Abstract:
The application relates to a system and method for identification of parts. In one preferred embodiment the invention is used for the identification of machined parts such as those used in automobiles, and other relatively complex machinery. The system includes a scalable database of identification data sets. Each data set is descriptive of an item and comprises information that aid in identifying the item including data relating to a numbering scheme, a family category, picture files depicting the item, and identification criteria defined from the family category. The system presents an input screen having a plurality of input boxes to a user display screen, including input boxes for input of a number scheme and a family wizard. Upon receiving user input from an input device, the system retrieves at least one data set descriptive of an item from the database based upon input received. The system is also configured to present a criteria screen, upon receiving input from the user device selecting a family wizard. The criteria screen includes identification questions that correlate to the identification criteria for the corresponding family. The system can also present a results screen that include all of the information from at least one data set.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     This invention relates generally to identification of objects and, more particularly, to apparatus and methods for identification of manufactured parts, such as transmissions and other manufactured parts, through visual inspection.  
         [0002]     When manufactured goods fail, they can often be repaired. For example, when an automotive part such as a transmission or engine fails, typically only a few components of the part require replacement, whereas the rest of the part remains operable. Correct identification of the failed part is imperative if repair is to be successful. However, parts are frequently misidentified, resulting in economic loss of considerable magnitude, particularly when the part is complex, as in machinery.  
         [0003]     In the automotive field, failed parts are frequently sent to facilities owned by third parties that remanufacture, refurbish, or repair failed parts. Such facilities receive a substantial number and variety of automotive parts for repair. For example, a typical repair facility may repair many thousands of transmissions per year. In addition, such facilities are typically configured to handle several hundred different variations of transmissions. Thus, a critical aspect of the repair and refurbishment process is to properly identify and sort the failed parts. Correct identification of failed parts is also important to insure that the cost of repairing parts is correctly allocated among the owner of the part and the repair facility. Today, losses sustained due to misidentification of parts are in the millions of dollars each year. The problem of misidentification is exacerbated by the practice of shipping failed parts to third party repair facilities, because a misidentified part is worthless when sent to a facility that is not equipped to repair that part.  
         [0004]     Automobile transmissions, as well as other kinds of complex machinery, are sometimes identifiable by indicia stamped or otherwise marked on the part. However, this information is generally not known or understood by the workers who repair the parts at a repair facility. While some parts may be identified by labels affixed to them by the manufacturer, it is often true that parts cannot be identified in this manner. For example, not all parts are marked with a part number. Moreover, on a certain percentage of parts received for refurbishment, labels once present are unreadable or missing entirely, thereby requiring identification by other means.  
         [0005]     Other techniques for identification of parts require familiarity with the replacement parts, including model numbers and variants. Such techniques are impractical when the parts are complex. In some instances, it is simply impractical to identify unmarked parts, resulting in an ineffective use of materials and creating environmental concerns. Similar issues arise in the repair and refurbishment of other parts, such as engines, braking assemblies, and the like.  
         [0006]     An additional issue addressed by the present invention is the need to accurately credit and value parts sent to third parties for repair or refurbishment. As previously mentioned, when a major assembly, such as a transmission, engine or brake assembly, fails, the entire assembly is often removed and replaced with a previously repaired or refurbished assembly. The removed, failed assembly is generally shipped to a third party business for repair. The original manufacturer of the assembly credits the third party repair facility for the residual value of the repaired part—in effect, purchasing the repaired assembly—for subsequent resale to authorized vendors of repaired parts. The residual value of a failed assembly is referred to in the automotive industry as the “core charge” for the assembly or part, as the case may be. The part or assembly may be referred to simply as “core.” It is apparent that misidentification of failed parts and assemblies in the above-described process results in considerable economic loss to the manufacturers if the core charge is credited to the repair facility but repair is impossible because the part, through misidentification, has been sent to a facility not equipped to repair that part.  
         [0007]     It is therefore evident that there is a need for a cost-effective approach for identifying manufactured objects in an efficient and accurate manner while at the same time improving accountability. Such an approach would have particular application to the automotive industry for identification of parts used in automotive transmissions, engines and brake assemblies. The present invention fulfills these needs and others.  
       SUMMARY OF THE INVENTION  
       [0008]     The present invention relates to a system and method for efficient identification of parts for manufactured objects, such as transmissions and engines. The system includes a scalable database of identification data sets. Each data set is descriptive of an item and comprises information that aids in identifying the item including data relating to a numbering scheme, a family category, picture files depicting the item, and identification criteria defined from the family category. The system presents an input screen having a plurality of input boxes to a user display screen, including input boxes for input of a number scheme and a family wizard. Upon receiving user input from an input device, the system retrieves at least one data set descriptive of an item from the database based upon input received. The system is also configured to present a criteria screen, upon receiving input from the user device selecting a family wizard. The criteria screen includes identification questions that correlate to the identification criteria for the corresponding family. The system can also present a results screen that include all of the information from at least one data set.  
         [0009]     In one preferred embodiment of the invention, system and method are provided for identification of parts wherein a user is afforded a choice of approaches for identification. For example, a user can search based upon the number scheme associated with the part or based upon the identification criteria. Moreover, the data sets can further include data relating to ownership, size, sort code, supplier and product line of the item.  
         [0010]     In yet another detailed aspect of a preferred embodiment, the system transmits information from at least one server to users by way of the Internet, an intranet, or similar technology. Broadcast of centrally-stored information to other facilities reduces the cost of information storage while allowing for rapid update of data without loss of security for proprietary information.  
         [0011]     Although embodiments of the invention are illustrated and described with reference to parts for automobile transmissions, those skilled in the relevant fields will readily recognize application of the invention to other manufactured parts, for example, motorcycles, marine and aircraft parts, as well as electrical motors for industry and related controllers. Accordingly, the scope and applicability of the invention should be understood to be broader than the embodiments illustrated and disclosed herein.  
         [0012]     Other features and advantages of the invention will become apparent from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]     Embodiments of the present invention will be described, by way of example only, with reference to the following drawings in which:  
         [0014]      FIG. 1  is a simplified schematic of a network for identification of objects in accordance with the present invention. Several devices are shown in communication with one another by way of the Internet.  
         [0015]      FIG. 2  is a simplified block diagram depicting a database schema implemented for the database of  FIG. 1 .  
         [0016]      FIG. 3  is a Web page, or main menu, of the system of  FIG. 1 , which presents options for either initiating a search or system maintenance.  
         [0017]      FIG. 4  is a Web page, or a look-up screen, of the system of  FIG. 1 , which presents input boxes by which a user can initiate identification of a part.  
         [0018]      FIG. 5A  is the look-up screen of  FIG. 4 , depicting a search initiated based upon a Service Part Number.  
         [0019]      FIG. 5B  is an item screen based upon the search initiated in  FIG. 5A .  
         [0020]      FIG. 6A  is the look-up screen of  FIG. 4 , depicting a search initiated based upon selection from the Family menu.  
         [0021]      FIG. 6B  is a search results screen based upon the search initiated in  FIG. 6A .  
         [0022]      FIG. 7A  is the look-up screen of  FIG. 4 , depicting a search initiated based upon selection from the Family Wizard menu.  
         [0023]      FIG. 7B  is a criteria screen based upon the Wizard initiated of  FIG. 7A .  
         [0024]      FIG. 7C  is a results screen based upon the answers provided in the criteria screen of  FIG. 7C .  
         [0025]      FIG. 8  is a file maintenance screen for maintaining the database of  FIG. 1   
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0026]     With reference now to the illustrative drawings, and particularly to  FIG. 1 , there is shown a simplified block diagram of an object identification system  10  including user devices  12  and an application server  14  in communication with one another, e.g., via Internet  16 , enabling access to a relational database  18  of information for identification of parts. The system enables a user to quickly and accurately identify a part by a number of different approaches, thereby accommodating users with varied familiarity with identification of parts, ranging from users merely able to identify the family of parts (e.g., transmission, engine, etc.) to those with considerable familiarity with such parts. For example, the system allows the user to identify the parts by different numbering schemes used in the automotive industry. The system also allows users with limited experience to identify a part or assembly based on its appearance.  
         [0027]     The user device  12  may be any Web-enabled device, such as a personal digital assistant (e.g., a PalmPilot, by Palm, Inc.), a personal computer or wireless telephone. The connections between these components are shown using a double-sided arrow and may be a physical, fiber optic, wireless, or any other type of link. Optionally, the Web site or other software embodiments of the system can be stored directly on a user device for access by a user in an off-line mode, as discussed in detail below. The server  14  hosts application files and a PHP scripting engine to facilitate interaction with the database  18 . The database can be hosted by the server or on separate hardware in communication with the server.  
         [0028]      FIG. 2  depicts an exemplary schema  22  for data sets of the database. In the exemplary embodiment, the database is structured via a relational data base management system, such as MYSQL. The database is scalable and, in the presently preferred embodiment, is loaded with information for over 54 families of parts. The database includes data sets  20 , identified as “Item_Master,” that include information descriptive of a particular item. In this embodiment, the database is configured for parts associated with the automotive industry, however, other embodiments are contemplated for other industries.  
         [0029]     In this embodiment, each data set includes several different numbering schemes for identifying an item, including Prefix, Base and Suffix numbering system  30 , Part Number  32 , Engineering Part Number  34 , which are discussed below. Each data set also includes additional designations for an item, e.g., family  36 , supplier  40 , core group  42 , disposition  43 , product line  44 , ownership  46 , size  48 , as well as photo files of the item for visual comparison. Family designation  36  corresponds to one of the listed core family of the family  50  data sets shown in Table 1. The Supplier designation  38  corresponds to the remanufacturing supplier of a given part, available in the suppliers  52  data set. The Product Line menu  44  corresponds to product catalog designations of a given part, i.e., suppliers data set  54 . Any particular item may or may not have data in each designation of its data set, depending upon applicability for that particular item.  
                                           TABLE 1                           Core Families                No.   Core Family                            1   ABS Modules           2   AC Clutch           3   AC Compressor           4   Alternator           5   Automatic Transmissions           6   Brake Caliper           7   Clutches and Pressure Plates           8   Complete Engines (Gas)           9   Crankshafts           10   CV Half Shaft           11   Cylinder Heads           12   Distributors           13   Integral Gear           14   Manual Transmissions           15   Power Steering Pump           16   Rack &amp; Pinion Gear           17   Starter           18   Torque Converters           19   Window Lift Motor           20   Wiper Motor           21   Water Pump           22   AC Accumulator and Hose           23   Blower Motor           24   Brake Boosters           25   Brake Pads           26   Brake Shoes           27   Camshafts           28   Catalytic Converter           29   Complete Engines (Diesel)           30   Diesel Fuel Nozzles &amp; Holders           31   Diesel Injection Pumps           32   Electric Air Temp Control           33   Electric Seat Motor           34   Electronic Instrument Cluster           35   Engine Control Module EEC           36   Engine Fan Motor           37   Fuel Injector           38   Fuel Pump           39   Fuel Sender           40   GEM Module           41   Mass Air Flow Sensor           42   Master Brake Cylinder           43   Oil Pump           44   Power Antenna           45   Radios           46   Rear Axle           47   Speed Control           48   Strut - Front           49   Strut - Rear           50   Throttle Body           51   Transfer Case           52   Transmission Control Modules           53   Trip Computer           54   Turbo Chargers                      
 
         [0030]     In one preferred embodiment of the invention, parts are organized by core families. The term “core” is used in its ordinary sense to refer to a foundational or fundamental part. In the preferred embodiment, there are fifty four (54) core families that describe the components of an automobile. Those skilled in manufacturing will recognize that core families can also be used to describe the organization of other manufactured parts, as well as parts made by different manufacturers.  
         [0031]     Thus, the following detailed description is presented as an example, illustrating how the invention may be used, and should not be understood as limiting the scope of the invention.  
         [0032]     With reference now to  FIG. 4 , system  10  presents the user with a Web page  60 , i.e., a look-up screen, that allows the user to initiate a search to identify a part by various methods of identification. These methods can be generally grouped into two approaches—a first approach based upon a number system or a second approach based upon other identification attributes. The look-up screen avails the user of both of these general approaches.  
         [0033]     The look-up screen presents a plurality of input boxes  62  based upon one of several different numbering systems used in the automotive industry, including blocks for UPC Code  64 , Service Part Number  66 , Motorcraft® Part Number  68 , Engineering Part Number  70 . Each numbering system is geared toward a particular segment of the automotive industry and/or stage of the product lifecycle. As an example, The Motorcraft® Part Number may be used by the for aftermarket parts used in automobiles from Ford Motor Co., Inc. The Engineering Part Number is used by the engineering group of an automobile manufacturer Parts can be identified by make and model of the vehicle using the Prefix, Base and Suffix numbering system. In this numbering system, the Prefix  72  defines the year and model; the Base  74  defines the part type; and the Suffix  76  defines the part specifics, e.g., left v. right side of vehicle, etc. In addition, parts can be identified by UPC (Universal Product Code). Also, certain types of parts have codes, or other number systems, stamped or otherwise placed on the body of the part. The system of the present invention accommodates use of these systems via the Core Id Code  78  input block. Thus, if the user is sufficiently familiar with the part, and its various numbering systems, identification can be quickly accomplished.  
         [0034]      FIGS. 5A and 5B  depict a search sequence using a service part number. As shown in  FIG. 5A , the user inputs service part number “1L5Z10346BARM” and, thereafter, initiates the search by selecting the “search” icon  80 . The system accesses the appropriate data set from the database and presents the information to the user in a part identification screen, as shown in  FIG. 5B ., including pictures  82  of the part and core identification criteria  84 . This screen allows the user to verify the part by comparing it to the information presented, such as the pictures and any core identification criteria.  
         [0035]     System  10  also provides efficient means of identification for users lacking familiarity with the aforementioned numbering systems. The look-up screen includes additional input boxes that provide drop-down menus, i.e., input menus, for selection by the user. These input menus represent various additional methods by which parts can be grouped. In this embodiment, the input menus includes the following menus: Family  86 , Supplier  88 , Core Group  90 , Disposition  92 , Product Line  94 , Ownership  96 , and Size  98 . These menus correlate to corresponding data sets forth in the representative database schema depicted in  FIG. 2 .  
         [0036]     With reference again to  FIG. 4 , the input boxes  62 , including the menus, can be used singly, or in combination, to initiate identification. The Family menu  86  lists core families found in database  18 . The Supplier menu  88  corresponds to the remanufacturing supplier of a given part. The Product Line menu  90  corresponds to product catalog designations of a given part.  
         [0037]     A particular core family can be utilized to produce multiple different finished products. The Core Group menu lists these various groupings.  
         [0038]     If known, the Ownership menu allows a user to tailor the identification search by selecting from a list of the party that owns the group in question (e.g., OEM, remanufacturer, supplier, etc.). The Disposition menu  92  lists various methods of disposition assignable for a given part, such as “RED” for Scrap, “GREEN” for shipment for remanufacturing, “HOLD” for hold for future disposition, and other unique sort identifiers. Notably, some cores are identifiable by size (e.g., clutch disks, etc.). The Size menu  98  allows the user to select for a list sizes, if known.  
         [0039]      FIGS. 6A-6B  depict a search sequence initiated by selecting a group from the Family menu  86 . As shown in  FIG. 6A , the user selects the “alternator” family and initiates the search by selecting the “search” icon  80 . The system, then, lists all data sets from the database corresponding to the alternator family on a search results screen  100 , as shown in  FIG. 6B . From the search results screen, the user can select a data set for comparison. If, for example, the user selects data set  102 , then the system will display the result screen shown in  FIG. 5B . The user has several options at this point, if the part does not match the information displayed. For example, the user can (a) go back to the previous page and select another part, (b) initiate a new search by selecting the home icon  104 , or (c) proceed to the Family Wizard by selecting the ‘identify part’ icon  106 , discussed below.  
         [0040]     With reference again to  FIG. 4 , the look-up screen  60  includes a Family Wizard  108 . The Family Wizard provides a drop down menu of all families found in the database  18 . Upon selection of a family from the Family Wizard, the system presents a screen of attribute type questions (e.g.,  FIG. 7B ). These questions are generally directed to visually observable characteristics of the selected core family.  
         [0041]      FIGS. 7A-7C , depict a search sequence initiated via the Family Wizard menu. As shown in  FIG. 7A , the user initiates this type of search by selecting a core family from the Wizard menu. In this example, the user selects the “alternator” family. Thereafter, the system presents a set of questions  1   10  directed to characteristics that aid in distinguishing various types of alternators from one another. Here, each question has an associated drop down menu  112  listing various responses to the question at hand. In this example, the user has answered four out of six of the questions based on visual inspection of the product ( FIG. 7B ). The system will then display the results of the attributes query.  FIG. 7C  depicts a search results screen  113  showing data sets, including pictures, corresponding to parts having the attributes identified by the user. Selection of the first alternator  114  of the list will take the user to the corresponding parts screen, as shown in  FIG. 5B .  
         [0042]     The system  10  further includes an approach for easily maintaining the database  18 , through a file maintenance screen  116  ( FIG. 8 ) accessed from the main menu  15  ( FIG. 3 ). From this screen, a user can update any of the data sets of the database. For example, by selecting maintenance items  118 , the user can add, modify or delete any item data set. Also, by selecting any of the maintenance selections  120  for core group, families, item types, ownership, product lines, sort codes, or suppliers, the user can edit the corresponding data set (see  FIG. 2 ). The user can, optionally, update the database though the upload options  122 . Thus, the system can be easily updated to accommodate new products, or delete others.  
         [0043]     The system also can be configured for offline use, in which a database is loaded onto a user&#39;s device. In an offline mode, the user&#39;s device is a fully independent application that allows read only access to the existing part data for identification purposes only. In an exemplary embodiment, the database, along with corresponding images, are on a host machine and transferred to the user&#39;s device, e.g., personal digital assistant, via means known in the art (e.g., synchronization programs, connectable storage devices, flash cards, etc.).  
         [0044]     It should be appreciated from the foregoing that the present invention provides an accurate and efficient system and method for efficiently identifying objects, such as transmissions and engines, as well as other manufactured parts, through visual inspection of the unknown object without disassembly or need of substantial familiarity with the system or objects of the object class. Although the invention was described in detail with regard to parts from a particular manufacturer, it is similarly applicable with regard to other types of complex catalogs of parts from other manufacturers.  
         [0045]     The system accommodates users of across a wide spectrum of familiarity with “core,” from users from merely able to identify the family of core (e.g., transmission, engine, etc.) to very experienced users. By selecting the wizard block, the user can initiate assisted searching for commodities based upon visual, structural attributes of the part. In this embodiment, the user can select a particular family, e.g., alternators, clutches, transmissions, fuel pumps, engines, etc. Following selection of a particular core family the system presents a web page that presents a set of attribute questions.  
         [0046]     The foregoing detailed description of the present invention is provided for the purposes of illustration and is not intended to be exhaustive or to limit the invention to the precise embodiments disclosed. Accordingly, the scope of the present invention is defined by the following claims.