Abstract:
A method for custom manufacturing decorative, cast stonework. The method includes receiving an order including at least one drawing of at least one part of a plurality of parts that comprise a unit, storing the order and referencing the at least one first part to a database of units and parts, wherein the least one first part number is associated with the at least one first part. The method then determines if a suitable unused part exists in inventory. If not, the method determines if a mold exists. If not, the method manufactures or buys a mold. If a mold exists and is available, the method casts the part.

Description:
CLAIM OF PRIORITY  
       [0001]    This application claims priority from U.S. Provisional Patent Application No. 60/449,493 entitled “METHOD AND APPARATUS FOR STONEWORK CONSTRUCTION” by Carey, on Feb. 21, 2003 (Attorney Docket No. STNL 2656000), and is related to U.S. Patent Application Ser. No. ______ , Attorney Docket No. STNL 2656001, entitled “METHOD AND APPARATUS FOR PARAMETRIC DESIGN OF CUSTOM DECORATIVE STONEWORK,” filed on even date herewith, and to U.S. patent application Ser. No. ______ , Attorney Docket No. STNL 2656003, entitled “METHOD AND APPARATUS FOR INTERACTIVELY DESIGNING CUSTOM DECORATIVE STONEWORK,” filed on even date herewith, the contents of which are hereby incorporated by reference. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention relates generally to automated manufacturing of stonework and, more particularly, to custom production of decorative stonework.  
         DESCRIPTION OF THE RELATED ART  
         [0003]    In the construction industry, decorative stonework has been common feature for a number of years. Larger and larger portions of stone are used in the construction of buildings and houses. Decorative stonework can be made by being cut from natural stone, cut from man-made materials, cast from molds, extruded or any combination of these techniques. Of these techniques, one of the most economical is casting using molds. Generally speaking, casting the stonework allows the aesthetics associated with decorative stonework to be preserved while reducing the overall cost.  
           [0004]    The process of manufacturing cast decorative stonework typically involves pouring a limestone-based material into a mold and allowing it to harden. Once the material has hardened it is removed from the mold as a manufactured decorative stonework piece.  
           [0005]    In some instances, a product may be formed of a single piece. However, more typically, more complex products, such as door frames, are not molded out of one continuous piece of manufactured stone. Instead, several pieces are assembled, usually at the job site, to yield the structure. The molds, then, are usually for the smaller components of the large whole product.  
           [0006]    Architecture is a high art form that has been around since earliest days. The Romans and Greeks were master architects. These groups adopted certain stylistic features that were associated with their architecture. In the traditional organizational scheme, architectural features are each given certain titles. For example, Doric, Ionic, and Corinthian columns are examples of Greco-Roman architectural features. Doric columns are least ornate of the three, having a plain shaft and a simple cap. Ionic columns are more ornate, having flutes caved into the shaft and a more ornate cap, such as scrolls. The Corinthian columns are the most ornate, usually with an extremely ornate cap. However, even through these architectural features accurately describe the features of a structure, the average layperson may not be able to describe a Doric column, let alone know the name of the feature.  
           [0007]    The customer is often a layperson and at the start of a project may not even know specifically what feature he or she desires. In fact, most laypersons would typically have only a holistic knowledge or a feel for what he or she wants. Traditional organizational schemes, though, may not necessarily provide a logical correlation to the average layperson.  
           [0008]    To alleviate the problem associated with logical associations, it would be desirable to have a database organizational scheme can be employed to better assist a lay customer or a professional in choosing the decorative stonework associated with desired architectural features.  
           [0009]    Several problems exist with the design, manufacture, and assembly of manufactured decorative stonework. For a given manufacturer of stone work, the molds can number in the tens of thousands. Changing the proportions of a given architectural feature can be cumbersome. There can be physical limitation as well as aesthetic considerations. Also, by changing the proportions of a given feature, the molds utilized to make the parts that compose the given architectural feature may have to be changed. Compounding the complexity of this problem is the fact that most decorative stonework products are custom designed to fit individual customer&#39;s tastes at the time a structure is designed. The decorative stonework products must also meet size and structural requirements dictated by other, non-stonework products (such as a wooden entry door) or natural geographic features of the site. Thus, oftentimes, no two decorative stonework products will be exactly alike.  
           [0010]    The parameters required for designing decorative stonework may not be known until the time a design for the entire structure is substantially complete. Nevertheless, decorative stonework must usually be incorporated into the design of a structure at the concept stage or it may be impractical to add later. Thus, the ability to design decorative stonework products at a very early stage of the conceptualization of a structure extremely quickly, from sometimes incomplete parameters, at least to the point that the appearance of the decorative stonework products in conjunction with the structure can be determined and the cost reliably estimated can be the difference between the structure ultimately including or not including any decorative stonework.  
           [0011]    Decorative stonework is typically very heavy. It can also be prone to damage during transportation if not properly packaged or unnecessarily handled. Typically, it will not be possible to pre-assemble the components at the stonework manufacturer&#39;s facility to ensure proper fit. To maintain an economical product, it is necessary to design and manufacture the components for the custom decorative stonework product, which may be one-of-a-kind, from tens of thousands of parts and their molds in an almost unlimited number of sizes, configurations and styles to fit with an unlimited number of structural designs. Then, all the components and their supporting documentation must be transported to the job site in all the correct sizes and at the right time.  
           [0012]    Therefore, there is a need for a method and/or apparatus for facilitating and at least partially automating the process of selection, identification, design and manufacturing of custom decorative stonework products that at least addresses some of the problems associated with conventional methods and apparatuses.  
         SUMMARY OF THE INVENTION  
         [0013]    The present invention provides a method for custom manufacturing decorative, cast stonework that comprises receiving an order, wherein the order at least comprises one drawing, and wherein the at least one drawing at least comprises at least one part of a plurality of parts that comprise a unit. The method also includes storing the order and referencing the at least one first part to a database of units and parts, wherein the least one first part number is associated with the at least one first part. The method further comprises determining if a suitable unused part of a plurality of unused parts exists within an inventory of unused parts by an associated part identifier, wherein each unused part of the plurality unused parts have part identifiers associated therewith. The method then checks to determine if no suitable part exists in the inventory of unused parts, and if no part exists, further comprises determining if a mold for the at least one part exists in an inventory of molds. The method then checks to determine if a mold exists in the inventory of molds. Then, if no mold exists, the method further comprises manufacturing or buying a mold for the at least one first part. If a mold exists in the inventory of molds, the method then determines if the mold is available. If the mold is available, the method retrieves the mold and casts the at least one first part with the mold that has been retrieved. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]    For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:  
         [0015]    [0015]FIG. 1 is a block diagram depicting an improved organizational structure;  
         [0016]    [0016]FIG. 2 is a block diagram depicting a circle top doorway;  
         [0017]    [0017]FIG. 3 is a first example of a profile;  
         [0018]    [0018]FIG. 4 is a second example of a profile;  
         [0019]    [0019]FIGS. 5 a - 5   d  are examples of units;  
         [0020]    [0020]FIG. 6 is a block diagram depicting the system for custom molding decorative, cast stonework; and  
         [0021]    [0021]FIGS. 7 a  and  7   b  are flow charts depicting the process of molding custom, decorative stonework. 
     
    
     DETAILED DESCRIPTION  
       [0022]    In the following discussion, numerous specific details are set forth to provide a thorough understanding of the present invention. However, those skilled in the art will appreciate that the present invention may be practiced without such specific details. In other instances, well-known elements have been illustrated in schematic or block diagram form in order not to obscure the present invention in unnecessary detail.  
         [0023]    Referring to FIG. 1 of the drawings, the reference numeral  100  generally designates an improved organizational structure. The improved organizational structure  100  comprises a unit description  102 , part descriptions  104 , and profile descriptions  106 .  
         [0024]    When either a professional or a customer begins the process of choosing stonework, typically there is a first association to a specific item, such as a window. This first association is designated as a unit  102 . The unit  102  can be either a very simple or a complex item ranging from a simple feature, such as a window frame, to more complex features, such as gazebos and staircases.  
         [0025]    As it is well known, decorative stonework products are often not composed of a single, continuously molded block. Instead, to maximize the ability to create numerous varieties of units  102  while attempting to minimize costs, individual components or parts  104  are utilized. These parts are sometimes interchangeable and, thus, are capable of being used for a number of units. Furthermore, the parts  104  can be increased in size to create a large individual unit. Therefore, in the improved organizational scheme  100 , each unit  102  is subdivided into numerous parts  104 . Some parts, however, are not properly interchangeable with other parts either for physical or for aesthetic reasons.  
         [0026]    To increase the appeal of each of the units  100  and to include as many architectural styles as is possible, each part  104  has an associated profile  106 . The profile  106  is typically a vertical or horizontal cross-sectional view of a given part  104 . The shapes associated with crown molding are one example of such a profile feature. With crown molding, a piece of wood or stonework is shaped to have curves or shapes on the surface. A cross-sectional view of the crown molding would be a profile. Also, profiles can also be overall views if the surface contains more intricate molded carvings, such as carved leaves.  
         [0027]    By creating the associative database, a lay customer or professional is more capable of choosing desired features in stonework. Instead of sorting through either pictures of buildings or of sets of architectural features, a customer or professional can look through components or units  102  of a design scheme. By allowing a customer, specifically, to sort through the varieties of stonework available by unit  102 , the attention of the customer will more likely be retained. Preservation of a customer&#39;s attention clearly can preserve a possible sale that would provide a benefit to the customer and to the manufacturer/retailer.  
         [0028]    Referring to FIG. 2 of the drawings, the reference numeral  200  generally designates an example of a unit. The unit comprises a first part  202 , a second part  204 , a third part  206 , a fourth part  208 , a fifth part  210 , a sixth part  212 , a seventh part  214 , and an eighth part  216 .  
         [0029]    The unit  200  is an example of a stone circle top door frame. The door frame of the unit  200  is not composed of a single, continuous piece of manufactured stone. Instead, the door frame of the unit  200  is composed of eight distinct parts  202 ,  204 ,  206 ,  208 ,  210 ,  212 ,  214 , and  216 . Each of the eight parts  202 ,  204 ,  206 ,  208 ,  210 ,  212 ,  214 , and  216  can vary in size depending on the dimensions of the door frame itself.  
         [0030]    Moreover, the style of the door frame of the unit  200  can be changed by interchanging some parts. For example, if a customer chooses to have an eyebrow door frame instead of a circular door frame, as shown in FIG. 2, then most of the original parts can be retained. The difference between an eyebrow door frame and a circular door frame is the arc across the top of the frame. The top of the circular door frame has a radius equal to one half the distance between the sides of the doorframe, whereas the top of an eyebrow doorframe is larger than the one half the distance between the sides of the doorframe. Therefore, it is possible to retain the third part  206 , the fourth part  208 , the fifth part  210 , the sixth part  212 , the seventh part  214 , and the eighth part  216 . Hence, the first part  202  and the second part  204  can be replaced with parts that possess a larger arc.  
         [0031]    Providing the customer with an association as expressed can therefore lead to easier choosing of design elements. If circular door frames and eyebrow door frames are associated with different architectural styles, a customer may holistically know that he or she prefers an eyebrow door frame. However, if the customer has a particular affinity for an architectural style that does not incorporate eyebrow door frames, then a customer can become frustrated because he or she does not know the name of the particular style of door frame or the specific architectural style to which the door frame belongs. Hence, organization of stonework into units, such as the door frame of unit  200 , can assist the customer.  
         [0032]    [0032]FIGS. 3 and 4 are examples of profiles. Both the first profile  300  and the second profile  400  are horizontal cross-sections of a given part. The dimensions of each profile  300  and  400  are typically measured by three dimensions. The height Y, the upper depth X and the lower depth Z are related to the overall size of the given part  104 . There are profiles that can be utilized in order to provide varying degrees of aesthetic flair.  
         [0033]    [0033]FIGS. 5 a - 5   d  are examples of units. FIG. 5 a  depicts an unfluted Corinthian column, and FIG. 5 c  depicts an unfluted Doric column. Specifically, the picture of FIGS. 5 a  and  5   c  only depict the caps of each of the respective columns because the caps are what differentiate the Corinthian column from the Doric column.  
         [0034]    [0034]FIGS. 5 b  and  5   d , on the other hand, depict more complex units. Specifically, each of the respective pictures depicts an entryway. FIG. 5 b  is denoted as a “Castile Aragon II” that is a style of architecture common to the Aragon region of Northeast Spain. FIG. 5 d  is denoted as “Boxwood Manor” that is a style of architecture more indicative of the Southwest United States.  
         [0035]    Referring to FIG. 6 of the drawings, the reference numeral  600  generally designates a block diagram depicting the system for custom molding decorative, cast stonework. The system  600  comprises a computer network  602 , a server  604 , a computer infrastructure  606 , a database of mold locations/uses  608 , an inventory database  610 , a warehouse of molds  614 , an inventory  616 , a manufacturing facility  618 , and an order database  638 .  
         [0036]    The process of molding custom, decorative stonework is a difficult task to accomplish. Firstly, the stone utilized in the decorative stonework is heavy, typically on the order of several hundred or more pounds. The stone is also cumbersome due to the shape and weight. Therefore, it is not economically feasible to store vast amounts of stone.  
         [0037]    To alleviate the problems associated with storing vast numbers of stone, the decorative stonework is, instead, manufactured after an order is placed and immediately before delivery. However, the molds, too, can be quite large and cumbersome. In fact, large warehouses are typically utilized to store thousands or tens of thousands of molds. As a result, maintaining a proper accounting of the location and usage of scarp materials and molds becomes increasely important.  
         [0038]    In order to provide a more rapid and efficient method to mold stonework, computer tracking system  600  is employed. The tracking system  600  is overlaid on the database  100  of FIG. 1. That way, for each unit designed, which corresponds to an architectural feature, the respective parts comprising the unit are easily determined.  
         [0039]    The system  600  operates receiving multiple transmissions of operable data. The server  604  for the system  600  is coupled to the computer network  602  through a first communication channel  620 . The computer network  602  can be a variety of computer networks including, but not limited to, the Internet. The server  622  is then coupled to the computer infrastructure  606  through a second communication channel  622 . Through the computer network  602  and the server  620 , drawings or designs can be transmitted. The computer infrastructure  606  stores the drawings or designs transmitted by a client on the order database  638 . The drawings are communicated to the order database  638  from the computer infrastructure  606  through a third communication channel  640 .  
         [0040]    Once the drawing or design has been stored in the order database  638 , the computer infrastructure  606  can then process the drawings or designs. However, to complete the orders in the most economical fashion, an inventory of unused stone is maintained along with a plurality of molds. The inventory database  610  is utilized to maintain a proper accounting of the inventoried stone that is previously unused, and the database of mold locations/uses  608  maintains a proper accounting of mold locations in the warehouses and if the molds are in use for another order. The computer infrastructure  606  maintains the inventory database  610  as well as the database of mold locations/uses  608 . The computer infrastructure  606  transmits data to and receives data from the inventory database  610  and the database of mold locations/uses  608  through a fourth communication channel  636  and a fifth communication channel  626 , respectively.  
         [0041]    The system of manufacturing may not be entirely automated, though. An employee can gain access to the order to fulfill the order. Typically, an employee will assist in transmitting usage of molds and inventoried stone to the computer infrastructure  606 . However, it is possible to have an entirely automated process. An employee can gain access to information stored on the computer infrastructure  606  though the workstation  612 . The workstation  612  sends and receives information from the computer infrastructure  606  through a sixth communication channel  632 . Updates regarding the inventory  616  are transmitted to the computer infrastructure  606  through a seventh communication channel  634 . Updates regarding the mold locations in the warehouse  614  and mold usage in the manufacturing facility  618  are transmitted through an eighth communication channel  630  and a ninth communication channel  624 , respectively.  
         [0042]    Referring to FIGS. 7 a  and  7   b  of the drawings, the reference numeral  700  generally designates a flow chart depicting the process of molding custom, decorative stonework.  
         [0043]    The process of molding the parts of a unit is a relatively complex process that can be accomplished electronically. In step  702 , a CAD drawing, complete with part numbers or other identifiers, is received. The reception of the CAD drawing of step  710  is accomplished through the usage of the computer network  602  of FIG. 6. Included in step  702 , the computer infrastructure  606  of FIG. 6 stores the order in the order database  638  of FIG. 6.  
         [0044]    Associated with each drawing is a timeframe in which the order is to be completed. The computer infrastructure  606  of FIG. 6 will almost continually determine whether the time is proper to cast the stonework in step  704 . If the timing is not correct, then the computer infrastructure  606  of FIG. 6 waits in step  706 . The reason for waiting for the correct timing is that the timing for the casting of the stonework is important. The stonework, typically, is cast just prior to shipping because it is not convenient or economically feasible to cast the stonework for too far in advance. The stonework is oftentimes large, cumbersome, and heavy, making storage difficult. Moreover, the possibility often exists that an order may be cancelled.  
         [0045]    Once the timing for the creation of the stonework has come, each part comprising a unit has to be cast or brought out of inventory. Prior to casting a new stone part, the computer infrastructure  606  of FIG. 6 makes a determination as to whether there is a part in inventory that may suffice in step  708 . If there may be a suitable piece of unused stone, another determination is made as to whether the stone is the correct size in step  710 . In step  712 , if the unused stone is not the correct size a determination is made as to whether the stone can be cut to the proper size. The stone is then cut to size in step  714 . Once a stone of the correct size is brought out of inventory, then the stone is ready to be shipped in step  716 . Then in step  718 , a determination is made if the order has been complete.  
         [0046]    Once a determination has been made that a suitable part is not in inventory  616  of FIG. 6, the molding process is employed. The computer infrastructure  606  of FIG. 6 determines whether a mold for the part exists in step  720 . If the mold does not exist, then the mold is manufactured in step  721 . However, if the mold does exist, a problem can arise if the mold is in use. Therefore, the computer infrastructure  606  of FIG. 6 determines if the mold is in use in step  722 , and waits for the mold to become available in step  724 .  
         [0047]    Once a mold has become available, then the part is cast. In steps  726  and  728 , the computer infrastructure  606  of FIG. 6 locates and retrieves the mold. The mold is then poured and allowed to harden in steps  730  and  732 . Once hardened, the mold is returned and the part is ready to ship in step  734 . A determination is then made as to the status of completion in step  736 . If the order is complete, then the process begins again for another part in step  708 . An example of an embodiment of the invention is further described in Appendices A to M, the contents of which are hereby incorporated by reference.  
         [0048]    By providing a sophisticated automation system to custom manufacture stonework, the economic benefits are substantial. The systems and software allow a manufacturer to use CAD or other drawing types to easily cast custom stonework while maintaining a proper accounting of all inventoried, unused stone and of the vast numbers of molds required to manufacture cast stonework. By reducing the number of personnel required to manufacture the cast stonework, overhead costs are substantially reduced. Therefore, the competitive edge in the cast stonework industry would tilt toward a manufacturer that has reduced overhead as a result of increased automation.  
         [0049]    It is understood that the present invention can take many forms and embodiments. Accordingly, several variations may be made in the foregoing without departing from the spirit or the scope of the invention. The capabilities outlined herein allow for the possibility of a variety of programming models. This disclosure should not be read as preferring any particular programming model, but is instead directed to the underlying mechanisms on which these programming models can be built.  
         [0050]    Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Many such variations and modifications may be considered desirable by those skilled in the art based upon a review of the foregoing description of preferred embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.