Data processing: generic control systems or specific application – Specific application – apparatus or process – Product assembly or manufacturing
Reexamination Certificate
2000-03-02
2003-09-23
Picard, Leo (Department: 2125)
Data processing: generic control systems or specific application
Specific application, apparatus or process
Product assembly or manufacturing
C700S097000
Reexamination Certificate
active
06625509
ABSTRACT:
FIELD OF INVENTION
This invention relates to an automated multisection rail material list generation system and method and, more particularly, to such a system and method which automatically produces a material list which itemizes the discrete dimensioned elements required to produce each section of the multisection rail.
BACKGROUND OF INVENTION
The design and construction of a railing for use on a staircase can be a complex job, especially when the staircase is anything other than a simple design. On complex staircases that incorporate one or more landings and numerous stair sections, the design and construction of these railings can be quite tedious and time consuming.
Typical railings used on staircases, guardrails or for fences incorporate various components. Posts are used to anchor the sections of railing in the ground, where each rail section is constructed of a top rail, a bottom rail and numerous pickets connecting the rails together. Additionally, decorative items such as rings and scrolls may be incorporated into the rail section for aesthetic purposes. Further, additional top rails or bottom rails may be incorporated to add strength and aesthetic appeal.
Traditionally, rail sections were laid out by hand, where lengths of steel or wrought iron were cut to approximate length and hand trimmed or ground until they fit properly. As can be imagined, this is a very time consuming process that often resulted in a substantial amount of waste due to miscut parts. In order to avoid cutting parts too short, they were often intentionally cut too long so that they could be trimmed to fit, which resulted in further waste.
In an effort to simplify rail design, computer programs were generated which attempted to automate the design process. Specifically, the user would input the length of the section of rail into the program and, in turn, the program would calculate the number of pickets, the picket length, the picket spacing, etc. However, these programs failed to address the truly complex issues concerning rail design and manufacturing, namely the problems encountered when designing a complex multisection rail system.
Anytime a stairway incorporates a landing, at least two sections of railing have to be joined together to make the railing for that stairway. Since safety regulations can require different overall heights for the railing used on a landing versus the railing used on a stair (or rake or bevel) section, numerous problems are encountered when these two sections of varying height railing are joined together. Typically, a landing rail section has an overall height of 36 inches, while a stair rail section has an overall height of 34 inches. Simply abutting these two sections together at a post will result in a two inch deviation of overall height between the landing side and the stair side.
In order to alleviate this problem, the transition point between these two rail sections can be shifted towards the stair rail (in the event of an inclining stair section) so that the landing will continue horizontally until it intersects the stair rail. Alternatively, the transition point can be shifted away from the stair rail (in the event of a declining stair section). Calculating the amount of the offset for this transition point is further complicated by the angle of the stair section. Additionally, any setback of the post in relation to the true intersection of the landing and the stair section will result in a railing in which the rail height of the stair section is too low. Therefore, if the post of a railing is set back in relation to this intersection, the post height must be increased or decreased accordingly to maintain the proper height of the stair section railing. Additional complications in multisection rail design include the fact that as the angle of the stair section increases, the horizontal spacing of the pickets in that section will decrease, as the picket spacing varies in accordance with the cosine of the angle of incline of the stair.
BRIEF SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide an automated multisection rail material list generation system and method which automates the design process for multisection rails.
It is a further object of this invention to provide such a system and method which minimizes material waste and maximizes design efficiency.
It is a further object of this invention to provide such a system and method which automatically calculates the required transition offset when joining rail sections of varying height.
It is a further object of this invention to provide such a system and method which automatically calculates the required post height in relation to post set back and rail height.
It is a further object of this invention to provide such a system and method which automatically calculates the required picket spacing in relation to the angle of incline of the stair selection.
This invention results from the realization that a truly effective automated multisection rail material list generation system and method can be achieved by receiving dimensional data concerning a multisection rail and utilizing that data to generate a material list which itemizes the individual dimensioned components required to assemble that multisection rail.
This invention features an automated multisection rail material list generation system including: a data importer for receiving dimensional data concerning each section of a multisection rail; a rail calculator, responsive to the data importer receiving the dimensional data, for determining the dimensions of the physical rail elements required to produce each section of the multisection rail; and a material list generator, responsive to the rail calculator, for producing a material list itemizing the physical rail elements and their dimensions required to produce each section of the multisection rail.
In a preferred embodiment, the dimensional data may describe a multisection rail in which each section of the multisection rail is at a different angle in relation to the horizon. The data importer may include a data interface for connecting the data importer to a network. The network may be the Internet. The network may be a telephone network. The material list generator may include a data exporter for providing the material list, which includes the physical rail elements, to an automated cutting station for producing a plurality of dimensioned components. The data exporter may provide the material list, which includes the physical rail elements, to an automated assembly station for assembling the plurality of dimensioned components into the multisection rail. The data exporter may include a graphical interpreter for producing a graphical diagram showing the physical rail elements arranged to form the multisection rail. The dimensional data may describe a multisection rail in which each section of the multisection rail includes a top rail and a bottom rail. The rail calculator may include a transition manager for allowing the user to define a transition radius at any transition point between adjacent rail sections. The transition manager may include a material elasticity compensator for compensating for any change in length of any the rail bent around the transition radius. The rail calculator may include an upper transition offset calculator for determining the offset of an upper transition point between each top rail of each rail section in relation to the point of contact between the sections. The rail calculator may include a lower transition offset calculator for determining the offset of a lower transition point between each bottom rail of each rail section in relation to the point of contact between the sections. The dimensional data may describe a multisection rail that includes at least one post. The rail calculator may include a post height calculator to determine the required height for a post in relation to post offset and specific design criteria. The dimensional data may describe a multisection rail in which each section of multisection rail includes a plur
Flynn, Sr. Roger Lee
Henkel Robert
Fish & Richardson P.C.
Kosowski Alexander
Picard Leo
R & F Industries, LLC
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