U.S. patent application number 13/186069 was filed with the patent office on 2011-11-10 for systems, methods, and software for automated design and manufacturing of hvac control panels.
This patent application is currently assigned to Design Ready Controls, Inc.. Invention is credited to Ted Bartell, Mitchell T. DeJong, Dipesh Karki, Troy Schmidtke.
Application Number | 20110276167 13/186069 |
Document ID | / |
Family ID | 44358622 |
Filed Date | 2011-11-10 |
United States Patent
Application |
20110276167 |
Kind Code |
A1 |
Schmidtke; Troy ; et
al. |
November 10, 2011 |
SYSTEMS, METHODS, AND SOFTWARE FOR AUTOMATED DESIGN AND
MANUFACTURING OF HVAC CONTROL PANELS
Abstract
The present inventors devised, among other things, systems,
methods, and software that radically simplify and reduce the time
necessary to specify, design, manufacture, and document control
panels and wiring harnesses for semi-custom and custom equipment,
such as HVAC equipment. One exemplary system includes a
computerized product configuration module that defines product
family parameters from user input and outputs a product family data
structure, for example, a coded character string, to a technical
design module. The technical design module, which incorporates
engineering design rules for control panels and wiring modules,
automatically processes the coded character string, outputting
detailed engineering drawings, component listings, and even
assembly instructions to robotic manufacturing equipment. The
exemplary system dramatic reduces the product specification and
engineering time required for any custom control panel and makes it
possible for OEMs to efficiently offering more options and shorter
turn-around times to its customers.
Inventors: |
Schmidtke; Troy; (St. Paul,
MN) ; DeJong; Mitchell T.; (St. Paul, MN) ;
Karki; Dipesh; (Shakopee, MN) ; Bartell; Ted;
(Princeton, MN) |
Assignee: |
Design Ready Controls, Inc.
Rockford
MN
|
Family ID: |
44358622 |
Appl. No.: |
13/186069 |
Filed: |
July 19, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12228258 |
Aug 6, 2008 |
8000832 |
|
|
13186069 |
|
|
|
|
60963747 |
Aug 6, 2007 |
|
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Current U.S.
Class: |
700/106 ; 700/97;
705/400; 707/803; 707/E17.005 |
Current CPC
Class: |
G05B 19/042 20130101;
G06Q 10/06 20130101; G06Q 30/0283 20130101 |
Class at
Publication: |
700/106 ;
707/803; 700/97; 705/400; 707/E17.005 |
International
Class: |
G06F 19/00 20110101
G06F019/00; G06Q 30/00 20060101 G06Q030/00; G06F 17/30 20060101
G06F017/30 |
Claims
1. A method comprising: receiving into a computer processor a set
of two or more product options; and automatically generating in a
memory coupled to the computer processor a coded product data
structure based on the received set of two or more product options,
the coded product data structure including data relating to
electrical and mechanical parameters of a product.
2. The method of claim 1, wherein the product, the product options,
and the coded product data structure relate to a heating,
ventilation, and air conditioning (HVAC) product.
3. The method of claim 1, wherein the product and product options
are associated with an original equipment manufacturer (OEM).
4. The method of claim 1, wherein automatically generating in
memory the coded product data structure comprises using one or more
of the received set of product options to identify information in a
translation data structure.
5. The method of claim 4, wherein the translation data structure
identifies at least one predetermined value or a formula for
determining a value.
6. The method of claim 1, comprising automatically generating one
or more of an electrical schematic and a mechanical schematic based
on the coded product data structure.
7. The method of claim 6, wherein one or more of the electrical
schematic and the mechanical schematic define at least a portion of
a product control panel.
8. The method of claim 7, wherein one of more of the electrical
schematic and the mechanical schematic define at least a portion of
a harness for coupling the product control panel to the
product.
9. The method of claim 6, wherein automatically generating one or
more of the electrical schematic and the mechanical schematic
comprises: automatically defining a parts list of two or more parts
based on the coded product data structure; automatically
retrieving, based on at least one of the parts in the parts list, a
macro for an electronic computer aided design system; and
automatically generating one or more of the electrical schematic
and the mechanical schematic based on the retrieved macro.
10. The method of claim 9, wherein automatically retrieving the
macro comprises: retrieving the macro from a macro database,
wherein each macro in the macro database is logically associated
with a generic macro placeholder; and accessing a set of macro
attributes based on a model number associated with at least one of
the parts.
11. The method of claim 7, comprising: generating assembly
instructions using engineering design rules and the coded product
data structure; generating and ordering parts using the coded
product data structure and an enterprise resource planning system;
and communicating the assembly instructions to robotic
manufacturing equipment.
12. The method of claim 11, comprising: receiving in the computer
processor the assembly instructions; and manufacturing the product
using the robotic manufacturing equipment.
13. The method of claim 12, comprising: receiving into the computer
processor instructions for the product control panel; and testing
the product control panel using the instructions.
14. The method of claim 1, comprising validating data in the coded
product data structure to verify that the two or more options are
compatible as a function of a set of option rules.
15. The method of claim 1, comprising generating a product price
quote using the coded product data structure.
16. The method of claim 1, wherein the electrical and mechanical
parameters comprise one or more of a model number,
voltage-phase-frequency data, a disconnect, a fan type and
quantity, a condenser type, a damper, gas heat data, an electric
tempering coil, electric heat data, heat recovery data, enthalpy
wheel phase data, a compressor crankcase, a ground fault circuit
interrupter (GFCI) outlet, and head pressure control data.
17. A computer readable medium comprising instructions that when
executed by a computer processor execute a process comprising:
receiving a set of two or more product options; and automatically
generating a coded product data structure based on the received set
of two or more product options, the coded product data structure
including data relating to electrical and mechanical parameters of
a product.
18. The computer readable medium of claim 17, wherein the product,
the product options, and the coded product data structure relate to
a heating, ventilation, and air conditioning (HVAC) product; and
wherein the product and product options are associated with an
original equipment manufacturer (OEM).
19. The computer readable medium of claim 17, comprising
automatically generating one or more of an electrical schematic and
a mechanical schematic based on the coded product data structure;
wherein one or more of the electrical schematic and the mechanical
schematic define at least a portion of a product control panel.
20. A system comprising: a computer processor configured for
receiving a set of two or more product options; and a computer
processor configured for automatically generating a coded product
data structure based on the received set of two or more product
options, the coded product data structure including data relating
to electrical and mechanical parameters of a product
Description
RELATED APPLICATION
[0001] The present application claims priority to U.S. Provisional
Application 60/963,747, which was filed on Aug. 6, 2007, and U.S.
Ser. Appl. No. 12/228,258, which was filed on Aug. 6, 2008. These
applications are incorporated herein by reference.
COPYRIGHT NOTICE AND PERMISSION
[0002] A portion of this patent document contains material subject
to copyright protection. The copyright owner has no objection to
the facsimile reproduction by anyone of the patent document or the
patent disclosure, as it appears in the Patent and Trademark Office
patent files or records, but otherwise reserves all copyrights
whatsoever. The following notice applies to this document:
Copyright .COPYRGT. 2007, Design Ready Controls, Inc.
[0003] 1. Technical Field
[0004] Various embodiments of the present invention concern
automated design and manufacture of equipment control panels, such
as control panels for heating ventilation and air conditioning
(HVAC) equipment. Some embodiments also concern control panels and
other subassemblies, such as wiring harnesses, for the design and
manufacture of pumps, large compressors, conveyors, packaging, and
air-handling equipment.
[0005] 2. Background
[0006] Equipment, such as HVAC equipment, is manufactured by
Original Equipment Manufacturers (OEMs) which have a variety of
customers with differing needs. To meet these needs efficiently,
OEMs develop semi-custom product lines, or product families, for
particular market segments . Customers then select among various
lists of parameters, configurations, and options of the product
family to order semi-customized equipment in much the same way as
automobile buyers customize their automobiles by choosing among
available options.
[0007] For example, an HVAC equipment customer might choose among
parameters, such as cooling capacities and electrical supply
voltages, and among configurations, such as numbers and sizes of
supply and exhaust fans. By selecting particular parameters,
configurations, and options, the customer is ultimately choosing a
single product from thousands or even millions of unique
possibilities.
[0008] Once the HVAC customer has committed to its selections by
placing an order, an HVAC OEM typically completes the order using
an ETO (Engineer To Order) process. Specifically, this process
entails passing the order to a team of engineers, who study the
selections and adapt or customize a generic electrical and
mechanical design to incorporate the customer selections. Among
other things, this customization effort frequently requires
redesigning the electrical control panel of the HVAC equipment.
[0009] However, one problem recognized by the current inventors is
that conventional control panel redesign is particularly time
consuming and expensive because the control panel functions as the
brains of the HVAC equipment, and includes hundreds of
interconnected components. This added time and expense places
significant pressure on OEMs to limit the range of options they
offer customers in a market where many customers are actually
wanting more options and lower pricing.
[0010] Moreover, because of this timing and pricing pressure, many
OEMs have sought to shorten the conventional design and manufacture
process by skipping steps such as fully documenting their control
panel designs with accurate as-built drawings. However, the lack of
these drawings creates the further problem of making it difficult
to service and troubleshoot HVAC equipment after installation.
[0011] Accordingly, the present inventors have identified a need
for better ways of designing and manufacturing OEM equipment
generally, and HVAC control panels particularly.
SUMMARY
[0012] To address this and/or other needs, the present inventors
devised, among other things, systems, methods, and software that
radically simplify and reduce the time necessary to specify,
design, manufacture, and document control panels for semi-custom or
even fully custom OEM equipment, such as control panels and wiring
harnesses for HVAC equipment. One exemplary computerized system
includes a product-configuration module, a technical-design module,
and a manufacturing module.
[0013] In operation, the product-configuration module receives user
input about product family parameters through a specialized
configuration interface, and outputs a product family data
structure, for example a coded character string analogous to human
DNA, to the technical-design module. The technical-design module,
which incorporates engineering design rules, automatically
processes the coded character string, outputting true as-built
engineering drawings, component listings, wiring listings, and even
assembly instructions for robotic manufacturing equipment. The
manufacturing module receives output of the technical-design
module, generates and orders parts using an enterprise resource
planning system, and communicates assembly instructions to robotic
manufacturing equipment.
[0014] The exemplary system dramatically reduces the product
specification and engineering time required for any custom control
panel and makes it possible for OEMs to efficiently offer more
options and shorter turn-around times to its customers and thus
enjoy a significant competitive advantage.
BRIEF DESCRIPTION OF DRAWINGS
[0015] FIG. 1 is a block diagram of an exemplary control panel
design and manufacturing system 100, which corresponds to one or
more embodiments of the present invention.
[0016] FIG. 2 is a flow chart of an exemplary method of operating
system 100, which corresponds to one or more embodiments of the
invention.
[0017] FIG. 3 is a facsimile of exemplary graphical user interface
300 corresponding to one or more embodiments of the present
invention.
[0018] FIG. 4A is a tabular rendition of an exemplary control panel
DNA data structure which corresponds to one of more embodiments of
the present invention.
[0019] FIG. 4B is a tabular rendition of an exemplary
option-to-coded-string translation table corresponding to one or
more embodiments of the present invention.
[0020] FIGS. 5A and 5B are combination flow and block diagrams,
which taken together, represent an exemplary architecture 500 that
corresponds to one or more embodiments of the present
invention.
[0021] FIG. 6 is a facsimile of exemplary graphical user interface
600 corresponding to one or more embodiments of the present
invention.
[0022] FIG. 7 is a facsimile of exemplary graphical user interface
700 corresponding to one or more embodiments of the present
invention.
[0023] FIG. 8 is a facsimile of exemplary graphical user interface
800 corresponding to one or more embodiments of the present
invention.
[0024] FIG. 9 is a facsimile of exemplary graphical user interface
(and database structure) 900 corresponding to one or more
embodiments of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT(S)
[0025] This description, which incorporates the Figures and the
claims, describes one or more specific embodiments of an invention.
These embodiments, offered not to limit but only to exemplify and
teach the invention, are shown and described in sufficient detail
to enable those skilled in the art to implement or practice the
invention. Thus, where appropriate to avoid obscuring the
invention, the description may omit certain information known to
those of skill in the art.
Overview
[0026] The exemplary system and method embody a unique approach to
the design and manufacture of control panels for custom OEM
(original equipment manufacturer) products, particularly custom
HVAC equipment. Conventionally, OEMs develop and offer families of
products that address particular market segments. For example,
OEM's that produce HVAC equipment typically offer a family or range
of products. Within a product family, OEM customers choose from a
relatively large number of options. Within each product family,
millions of permutations or potentially unique option combinations
are generally possible. Because of this variability in product
configuration, each OEM product ordered is considered to be at
least somewhat unique or custom in terms of content and design.
[0027] To bring a highly variable product family to market, an OEM
typically operates as follows: [0028] 1) Recognize a market
opportunity. [0029] 2) Define specifications for a product family
that meets the opportunity. [0030] 3) Detail and design engineering
for the product family [0031] 4) Provide list of options for
customers to choose from [0032] 5) Finalize the design and layout
as each individual order is received (ETO engineer to order
process) [0033] 6) Manufacture, test and deliver product to
customer specifications.
[0034] Development of the controls subsystem or control panel for
the product family follows the same process, specifically steps
2-6.
[0035] The exemplary control panel design and manufacturing system
streamlines the upfront development of control panels for such OEM
product families (steps 2, 3 and 4), automates the ETO process
(step 5), and provides the manufacturing information and reports
necessary for the just-in-time mass production of custom controls
panels for OEM products (step 6).
Exemplary Control Panel Design and Manufacturing System
[0036] FIG. 1 shows an exemplary control panel design and
manufacturing support system 100. System 100 includes a computer
workstation 110, an enterprise resource planning (ERP) system 120,
and a manufacturing complex 130. In the exemplary embodiment,
access device 110 takes the form of a personal computer, laptop
computer, personal digital assistant, mobile telephone, or any
other devices capable of supporting the functionality described
herein. Specifically, workstation 110 includes a processor module
111, a memory 112, a display 113, a keyboard 114, and a graphical
pointer or selector 115.
[0037] Processor module 111 includes one or more processors,
processing circuits, or controllers. In the exemplary embodiment,
processor module 111 takes any convenient or desirable form.
Coupled to processor module 111 is memory 112.
[0038] Memory module 112, which takes the exemplary form of one or
more electronic, magnetic, or optical data-storage devices, stores
automated panel expert (APE) design and manufacturing module
116.
[0039] Module 116, which includes machine readable and/or
executable instruction sets and related data, includes a general
product specification module 1161, a product definition data
structure 1162, technical specification module 1163, manufacturing
support module 1164, and associated graphical user interfaces
1165.
[0040] General product (control panel) specification (or
configuration) module 1161 includes instruction sets and data for
producing one or portions of graphical user interface (GUI) 1165,
accepting user input related to attributes of an HVAC system, and
defining and outputting general product specification data
structure (DNA) 1162 based on the selected attributes or on
imported attributes or requirements. In the exemplary embodiment,
general product specification data structure takes the form of an
encoded text string, which is validated based on
options-compatibility rules. DNA 1162 is output to technical
specification module 1163.
[0041] Technical specification module 1163 decodes DNA 1162 into
various fields or segments. These segments are used in
automatically selecting components and defining mechanical and
electrical schematics for a product, such as an HVAC control panel,
using design rules and macros for computer-aided-design tools.
[0042] Manufacturing module 1164, which receives the mechanical and
electrical schematics, includes instructions sets and data for not
only defining one or more portions of GUI 1165, such as ECAD
interfaces, but also defining wiring lists, mechanical layouts, ERP
order administration, etc.
[0043] In addition to workstation 110, system 100 includes ERP
system 120 and manufacturing complex 130, both of which interface
with manufacturing module 1164 to facilitate just-in-time mass
production of HVAC control panels and associated wiring
harnesses.
Exemplary Method of Operation
[0044] FIG. 2 shows a flowchart of an exemplary method 200 of
operating a system 100 in FIG. 1. Flow chart 200 includes blocks
210-240, which are arranged and described serially. However, other
embodiments execute two or more blocks in parallel using multiple
processors or processor-like devices or a single processor
organized as two or more virtual machines or sub processors. Other
embodiments also alter the process sequence or provide different
functional partitions or blocks to achieve analogous results.
Moreover, still other embodiments implement the blocks as two or
more interconnected hardware modules with related control and data
signals communicated between and through the modules. Thus, the
exemplary process flow applies to software, hardware, and firmware
implementations.
[0045] The exemplary method begins at block 210, which entails
receiving input defining a set of product options. In the exemplary
embodiment, this entails displaying a product definition or
configuration interface portion of GUI 1165 which lists a variety
product selection option. FIG. 3 shows an exemplary configuration
interface 300.
[0046] Configuration interface 300 includes a product line listing
region 310, a feature listing region 320, and a corresponding
feature definition region 330. Product line listing region lists
one or more selectable product lines. Feature listing region 320
lists a set of features or attributes, such as
voltage-phase-frequency attributes 321, which associated with the
active or selected product line within region 310. Feature
definition region 330 includes a set of feature definition regions,
such as pull-down menu 331, which corresponds to the
voltage-phase-frequency attributes 321. Pull-down menu 331 lists
selectable options. Execution continues at block 220.
[0047] Block 220 entails defining an equipment data structure based
on the selected product options. In the exemplary embodiment this
entails defining a DNA data structure in the form of a coded text
string based on the selections made using configuration interface
portion of GUI 1165 or interface 300.
[0048] FIG. 4A shows a tabular rendition of an exemplary DNA data
structure 400, which includes 45 data fields, each associated with
a particular user-selected or otherwise defined OEM product option,
such as an OEM HVAC system. In the exemplary character-string
implementation, each data field is associated with a position
within the character string and has a predetermined number of
characters representative of some aspect of an OEM HVAC system that
affects its control panel (and wiring harness.) For example, data
field #1 is 9 characters long and defines the model number of the
HVAC system; data field #2 is 3 characters long and defines some
aspect of the voltage-phase-frequency of the HVAC system with the
selected model number; data field #3 defines some aspect of the
HVAC disconnect and has a length of one character. In the exemplary
embodiment, the data field number also indicates its cardinal
position within a concatenated text string.
[0049] In defining the DNA structure based on the selected options,
the exemplary embodiment uses a translation data structure or
table. FIG. 4B shows an exemplary translation data structure 450,
which is stored in memory of the exemplary system. Translation data
structure 450 includes options 452, code strings 454, and lookup
codes 456. In the exemplary system, one or more of the user
selections for the configuration menu is calculated based on other
selected parameters or selected from a lookup table using a lookup
coding scheme that either addresses a predetermined value or a
formula for determining a value. (In the exemplary embodiment, DNA
coding table 450, implemented as a spreadsheet or database, is also
used to define the content and sequencing of menus and menu
listings in the configuration interface. Thus, changing the
position of the model number options within the spreadsheet changes
its position within interface 300.) An exemplary control panel DNA
data structure follows: [0050]
VPR110D05203N1V00.301.60N00.000.0NA000.000.0000.000.0000.
000.00.0000.000.0NANANCNA00.0NAS00.200.5NNNNNNN
[0051] The exemplary method also entails validating the DNA data
structure using validation rules, specifically ensuring that the
selected options presented in the DNA data structure are compatible
based on options rules. Some embodiments perform validation during
general product specification on a selection-by-selection basis,
alerting the user whenever a given selection is incompatible with a
prior selection, or alternatively narrowing the available feature
space as the user moves through the configuration interface.
[0052] FIG. 2 shows that after defining an equipment data structure
based on the selected product options, execution continues at block
230.
[0053] Block 230 entails automatically generating technical design
data structures and documentation based on the defined (and
validated) equipment data structure (which is representative of the
general product specification.) In the exemplary embodiment, this
generally entails defining a parts lists based on the DNA data
structure, generating electrical and mechanical schematics based on
ECAD macros for the parts and related macro attributes logically
associated with parts and one or more portions of the DNA data
structure, such as model number or product line.
Block 240 entails automatically manufacturing a piece of equipment,
in this case a control panel, based on the technical design data
structures. In the exemplary embodiment, manufacturing entails
defining wiring lists, mechanical layouts, etc. and communicating
relative instructions sets to one or more automated or robotic
manufacturing devices, such as wiring machine, laser cutter, or
milling machine, to complete the desired control panel.
Additionally, automated testing is performed.
[0054] Further structural and operational details are described
below in relation to an exemplary software architecture.
Exemplary Software Architecture
[0055] FIGS. 5A and 5B shows an architectural block and flow
diagram of an exemplary implementation 500 of software 116 in FIG.
1. These two figure shows three sets of color coded components,
with the green components generally corresponding to module 1161,
the yellow components corresponding to module 1163, and the blue
components corresponding to module 1164. Flow through the diagram
is generally left to right.
General Product Specification
[0056] In operation, the exemplary method starts with presenting a
"design ready" list of common technical options (EDB PROGRAM
OPTIONS 202) found within an OEM industry such as HVAC, pump, large
compressor, conveyor, packaging or air handling etc. For example,
an HVAC OEM can select options for a range of supply fans based on
horsepower. (FIGS. 3 and 4 shows respective graphical user
interfaces 300 and 400 for selecting options.)
[0057] By choosing from this list of options and limiting the
available selections within each option, the OEM can use the
exemplary system to quickly define and generate the general
engineering specifications for a product family (Step 2 in
Overview). In the exemplary embodiment, the OEM can further develop
the engineering product family specifications by adding to this
list any additional options that may be unique to its offering.
[0058] Because the system helps reduce the time and cost of upfront
product development (Step 3) and ETO (step 5), OEMs are often able
to economically expand the number and variety of product family
options (EDB PROGRAM OPTIONS 2021). Once a set of options is
defined, the system defines a DNA code string or data structure 208
(analogous to DNA 1162 in FIG. 1) that effectively captures the
customized order from the OEM's customers.
[0059] More specifically, in the exemplary embodiment, an APE
CONFIG DLL module 503, reads the original engineering
specifications from an OPTIONS DATABASE 502 and automatically
defines a Control Panel DNA data structure 508) for the product
family.
[0060] To capture an order, the exemplary system configures the EDB
PROGRAM OPTIONS preselected by an OEM into a dynamic GUI interface
list, such as GUI 300 in FIG. 3 This GUI is used for manually
configuring orders (Step 4) through the selection of control panel
options (ORDER CONFIGURATION, ORDER CONFIGURED MANUALLY). Selection
listed in the GUI 300 are populated from an EDB program options
database 5051. FIG. 6 shows that the EDB program options database
can take the form of an Excel spreadsheet; however, some
embodiments use a SQL database format.
[0061] The EDB program options database contains the list of
options or parameters that are used to define translation table in
FIG. 4B, which as noted earlier to translate selected equipment
options into the DNA code string for a control panel. Some of these
options are displayed dynamically through the configuration
interface in FIG. 3 when someone configures a control panel. These
are the options highlighted in yellow in FIG. 4. The ones
highlighted in orange/tan are calculated on the fly or using lookup
tables kept in other Microsoft Excel spreadsheet files. In many
cases, the user need not be prompted. For example, the exemplary
embodiment calculates amperage if we prompt for voltage and
horsepower. In this case, the DNA strand will show horsepower,
voltage and amperage even though we only prompted the user for
horsepower and voltage. All of the parameters are used to complete
the fields in the DNA strands. EDB files are fully customizable for
each individual customer's control panel requirements
[0062] The exemplary system offers a unique link between how a
customer views requirements and how these requirements translate
into a set of engineering specifications in the form of a PANEL DNA
CODE STRING. For example, a customer may view a requirement as the
need for an HVAC system for a 25,000 sq. ft. warehouse, and the
exemplary system ultimately translates this into an engineering
requirement of an HVAC system having 4 units of a specified
capacity with each unit having 5 hp supply fans.
[0063] The exemplary system presents options to a customer in a
menu using customer friendly language and then uses RDB OPTIONS
RULES 5022 within OPTIONS DATABASE 502 to translate or map the
customer requirements into the engineering requirements. For
example, the system can query a customer for the size of warehouse
they need air conditioned and in response select an appropriate
quantity and product recommendation based on model number. From the
model number, the exemplary system provides further rules to select
more detailed engineering criteria such as supply fan horsepower
etc. This automated translation from customer requirements to
engineering specifications enables the OEM to quickly identify
customer requirements and instantly provide customized engineering
specifications including quotes and bills of material (BOMs).
[0064] In exemplary embodiment, APE CONFIG DLL 504 used to map
customer requirements and configure orders into Panel DNA code
string 508 can also be embedded or called directly from an OEM's
internal order entry software as represented by CUSTOMER GENERATED
PRODUCT DNA 509. The APE GUI interface can be hosted on a web
server to define a WEB CONFIGURED ORDER 510, allowing OEM customers
to order products from anywhere via a wide- or local-area
network.
[0065] To detect and allow correction of compatibility issues
between selected options, APE RULES.DLL 510 reads the list of
options selected within PANEL DNA CODE STRING 508 and dynamically
checks for errors and option incompatibilities, using engineering
rules within RDB OPTIONS RULES database 5022 to validate each
potential order. DNA VALIDITY CHECK interface 511 is used in
concert with the ORDER CONFIGURATION interface 506 to guide OEM
sales personnel and their potential customers through the order
configuration process. (In some embodiments, the APE RULES.DLL can
also be used in concert with and be directly called from an OEM's
internal order-entry software tool.)
[0066] More specifically, RDB OPTIONS RULES database 5022 includes
a series of if/then Boolean operations that point to fields in the
PANEL DNA CODE STRING. For example if field one equals 30 (which
could stand for a model number 30 pump control) then perhaps field
2 cannot be X, Y, or Z (which could represent certain types of
disconnects). Each rule violation points to an error message that
can be dynamically displayed to the user as a DNA ERROR REPORT 512
from the DNA VALIDITY CHECK interface 512. For example; "Error you
cannot have a type X, Y or Z disconnect in a model 30 product."
FIG. 7 shows an exemplary DNA error report GUI 700 (300), with an
error message region 710.
[0067] When APE RULES.DLL 510 determines that all the rules in RDB
OPTION RULES database 5022 have been met for a particular order
defined by PANEL DNA CODE STRING 508, it validates the DNA code
string and clears the order, now captured in the VALID DNA format,
for use with the automated ETO processing tools. FIG. 8 shows an
exemplary valid DNA GUI 800 that is output in response to a
validity confirmation.
[0068] FIG. 9 shows an exemplary spreadsheet version 900 of RDB
option rules database 5022. The rules are set up as complex sets of
IF-THEN statements of the form IF (DNA code (=, <, >, etc)
some calculated value) THEN (select size, part, macro, wire, etc).
(Rules of this form can also be created and managed using
off-the-shelf applications such as Rules Stream expert-system
software.)
[0069] These are the rules that are executed against a DNA code
string. In some cases the rules describe DNA code compatibility and
which options may or may not work with others. In this case they
are used in the DNA error checking routines that validate a desired
configuration or DNA code string. In other instances these rules
are used to select and size components that go into a control
panel. For example if the DNA code for hp=30 then a motor starter
of a certain size from a particular vender will be selected. When
we use the RDB format for such selections we sometime refer to the
file as a DWEEEB database.
Detailed Technical Design Specification
[0070] The upfront engineering of the controls for an OEM family of
products typically involves creating the following: [0071] A) A
series of general yet detailed electrical schematics that cover the
options and basic controls functions necessary for the OEM product
family. [0072] B) A complete list of all the components and parts
that are potentially needed to complete the control panels for an
entire OEM product family. [0073] C) A detailed scheme for the
physical layout, of the parts from step B, for the family of
control panels.
[0074] The exemplary process and software tools are designed to
help streamline the upfront detailed design process (Steps A, B
& C) and automate the ETO process. The exemplary system
automates the process in such a way that the detailed design
information from steps A, B and C are captured (MACRO OBJECT DR,
APE MASTER ENGINEERING PARTS DB and MACROS along with ETO
engineering or decision making expertise (DWEEEB database with
electrical engineering and estimating brains DATABASE) within the
system. The system incorporates off-the-shelf, 3D solid-modeling
applications (SOLIDWORKS 3D LAYOUT) for interference checking and
the development of a layout scheme. (Step C).
[0075] The detailed design process (steps A, B, C) is therefore
streamlined to a standardized process of selecting appropriate
generic macros and rules and augmenting them with any additional
data necessary to complete the design of the controls for a family
of products. (Note: ECAD macros are small schematic or layout
drawings that can be picked, placed and linked into complete
schematic and layout drawings.) Once populated with the detail
design information and ETO rules, the exemplary system completely
automates the ETO process and produces as-built schematics,
as-built layouts, BOMs, and a host of manufacturing reports for
each unique panel at the touch of a button (SCHEMATICS, LAYOUTS,
BOM, LABELS, WIRE LISTS, MFG REPORTS).
Automated Manufacturing
[0076] In general terms, the exemplary system captures the
expertise and criteria used by ETO engineers and processes orders
(VALID DNA) with this information. Instead of an engineer handing
off marked up schematics to a drafter, the exemplary system uses
the APE GUI ECAD INTERFACE, APE (APE PROMISE DLL, APE EPLAN DLL) to
create an ECAD instruction set (PROMISE INSTRUCTION SET, EPLAN
INSTRUCTION SET) that can be executed through the API (application
programming interface) of standard off the shelf ECAD drafting
packages (APE PROMISE API, APE EPLAN API). Through the APIs,
as-built schematics and layouts can be generated with the touch of
a button or via a single command or call from another application.
The schematics and layouts are then efficiently checked for errors
and completeness utilizing standard utilities available within the
ECAD packages (ECAD ENVIRONMENT).
[0077] The exemplary system includes a unique populated master
parts database (APE MASTER ENGINEERING PARTS DB) that is associated
with a unique set of macro information or MACRO OBJECT DATA BASE
and a catalog of ECAD macros (MACROS, MACROS/PLACEHOLDER).
[0078] Electrical CAD systems such as PromisE, EPLAN or AutoCAD
electric use the concept of Macros or sub drawings that can be
quickly accessed to build up larger or complete schematics. In
addition to the graphical representation, each software vender
allows data or attributes to be assigned to a macro. This
information can include items such as part numbers of components,
wire numbers, wire gauge, wire colors, harness designations,
schematic page and X,Y location coordinates, device IDs, connection
point labels, wire terminations, strip lengths, wire lengths,
etc.
[0079] Conventional macros contain this type of attribute
information on a product family basis. Thus, conventional macro
catalogs normally need to be recreated for each different product
family or schematic and layout design. However, the present
inventors recognized the inefficiency of this approach and devised
a unique MACRO OBJECT DATABASE that captures, maintains and manages
ECAD macro attribute information. This allows one to create truly
generic catalogs of macros (with generic placeholders for the
attribute information) for all off-the-shelf ECAD packages. These
generic macros can be used repeatedly across various OEMs and
across various product families as well as schematic and layout
configurations. Once generic macros are placed, information
specific to the product family can be assigned to the macros from
the MACRO OBJECT DATABASE.
[0080] The benefits and efficiencies of this unique approach are
many. The need to redraw and manage macros used for specific
product families is reduced. An original design manufacturer can
share generic macros across product families and customers reducing
upfront development costs. ECAD attribute data is managed
independently from any specific ECAD software application, thus
allowing the ability to change an APE installation from one ECAD
software vender to another. And by managing the attribute data
within a sophisticated database utility, such as the Microsoft SQL
utility, the data is much easier to maintain, update and revise.
And those that maintain this attribute data can do so directly
without having to access or even know how to access the ECAD
software applications, again reducing engineering time, resources
and expertise required for implementing initial installations of
the APE system or future engineering changes in a product
family.
[0081] Associated with each part in the master library and with
each macro is a set of rules (DWEEEB DATABASE) that describe what
parts and what macros may be selected for any given VALID DNA code
string. The rules include a series of if/then Boolean operations,
which once satisfied point to a part (PARTS SELECTOR) to be
included in the BOM or a macro (MACRO SELECTOR) to be included in
the as-built SCHEMATICS or LAYOUTS.
[0082] As the APE PROMISE DLL or APE EPLAN DLL processes each rule
(DWEEEB DATABASE) against an order (VALID DNA), instruction sets
for the picking and placing of macros and the assignment of parts
(PROMISE INSTRUCTION SET, EPLAN INSTRUCTION SET) and ECAD
attributes are generated as input for the ECAD systems (PROMISE
APPLICATION, EPLAN APPLICATION). Through the ECAD APIs, (APE
PROMISE API, APE EPLAN API), the instruction sets are automatically
executed and as-built drawings, BOMs and manufacturing reports
(SCHEMATICS, LAYOUTS, BOM, LABELS, WIRE LISTS, MFG REPORTS) are
generated without the need for manual intervention (ECAD
INTERFACE). Results are verified within the ECAD ENVIRONMENT and
then electronically sent to the appropriate manufacturing group
(ECAD INTERFACE).
[0083] As-built manufacturing reports (SCHEMATICS, LAYOUTS, BOM,
LABELS, WIRE LISTS, MFG REPORTS are archived (PROCESSED JOB
LIBRARY) using the APE DB SYNC DLL and DB SYNC interface for future
aftermarket and support access (AFTER MARKET WEB INTERFACE,
REPLACEMENT PART PO).
[0084] The handling of macros is a notable aspect of the exemplary
system. In contrast to conventional ECAD systems which bundle
macros and macro attributes, the exemplary embodiments effectively
separates them, storing product-line-specific macro attributes in a
separate database that can be called by the ECAD APIs. The ECAD
systems include the drawings macros for relevant components along
with their conventional macro attributes; however, when ECAD APIs
in the exemplary embodiment call for a particular macro from an
ECAD program, they also call for or retrieve a set of
product-line-specific macro attributes from the macro attribute
database (DWEEEB in FIG. 5A). The conventional macro attributes are
ignored or overridden by the ECAD API according to the
product-line-specific macro attributes. Thus, in the exemplary
embodiment, ECAD macros can be paired with multiple sets of
product-specific macro attributes that effectively redefine the
macro as necessary to facilitate the production of schematics and
as-built drawings for not only multiple product lines of a given
OEM, but also across the product lines of multiple OEMs.
[0085] The overall advantages to this system includes ETO
turn-around times measured in minutes versus days or even weeks,
fewer human touches and therefore fewer errors in the drafting
process, complete manufacturing and after-market support
specifications in the form of as-built drawings, BOMs and
manufacturing reports (SCHEMATICS, LAYOUTS, BOM, LABELS, WIRE
LISTS, MFG REPORTS), and a system that continually improves through
the iterative process of quality control.
Extensions
Pricing Tool Extensions
[0086] Pricing information can optionally be added to the master
parts list (ERP PARTS INFO DB). Along with PARTS SELECTOR rules,
the exemplary system uses a QUOTING DLL and QUOTING/PRICING TOOL
GUI interface to calculate and display pricing information (CONTROL
PANEL BOM, CONTROL PANEL QUOTE) when the sales organization
configures an order (VALID DNA). This capability to generate
instant quotes at the time an order is configured for custom
control panels is another competitive advantage.
Harness and Wire Processing Extensions
[0087] If control panels can be thought of as the brains and the
OEM product as the body, then harnesses that connect the brains to
the body can be seen as the nervous system. For each potential
control panel within an OEM product family, there is a unique set
of corresponding harnesses that are required to connect the control
panel to the OEM product.
[0088] The exemplary system includes a harness parts and pricing
rules database (HDB HARNESS, HDB COMPONENT PRICE) that is processed
(HARNESSES GUI) with the APE HRNS DLL to create both quotes (EXT
HARNESS QUOTE) and manufacturing reports (HRNS PROD FLOOR REPORT,
HRNS LABEL REPORT) for the external harnesses. Harness production
floor reports may include instruction sets for use with automated
wire processing machines.
[0089] While most of the harness information can be captured in a
design ready format, the lengths of the harnesses are dependant on
the size, shape and electrical routing within the ordered OEM
equipment. Through the exemplary system, OEMs can choose to include
this additional harness information (CUSTOMER GENERATED EXTERNAL
HARNESS INPUT FILE) along with the control panel configuration
(VALID DNA+HARNESS).
[0090] In addition to harnesses data, a set of control panel wire
information (WDB WIRES) can also be created for the product family.
This set of data/rules is used by the APE WIRE MACHINE DLL to
compile a manufacturing wire report (WIRE PRODUCTION FLOOR REPORT)
and a set of instructions for an automated wire process machine.
The exemplary embodiment supports the Schleneger brand of wire
machine (SCHLENEGER INTERFACE, SCHLENEGER INSTRUCTION SET), but the
system architecture allows that others such as Komax can added. The
use of automated wire processing machines drastically reduces the
time to cut, strip, label and terminate wires.
Database Synchronization
[0091] The exemplary system manages and synchronizes the databases
used through out the specification, detailed design, ETO process
and manufacturing process (Steps 2-6) and future aftermarket
activities. Through the PARTS DATABASE ENVIRONMENT and the DB SYNC
GUI interface, APE establishes industry libraries of design-ready
data, manages historic production data, and synchronizes
information with internal, supplier and customer order to
remittance applications.
[0092] The exemplary system also helps differentiate and manage
both commercial and engineering data for parts. On the commercial
side, the system recognizes a central ERP (enterprise resource
planning) system as the source for current parts, pricing and
scheduling information (M1 APPLICATION).
[0093] While the ERP system specializes in commercial information,
there is still a need to manage the engineering data such as part
specifications, mounting whole locations, connection point
specifications etc. In many cases, the ECAD software applications
have proprietary database utilities to manage this type of parts
data. Similar to the MACRO OBJECT DATABASE, the exemplary system
employs a more generic APE ENGINEERING PARTS DB that can manage
generic parts data across multiple product families, customers,
vendors and ECAD software applications, all while being seamlessly
synchronized with an ERP system.
[0094] The exemplary system uses this information (ERP PARTS INFO
DATA) to populate and refresh the design ready master libraries
(MACRO OBJECT DB, ENGINEERING PARTS DB and DWEEEB DATABASE PARTS
SELECTOR). Through the DB SYNC interface, the APE DB SYNC DLL
extracts information from the ERP system (APE M1 API), combines
this information with the APE ENGINEERING PARTS DB and is makes all
necessary data available and accessible by the ECAD ENVIRONMENT,
QUOTING TOOLS, MFG REPORTS generation such as BOMs, and aftermarket
part selection utilities such as the AFTER MKT WEB INTERFACE.
[0095] As orders enter the ETO engineering process, the orders are
in parallel managed from a supplier and order-to-remittance
perspective. Electronic communication from the exemplary system
generates purchase orders (Pos) for components (PART PO) and
automatically sends them to suppliers, manages inventories (XML
ELECTRONIC SUPPLIER BOMS, PICK LISTS), and coordinates schedules
(MFG SCHEDULES, MFG REPORTS) between the manufacturing department
and OEM customer.
[0096] As jobs are complete through the automated ETO process
embodied within the system, manufacturing reports (SCHEMATICS,
LAYOUTS, BOM, LABELS, WIRE LISTS, MFG REPORTS) and project data
(ECAD PROJECTS) are stored in a PROCESSED JOB LIBRARY. This library
can in turn be accessed through the DB SYNC interface for future
reference. An additional web portal (AFTER MKT WEB INTERFACE) to
this historic project data is available for aftermarket support and
the generation of REPLACEMENT PART POs.
Final Test and PLC Logic
[0097] The exemplary system also assists in the final programming
and testing of the panel before it leaves for the OEM customer.
Once the panel is assembled, the APE PLC LOAD AND TEST interface
utilizes the APE MFG PLC DLL to download the correct controller
instructions (PLC LICENSE INSTRUCTION SET) to the panels PLC
(programmable logic controller) and then tests the panel to make
sure it is functionally correctly (PANEL TEST). Thus, testing
protocols or instructions are dynamically loaded to match the
particulars of any given panel under test.
Full Customization
[0098] The exemplary system enables "true custom" design and
manufacturing by providing for manual interface into the ECAD
applications. Specifically, the system can be used to define a
semicustom product using the configuration interface to define a
product DNA structure and develop a detailed technical design,
including ECAD schematics. The ECAD schematics can then be manually
modified to include options not available in the configuration
interface. Once the schematics are fully customized with these
options, they and related BOMs, etc can be generated as with any
product defined fully in the configuration interface. This
customization process also applies to mechanical layout and
enclosure dimensioning and design, with the exception that 2D or 3D
modeling software can be used to manually or automatically generate
layouts and enclosure designs after determination of electrical
schematics and BOMs. The system can process these technical design
using its manufacturing and ERP automation as with semicustom
designs.
CONCLUSION
[0099] The embodiments described above and in the claims are
intended only to illustrate and teach one or more ways of
practicing or implementing the present invention, not to restrict
its breadth or scope. The actual scope of the invention, which
embraces all ways of practicing or implementing the teachings of
the invention, is defined only by the issued claims and their
equivalents.
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