Edit Vehicle Type” button  128  and is presented with the corresponding specification data previously uploaded to the central vehicle alignment data repository.  
         [0041]    [0041]FIG. 8 illustrates a GUI for reviewing and updating alignment characteristic control limit values. Generally, updates to control limit values are made by a vehicle alignment center operator in response to a process change. For example, an alignment audit process change may be implemented that results in shifting a process mean toward a nominal alignment value.  
         [0042]    To view an existing control limit, the operator selects the measurement  140  and inputs the vehicle type  142  and description  144 . To update control limits for a specified vehicle, the operator selects the “Change Limits” button  146  and the application automatically inputs the updated control limits  156 .  
         [0043]    In accord with a preferred embodiment of the ADM application, process control limits  156  are defined according to the following equations:  
             X   _     _     =       Process                 Mean     =       ∑     (       X   1     +     X   2     +     X   R       )       n         ;               R   _     =       Range                 Mean     =           ∑     (       R   2     +     R   3     +     R   R       )         n   -   1                     where                 R     =            X   R     -     X     R   -   1                    ;                         
 
         [0044]    Referring again to FIG. 1, other distributed users of the present invention include but are not limited to field personnel  37  and corporate management  39  running the ADM application on their respective personal computers networked to the central alignment data repository  24 . Authorized remote users upload specification and/or control limit data to the central alignment data repository  24 . Additionally, remote users utilize the ADM application report generation utility to generate any of the plurality of historical alignment data reports, as discussed in detail supra.  
         [0045]    While the best mode for carrying out the invention has been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims.