U.S. patent application number 10/783358 was filed with the patent office on 2004-08-26 for method and apparatus for custom of manufacturing of decorative, cast stonework.
Invention is credited to Carey, Richard.
Application Number | 20040167651 10/783358 |
Document ID | / |
Family ID | 32872158 |
Filed Date | 2004-08-26 |
United States Patent
Application |
20040167651 |
Kind Code |
A1 |
Carey, Richard |
August 26, 2004 |
Method and apparatus for custom of manufacturing of decorative,
cast stonework
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.
Inventors: |
Carey, Richard; (Dallas,
TX) |
Correspondence
Address: |
CARR LAW FIRM, L.L.P.
670 FOUNDERS SQUARE
900 JACKSON STREET
DALLAS
TX
75202
US
|
Family ID: |
32872158 |
Appl. No.: |
10/783358 |
Filed: |
February 20, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60449493 |
Feb 21, 2003 |
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Current U.S.
Class: |
700/98 ; 700/99;
705/1.1 |
Current CPC
Class: |
G06T 17/10 20130101 |
Class at
Publication: |
700/098 ;
705/001; 700/099 |
International
Class: |
G06F 017/60; G06F
019/00 |
Claims
1. A method for custom manufacturing decorative, cast stonework,
comprising: 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; storing the order; 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;
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; if no suitable
part exists in the inventory of unused parts, then determining if a
mold for the at least one part exists in an inventory of molds; if
no mold exists in the inventory of molds, then manufacturing or
buying a mold for the at least one first part; if a mold exists in
the inventory of molds, then determining if the mold is available;
retrieving the mold, once available, manufactured, or bought; and
casting the at least one first part with the mold that has been
retrieved.
2. The method of claim 1, wherein the step of determining if a
suitable unused part of the plurality of unused parts exists within
the inventory of unused parts further comprises: searching part
identifiers associated with each of the unused parts of the
plurality of unused parts for a part identifier that at least
matches the at least one first part identifier associated with the
at least one first part to determine if the suitable part
identifier exists within the inventory of unused parts; determining
if the suitable unused part has correct dimensions; and if the
suitable unused part is too large, then cutting the suitable unused
part to the correct dimensions.
3. The method of claim 1, wherein the step of determining if the
mold is available further comprises: retrieving a schedule of use
for the mold; and determining periods of time when the mold is in
use for other projects.
4. The method of claim 1, wherein the method further comprises: if
the mold is not available, determining if the mold exists in a mold
inventory; and if the mold does not exist in a mold inventory,
manufacturing or buying the mold.
5. A computer program product for custom manufacturing decorative,
cast stonework, the computer program product having a medium with a
computer program embodied thereon, the computer program comprising:
computer code for 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; computer code for storing the order; computer code
for 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; computer code for 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; if no suitable part exists in the
inventory of unused parts, then computer code for determining if a
mold for the at least one part exists in an inventory of molds; if
no mold exists in the inventory of molds, then computer code for
manufacturing or computer code for buying a mold for the at least
one first part; if a mold exists in the inventory of molds, then
computer code for determining if the mold is available; computer
code for retrieving the mold, once available, manufactured, or
bought; and computer code for casting the at least one first part
with the mold that has been retrieved.
6. The computer program product of claim 5, wherein the computer
code for determining if a suitable unused part of the plurality of
unused parts exists within the inventory of unused parts further
comprises: computer code for searching part identifiers associated
with each of the unused parts of the plurality of unused parts for
a part identifier that at least matches the at least one first part
identifier associated with the at least one first part to determine
if the suitable part identifier exists within the inventory of
unused parts; computer code for determining if the suitable unused
part has correct dimensions; and if the suitable unused part is too
large, then computer code for cutting the suitable unused part to
the correct dimensions.
7. The computer program product of claim 5, wherein the computer
code for determining if the mold is available further comprises:
computer code for retrieving a schedule of use for the mold; and
computer code for determining periods of time when the mold is in
use for other projects.
8. The computer program product of claim 5, wherein the computer
program product further comprises: if the mold is not available,
computer code for determining if the mold exists in a mold
inventory; and if the mold does not exist in a mold inventory,
computer code for manufacturing or computer code for buying the
mold.
9. A processor for custom manufacturing decorative, cast stonework,
the processor including computer program comprising: computer code
for 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;
computer code for storing the order; computer code for 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; computer code for 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; if no suitable part exists in the
inventory of unused parts, then computer code for determining if a
mold for the at least one part exists in an inventory of molds; if
no mold exists in the inventory of molds, then computer code for
manufacturing or computer code for buying a mold for the at least
one first part; if a mold exists in the inventory of molds, then
computer code for determining if the mold is available; computer
code for retrieving the mold, once available, manufactured, or
bought; and computer code for casting the at least one first part
with the mold that has been retrieved.
10. The computer code of claim 9, wherein the computer code for
determining if a suitable unused part of the plurality of unused
parts exists within the inventory of unused parts further
comprises: computer code for searching part identifiers associated
with each of the unused parts of the plurality of unused parts for
a part identifier that at least matches the at least one first part
identifier associated with the at least one first part to determine
if the suitable part identifier exists within the inventory of
unused parts; computer code for determining if the suitable unused
part has correct dimensions; and if the suitable unused part is too
large, then computer code for cutting the suitable unused part to
the correct dimensions.
11. The computer code of claim 9, wherein the computer code for
determining if the mold is available further comprises: computer
code for retrieving a schedule of use for the mold; and computer
code for determining periods of time when the mold is in use for
other projects.
12. The computer code of claim 9, wherein the computer code further
comprises: if the mold is not available, computer code for
determining if the mold exists in a mold inventory; and if the mold
does not exist in a mold inventory, computer code for manufacturing
or computer code for buying the mold.
13. An apparatus for custom manufacturing decorative, cast
stonework, comprising: means for 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; means for storing the order; means for
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; means for 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; if no suitable part exists in the
inventory of unused parts, then means for determining if a mold for
the at least one part exists in an inventory of molds; if no mold
exists in the inventory of molds, then means for manufacturing or
means for buying a mold for the at least one first part; if a mold
exists in the inventory of molds, then means for determining if the
mold is available; means for retrieving the mold, once available,
manufactured, or bought; and means for casting the at least one
first part with the mold that has been retrieved.
14. The apparatus of claim 13, wherein the means for determining if
a suitable unused part of the plurality of unused parts exists
within the inventory of unused parts further comprises: means for
searching part identifiers associated with each of the unused parts
of the plurality of unused parts for a part identifier that at
least matches the at least one first part identifier associated
with the at least one first part to determine if the suitable part
identifier exists within the inventory of unused parts; means for
determining if the suitable unused part has correct dimensions; and
if the suitable unused part is too large, then means for cutting
the suitable unused part to the correct dimensions.
15. The apparatus of claim 13, wherein the means for determining if
the mold is available further comprises: retrieving a schedule of
use for the mold; and determining periods of time when the mold is
in use for other projects.
16. The apparatus of claim 13, wherein the apparatus further
comprises: if the mold is not available, means for determining if
the mold exists in a mold inventory; and if the mold does not exist
in a mold inventory, means for manufacturing or means for buying
the mold.
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'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'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] FIG. 1 is a block diagram depicting an improved
organizational structure;
[0016] FIG. 2 is a block diagram depicting a circle top
doorway;
[0017] FIG. 3 is a first example of a profile;
[0018] FIG. 4 is a second example of a profile;
[0019] FIGS. 5a-5d are examples of units;
[0020] FIG. 6 is a block diagram depicting the system for custom
molding decorative, cast stonework; and
[0021] FIGS. 7a and 7b 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'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] 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] FIGS. 5a-5d are examples of units. FIG. 5a depicts an
unfluted Corinthian column, and FIG. 5c depicts an unfluted Doric
column. Specifically, the picture of FIGS. 5a and 5c only depict
the caps of each of the respective columns because the caps are
what differentiate the Corinthian column from the Doric column.
[0034] FIGS. 5b and 5d, on the other hand, depict more complex
units. Specifically, each of the respective pictures depicts an
entryway. FIG. 5b is denoted as a "Castile Aragon II" that is a
style of architecture common to the Aragon region of Northeast
Spain. FIG. 5d 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. 7a and 7b 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.
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