AUTOMATED SYSTEM FOR DESIGN AND FABRICATION OF ARTIFICIAL ROCKWORK STRUCTURES

Number: 20200201948
Published: 2020-06-25
Filed: 2018-12-20
Assignee: DISNEY ENTERPRISES, INC.
Inventors: MARSHALL; ANDREW STEVEN, RICHARDSON; DANIEL ROBERT, WILDER; KATRINA ANNE, SCHARFENBERG; DOUGLAS CHARLES, HOLMES; SHAWN MICHAEL, CHANDRANAND; HEPZIBAH, WELCH; MIKE S., TSCHANZ; MICHAEL
CPC: G06F30/13; G06T17/00; G06T17/20
Verdict: Low Notable software
Source: Google Patents · FreePatentsOnline

The keeper's note

CAD/fabrication design tool for themed-environment rockwork.

Abstract

A system for automating design of a support frame for artificial rockwork structures. The system includes a processor and memory storing a three dimensional (3D) mesh for an exterior surface of a rockwork structure. The system includes an offset module that is code/instructions or software executed by the processor to process the 3D mesh and generate an offset mesh defining a 3D topology of the exterior surface at an offset distance from the 3D mesh. The system also includes a chip-defining module including software executed by the processor to divide the offset mesh into a plurality of subsections. The system further includes a rebar line-defining module with software executed by the processor to generate an assembly of rebar pieces for each of the subsections that defines for each of the rebar pieces a length, a location within the subsection, and a set of spaced apart bends.

Background

BACKGROUND1. Field of the Description

The present description relates, in general, to design and fabrication of structures that are built upon or supported on an interior frame or cage such as artificial rockwork structures formed by plastering upon a metal rod frame or cage and used for scenery at theme or amusement parks, shopping malls, pedestrian malls, urban parks, or the like. More particularly, the description is directed to a new method and corresponding system for automating the design and fabrication of the underlying support frame that is formed of individually bent metal rods (herein referred interchangeably to as “rebar” to mean any rod or tube of any metal or metal alloy and of any diameter), as well as then completing the rockwork or similar structure by applying plaster and/or other materials to form an outer or encasing layer or shell.2. Relevant Background

There are numerous uses for artificial structures to create or enhance an indoor or, more commonly, outdoor space to create a desired look and feel. For example, many designers of common spaces for office buildings, residential complexes, and shopping malls will include large rockwork portions. The rockwork portions can be implemented using artificial or manmade structures fabricated with a plaster or other material(s) applied over a metal rod frame or support structure or cage (or a “rebar structure”). In another example, theme and amusement parks often each will include large amounts of rockw

Claims

1. A system for automating design of a support frame for artificial rockwork structures, comprising: a processor; memory storing a three dimensional (3D) mesh for an exterior surface of a rockwork structure; an offset module comprising software executed by the processor to process the 3D mesh and generate an offset mesh defining a 3D topology of the exterior surface at an offset distance from the 3D mesh; a chip-defining module comprising software executed by the processor to divide the offset mesh into a plurality of subsections; and a rebar line-defining module comprising software executed by the processor to generate an assembly of rebar pieces for each of the subsections that defines for each of the rebar pieces a length, a location within the subsection, and a set of spaced apart bends. 12. A system for automating design of a support frame for artificial rockwork structures, comprising: a processor; memory storing a digital model defining an exterior surface of a rockwork structure; and a set of program instructions executable by the processor to: generate an offset mesh from the 3D model defining a 3D topology of the exterior surface at an offset distance; divide the offset mesh into chips; and generate a plurality of rods for each of the chips arranged to provide a portion of a support frame for an exterior material layer for fabricating the rockwork structure, wherein each of the rods is defined by a length, a location within one of the chips, and a set of spaced apart bends defined by a bend angle. 19. A system for automating design of a support frame for artificial rockwork structures, comprising: a processor; memory storing a three dimensional (3D) mesh for an exterior surface of a rockwork structure; an offset module comprising software executed by the processor to process the 3D mesh and generate an offset mesh defining a 3D topology of the exterior surface at an offset distance from the 3D mesh; a chip-defining module comprising software executed by the processor to divide the offset mesh into a plurality of subsections; and a rebar line-defining module comprising software executed by the processor to generate an assembly of rebar pieces for each of the subsections that defines for each of the rebar pieces a length, a location within the subsection, and a set of spaced apart bends, wherein the rebar line-defining module processes each of the subsections of the offset mesh first using a common point algorithm and second using an RDP algorithm on a subset of segments.