Abstract:
Product design apparatus and methods including a product database server operable to display a plurality of product styles, a plurality of customizable attributes, and a plurality of composite images. The database server is accessible by at least one client computer operable to select a product style having customizable attributes based upon choices presented by the product database server and elections made via the client computer. The product design server is operable to display a custom product design by combining a selected product style with one or more of the available attributes. Graphic displays including a composite image having the selected product style and the selected customizable attributes are transmitted via the database server to the client computer.

Description:
RELATED APPLICATION  
       [0001]     This application is a continuation of application Ser. No. 09/777,246, filed Feb. 5, 2001. 
     
    
     TECHNICAL FIELD  
       [0002]     The preferred embodiment of the disclosed invention applies generally to apparatus and methods for designing tools, such as carbide rotary tools (CRT) and facilitating the ordering of such tools.  
       BACKGROUND OF THE INVENTION  
       [0003]     Computer numerically controlled (CNC) machines are widely used in industry to manufacture components or parts from different types of materials. These machines typically include a rotary spindle mechanism having a tool holder at one end for holding a rotary cutting tool during a machining operation. It often is desirable to create a custom rotary tool for use in CNC machining. To create the custom tool properly several values must be known: (1) the rotary tool style, (2) the diameter and over-all length, (3) the length of cut, (4) an end style, (5) a coating type, and (6) whether there is a flat or reduced cutting diameter and/or an added neck for clearance.  
         [0004]     Heretofore a custom tool designing and ordering process typically required an average of two to three days. The process involved a chain of information between a client or customer, an outside distributor or salesperson to an inside distributor or salesperson and then to a tool manufacturer. This process would then proceed back and forth through the chain.  
         [0005]     It is an objective of the disclosed invention to have the custom tool design and order process occur on-line, in real-time, with the added benefit of a final specification or print of the tool being generated to the customer-defined specifications. Thus, the custom tool designing and ordering process that historically required several days to complete can now be accomplished in a few minutes on-line, without the need for the aforementioned chain and with a reduced number of personnel.  
       SUMMARY OF THE DISCLOSURE  
       [0006]     A product design apparatus and method according to the invention has a product database server operable to provide a plurality of product styles, a plurality of customizable attributes, and a plurality of composite images. There is at least one customer or client computer capable of accessing the product server and selecting the product styles and the customizable attributes based upon choices presented by the product database server and decisions made via the client computer. The product design server is operable to provide a custom product design by combining a selected product style with a plurality of selected attributes. The product database server is operable to generate graphic images of available product styles and the customizable attributes for display on the client computer. The product database server also is operable to provide a composite image representing a combination of the representations from which the user can view a finalized product.  
       THE DRAWINGS 
    
    
       [0007]     These and other features and advantages of the invention are disclosed in the accompanying drawings wherein:  
         [0008]      FIG. 1  illustrates a topology of a global network with a product database server, a client computer, and a product manufacturer connected to the network in accordance with the preferred embodiment;  
         [0009]      FIG. 2  illustrates a web page displaying a begin screen;  
         [0010]      FIG. 3  illustrates a web page displaying an information-gathering screen;  
         [0011]      FIG. 4  illustrates a web page displaying a design-system screen;  
         [0012]      FIG. 5  illustrates a general flow-of-control to create a cost-estimate;  
         [0013]      FIG. 6  illustrates a web page displaying a tool-style selection screen;  
         [0014]      FIG. 7  illustrates a web page displaying a dimension selection screen;  
         [0015]      FIG. 8  illustrates a flow-of-control of a LOC Subroutine;  
         [0016]      FIG. 9   a  illustrates a web page displaying a general customization screen;  
         [0017]      FIG. 9   b  illustrates a web page displaying a customization screen with a text-box to input a radius-end value;  
         [0018]      FIG. 9   c  illustrates a flow-of-control of a Radius-Value Subroutine;  
         [0019]      FIG. 9   d  illustrates a web page displaying a customization screen with a text-box to input a rLOC value;  
         [0020]      FIG. 9   e  illustrates a flow-of-control of a Reduced-Cutting-Diameter Subroutine;  
         [0021]      FIG. 9   f  illustrates a web page displaying a customization screen with a text-box to input rLOC values and a text box to input neck-values;  
         [0022]      FIG. 9   g  illustrates a flow-of-control of a Neck-Value Subroutine;  
         [0023]      FIG. 10  illustrates a web page displaying a quantity selection screen; and  
         [0024]      FIG. 11  illustrates a web page displaying a final specification screen. 
     
    
     DETAILED DESCRIPTION  
       [0025]     Apparatus and a method according to the invention are illustrated in  FIG. 1 . The several components of apparatus are designated generally by the reference character  10  and include, in general, a product manufacturer  12  providing access to a publicly accessible global computer network  14 , such as the Internet, having a database  16  maintained on a server connected to the Internet. For example, a Lotus Domino® Server can be used to provide a publicly accessible web interface into the database  16 . The product database server  16  can be accessed via the Internet from a client computer  18  anywhere in the world, thereby enabling anyone with Internet access to enter his own product specifications into the database  16 .  
         [0026]     A user begins by connecting to the apparatus  10  by utilizing an HTTP enabled browser over the global computer network  14 . Referring to  FIG. 2 , the user is prompted with a begin screen  20  to login as a current user, or to create a user account  22 . If the user chooses to create the new user account, he will be prompted with an information-gathering screen  30 , as shown in  FIG. 3 , to gather a plurality of required information about the user. The required information includes an external email address  31 , a system password  32  and full name  34 . The user&#39;s external email address  31  will be the user account name that the client will use to identify himself when accessing the design system  10 . Once the user creates an account the design system  10  returns the user to the begin screen  20 . If the user does not create the new user account, the begin screen  20  is available to continue through the design system  10 . To login as a current user, the user must enter the external email address  31  in a user-account-text box  24 , and the design system password  32  in a CRT-design-system-password-text box  26 .  
         [0027]     Once the user submits a valid user account name and design password, the design system  10  displays a screen  40  with at least two screen choices  41 , 42  as shown in  FIG. 4 . A first screen choice enables selections of a new cost-estimate  41  by clicking on the associated hyperlink. A second screen choice enables the selection of the ability to view a plurality of saved cost-estimates  42  by clicking on the associated hyperlink. Other sample screen choices can provide the user with technical information, contact information, company information, or additional information on product quality by simply clicking on the associated hyperlinks.  
         [0028]     In  FIG. 5  there are shown the data sources and general flows to create a new cost estimate. Creating the new cost estimate for the design system  10  takes four steps  44 ,  45 ,  46 ,  47 , beginning with step one  44 , selecting a tool-style. As shown in  FIG. 6 , a tool-style web page  50  contains a plurality of graphical representations  52  of the product manufacturer&#39;s stock tool designs. The user selects the desired tool-style by clicking on the graphic representation  52  or from a drop-down selection list, generally indicated at  54 . The user clicks a submit button  56  to continue to step two and the next web page in the design system  10 . Data indicating the user account name and the selected tool-style are transmitted to the next step for additional customization of the tool-style, using programming techniques already known in the art.  
         [0029]     In step two  45  as illustrated in  FIG. 7 , the user selects a dimension for the previously designated tool-style on a dimension selection screen  60 . The user selects the desired tool-style dimension by clicking on the graphic representation or from a drop-down dimension-selection list, generally shown at  62 . The dimension list is static based upon the manufacturer&#39;s capability to produce the tool. The form of the dimension measurement is diameter (D) by overall-length (OAL), or D×OAL. The user can select the dimension in either fraction (English) or metric dimensions.  
         [0030]     At this stage it is possible to include a plurality of manufacturer-defined settings that the user may customize. One example of the manufacturer-defined setting includes a length of cut (LOC). The user enters a LOC value in a LOC text box  64 . Using programming techniques known in the art, a LOC validation subroutine  70  validates the LOC to ensure it is not too large for the dimension selected with data flows illustrated in  FIG. 8 . The LOC validation subroutine  70  multiplies the OAL by a manufacturer-defined LOC percentage that is preferably less than 55%, but can be any value up to 55%, but not exceeding 56%. Thus, if the LOC is greater than preferably 55% of the OAL  71 , then the LOC is too large, and the LOC subroutine alerts the user  72  and requests the user to enter another value for the LOC. The design system  10  also restricts the value of the LOC to three decimal places if the LOC is in English  74 , or two decimal places if the LOC is in metric  76 . The LOC validation subroutine continues to alert the user  72  until the LOC is validated. Once the LOC validation subroutine has properly validated  78  the data entered by the user, the user then clicks a submit button  66  to proceed to step three and the next web page in the design system  10 . Data indicating the user account name, the selected tool style, and the customized dimensions (D, OAL, and LOC) are transmitted to the next step for additional customization of the tool style, using programming techniques already known in the art.  
         [0031]     Step three  46  illustrated in  FIG. 9   a  is the additional attribute customization step. In the preferred embodiment, a customization web page  80  with step three  46  contains at least one sub-step, but preferably three. In sub-step one of step three  46 , generally shown at  81 , the user can select one of three end styles generally shown at  82 : (1) a ball-end, (2) a square-end, and (3) a radius-end. If either the ball-end or the square-end is selected, the design system does not validate the user&#39;s choice because the ball-end and the square-end have predefined values. However as illustrated in  FIG. 9   b , if the radius-end is specified, the design system  10  displays a text box  90  to enter a radius-value. A radius-value subroutine  100  validates the radius-value to ensure the radius-end is not too large with data flow illustrated in  FIG. 9   c . The radius-value subroutine checks if the radius end is greater than 50% of the diameter  101 , then the subroutine determines the radius value is too large  102  and the user must enter a smaller value. But if the radius end is equal to 50% of the diameter  104 , then the subroutine requests the user to select the ball end  106 .  
         [0032]     As shown in  FIG. 9   d , sub-step  2  has additional manufacturer-specific requirements, generally shown at  84 : (1) a flat  85 , (2) a reduced-cutting-diameter  86 , and (3) a neck-for-clearance  87 . If the user selects to include the flat  85 , the design system  10  does no additional validation.  
         [0033]     However, if the user selects to add the reduced-cutting-diameter  86 , also referred to as the rLOC, the design system  10  presents the user with a text box  120  to specify a rLOC value.  FIG. 9   e  illustrates data flow for a reduced-cutting-diameter subroutine  140  that validates the rLOC value. The reduced-cutting-diameter subroutine checks whether rLOC&gt;D at  141 , and if so the reduced-cutting-diameter subroutine signals the rLOC value is too large  142  and activates the alert user  143 . Additionally, the reduced-cutting-diameter subroutine checks if D=3 or D=0.125 at  144 , then if the rLOC value&lt;49% of the diameter  146 , the rLOC value is too small  147  and a signal is sent to the alert user  148 . Otherwise if the rLOC value&lt;74% of the diameter  149 , the rLOC value is too small  150  and the alert user  143  is activated. If the rLOC value is neither too small nor too large, the reduced-cutting-diameter subroutine validates  152  the rLOC value and stores it as one of the customizable attributes.  
         [0034]     If the user selects to add the neck-for-clearance  87  as illustrated in  FIG. 9   f , the design system  10  presents the user with a text box  160  to specify a neck-value. A neck-value subroutine  170  validates the neck-value. If the neck-value&gt;6 times the diameter  171 , then the neck-value is too large and the subroutine alerts the user  172 . If the LOC+the neck-value&gt;2/3 the OAL  174 , then the neck-value is also too large and the subroutine alerts the user  172 . Otherwise, if the neck-value is not too large, the neck-value subroutine validates the neck-value and stores it as another of the customizable attributes.  
         [0035]     Finally, in sub-step three and referring back to  FIG. 9   a , the user can select another customizable attribute, namely, a coating type, generally shown at  82 . Possible coating selections include, but are not limited to: (1) no coating, (2) TiAiN, (3) TiCN, and (4) TiN. A plurality of graphic representations  82  are presented to aid in selecting the additional customized attributes. The user selects the coating type by clicking on the graphic representation  82  or from a drop-down selection list  88 . The user clicks a submit button  83  to continue to step four and the next web page in the tool design system  10 . Data indicating the user account name, the selected tool-style, the customized dimensions (D, OAL, and LOC), the added flat (if selected), the rLOC value (if selected), the neck-value (if selected), and the coating type are transmitted to the next step, using programming techniques already known in the art, for additional customization of the tool-style.  
         [0036]     In step four, the tool design system displays to the user a quantity selection screen  180 , as illustrated in  FIG. 10  where the user inputs a plurality of quantities, generally shown at  184 , to preview different price quotes based on the different quantities. Data indicating the user account name, the selected tool-style, the customized dimensions (D, OAL, and LOC), the added flat (if selected), the rLOC (if selected), the neck-value (if selected), the coating type, and the user-selected quantities are transmitted to a final specification result page, using programming techniques already known in the art. The user then finalizes the tool-style quotation to create a final specification by clicking a submit button  182  to proceed to a final specification and a next web page in the tool design system  10 .  
         [0037]     As illustrated in  FIG. 11 , a final specification web page  200  displays a graphic  202  that is a representation of the custom designed tool, as well as a plurality of numerical values  204  necessary to produce the tool. A graphic tool file name for the graphic  202  is created by concatenating a plurality of codes from the data obtained from steps one through three. The typical format is: a tool-style code+a customized attribute code+image format. For example, if the specification results in a tool design having five 45° flutes for stainless steel, nickel and titanium alloys, the tool-style code could be DEF 2 . If the tool further has a ball-end, and a reduced-cutting-diameter, the corresponding customized attribute codes are B, and rD, respectively. Thus, the displayed graphic  202  would be ABC1BrD.jpeg. However, it is possible to create the finalized graphic representation utilizing known programming techniques and object-oriented programming languages like Java®. The data from the previous three steps are also included on the final specification: the tool-style  206 , the end-style  208 , the coating-type  210 , the dimensions  204 , the LOC  214 , flat (if selected), rLOC  216  (if selected), the neck-value (if selected), and the sample quantities  217 .  
         [0038]     Once created, the specification becomes associated with the user account name, and is available according to a LIFO stack of saved specifications. The user can: (1) print the specification by pressing a print button  218 , (2) email the specification to the external email address  30  by pressing an email button  220 , (3) create a new quote, thereby returning to step one  44 , by pressing a new-create new-quote button  222 , or (4) order the rotary tool based upon the final specification with the prices shown for the desired quantities by pressing an order-now button  224 .  
         [0039]     The disclosure is representative of the presently preferred apparatus and methods, but is intended to be illustrative rather than definitive thereof. The invention is defined in the claims.