Method and assembly for forming a building element

Abstract

A method of designing and engineering a building element (e.g., a staircase) that is structurally verified and may be easily certified. The method uses a parametric three-dimensional (3D) model of the building element and a constraint space definition. It ensures that the building element will fit in the building and will comply with functional, legal, and/or other requirements, such as strength, dimensional requirements, or use of certain materials. A computer system provides a user tool for easily amending the building element while visualizing it in its specific use. It also converts the amended building element to processing instructions for 3D manufacturing, such that the end product complies with the constraint space definition. A user without extensive knowledge of engineering, complex computer-aided design (CAD) programs, or 3D manufacturing can easily amend a design to his or her personal need and have the building element custom produced.

Claims

1. A method for forming a building element, comprising defining in a computer memory: a building element parametric three-dimensional (3D) model of the building element, and a building element constraint space, said building element constraint space comprising building element dimensional parameters of said building element that are mathematically coupled to at least one selected from another dimensional parameter of the building element, a minimum value, a maximum value, and a combination thereof; providing at least one 3D manufacturing assembly comprising a control system having a data processor for processing control instructions for controlling said 3D manufacturing assembly, said method further comprising running a computer program on a computer system which: retrieves from said computer memory said building element parametric 3D model and its linked constraint space; visualizes said building element parametric 3D model through a display system; provides a user tool which is visualized through said display system and which allows a user to modify one or more building element dimensional parameters to provide an amended building element parametric 3D model by receiving user input via a user input system that is operationally coupled with said computer system, wherein said modification of said building element dimensional parameters by said user tool is limited by said building element constraint space; visualizes said amended building element parametric 3D model through said display system in response to said user input, and converts said amended building element parametric 3D model into control instructions for said control system for controlling at least one 3D manufacturing assembly for forming said amended building element and provides said control instructions to said control system.

2. The method of claim 1, further comprising: defining in said computer memory at least one building part parametric 3D model relating to a building part where said building element is to be used, and defining in said computer memory for said building part parametric 3D model a building part constraint space comprising at least one building part dimensional parameter of said building part that is mathematically coupled at least one building element dimensional parameter, and that are mathematically coupled to at least one selected from another building part dimensional parameter, to a minimum value, to a maximum value, and a combination thereof, and wherein said computer program further provides said user tool for receiving user input via said user input system that is operationally coupled with said computer system, to allow said user to modify one or more dimensional parameters of said building part parametric 3D model into an amended building part parametric 3D model, wherein said computer program compares modification of said one or more building part dimensional parameter by said user with limitations by said building part constraint space and said building element constraint space; modify said building element dimensional parameters in reaction to said modified building part dimensional parameters to provide an amended building element parametric 3D model, which modification of said building element dimensional parameters is limited by said building element constraint space and said building part constraint space; visualizing said amended building part parametric 3D model together with said building element parametric 3D model through said display system, thus showing said user an amended building element in combination with said amended building part via said display system in response to said user input.

3. The method of claim 2, wherein said method further comprises a constraint database comprising at least one database entry selected from a numerical value, a mathematical relation, and a combination thereof, wherein at least one parameter of said building part constraint space and at least one parameter of said building element constraint space are mathematically coupled to said database entry.

4. The method of claim 2, further comprising: defining in a computer memory a series of said building part parametric 3D models of a series of building parts; defining in a computer memory for each of said building part parametric 3D models one of said building part constraint space; said computer program further: presents a selection tool on said display system to allow a user to select a building part from said series of building parts, and retrieve user input via said user input system indicating a selected building part; retrieves from said computer memory said building part parametric 3D model of said selected building part and its linked constraint space, and visualizes through said display system said building element parametric 3D model of said selected building element with said building part parametric 3D model of said selected building part.

5. The method of claim 2, wherein said computer program further comprises indicating a nature of said constraint on said display system, when said user tool is limited by at least one selected from said building element constraint space, said building part constraint space, and a combination thereof.

6. The method of claim 2, wherein said user tools comprise visualizing on said display system design suggestions for amending dimensional parameters of said building element for fitting said building element parametric 3D model within said building element constraint space and said building part constraint space.

7. The method of claim 1, further comprising: defining in a computer memory a series of said building element parametric 3D models of a series of building elements; defining in a computer memory for each of said building element parametric 3D models one of said building element constraint space; said computer program further: presents a selection tool on said display system to allow a user to select a building element from said series of building elements, and retrieve user input via said user input system indicating a selected building element; retrieves from said computer memory said building element parametric 3D model of said selected building element and its linked constraint space, and visualizes through said display system said building element parametric 3D model of said selected building element.

8. The method of claim 1, wherein said building element constraint space comprises dimensional parameter requirements selected from legal requirements on said building element, design requirements on said building element, structural requirements of said building element, production requirements, installation requirements, and a combination thereof.

9. The method of claim 1, wherein for gathering data of said building element constraint space, said computer program runs at least one query on at least one remote computer system.

10. The method of claim 1, wherein said at least one 3D manufacturing assembly comprises a 3D printing assembly.

11. The method of claim 1, wherein said forming comprises applying a setting composition, and optionally molding said setting composition.

12. The method of claim 1, further comprising said computer program performing: transforming a building element constraint into said building element constraint space, wherein said transforming comprises transforming constraint space requirements into spatial dimensional boundaries and spatial dimensional boundary mathematical dependencies relating to said building element.

13. A computer program product for forming a building element, said computer program product when running on a computer system: retrieves from a computer memory a building element parametric 3D model and its linked building element constraint space; visualizes said building element through a display system; provides a user tool which is visualized through said display system and which allows a user to modify one or more building element dimensional parameters to provide an amended building element parametric 3D model by receiving user input via a user input system that is operationally coupled with said computer system, wherein said modification of said building element dimensional parameters by said user tool is limited by said building element constraint space; visualizes said amended building element parametric 3D model through said display system by showing said user an amended building element via said display system in response to said user input, and converts said amended building element parametric 3D model into control instructions for controlling at least one 3D manufacturing assembly for forming said amended building element.

14. An assembly for forming a building element, comprising: at least one 3D manufacturing assembly comprising a control system having a data processor for processing control instructions for controlling said 3D manufacturing assembly; a computer system comprising a display system, a computer memory storing a building element parametric 3D model and a data processing system comprising a computer program which, when running on said computer system: retrieves from said computer memory said parametric 3D model of said building element and its linked building element constraint space; visualizes said building element through a display system; provides a user tool which is visualized through said display system and which allows a user to modify one or more building element dimensional parameters to provide an amended building element parametric 3D model by receiving user input via a user input system that is operationally coupled with said computer system, wherein said modification of said building element dimensional parameters by said user tool is limited by said building element constraint space; visualizes said amended building element parametric 3D model through said display system, by showing said user an amended building element via said display system, in response to said user input, and converts said amended building element parametric 3D model into control instructions for controlling said at least one 3D manufacturing assembly for forming said amended building element and provides said control instructions to said control system.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the invention will now be described, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, and in which:

(2) FIG. 1 schematically depicts a schematic screenshot of a customization screen for the building part, here a room;

(3) FIG. 2 schematically depicts a further schematic screenshot of a customization screen for the building element, here a staircase;

(4) FIG. 3 schematically depicts a further schematic screenshot of a customization screen for the building element, here a staircase;

(5) FIG. 4 elements for providing a system for forming a building element, and

(6) FIGS. 5 and 6 a schedule showing part of a constraint space definitions, showing dependencies of the building part constraint space and the building element constraint space.

(7) The drawings are not necessarily on scale.

DESCRIPTION OF PREFERRED EMBODIMENTS

(8) In the current description, as an example of a building element a staircase or stairway will be shown and discussed to illustration the design and production of a building element. Many other building elements are possible, however. The building element will in this example be designed to fit into a building part. Currently, a room is presented as an example of a building part. Furthermore, in this example use is made of a display screen that is well-known to a skilled person. Alternatives, as mentioned before, are possible, for instance using virtual reality, 3D projections, and the like. In any of these alternatives, a building element can be presented in a building part, and with user tools for modifying the design and parameters of the building element in order to provide a customizable building element.

(9) In the current application a user will first select, from many possible building elements, a building element the user wants to be produced. It may be possible to present a series of different designs or types of similar building elements. For instance, various types of staircases may be presented. Next the user selects a design he wants to have produced. As a subsequent step, the user may be presented with a building part into which the building element has to be used, or alternatively the user may select such a building part, or, alternatively, the user may design a building part and place the building element into it. It may be clear that combinations, sequential orders and alternatives of these steps may be used.

(10) A next step is the customization of the selected design of the building element 1, in this example the staircase 1. A schematic representation of a screenshot of a customization screen is depicted in FIG. 1. In the customization screen of FIG. 1, a building element 1, here the staircase 1, is visualized. The building element 1 is here visualized in its use in a room 20 as an example of a building part 20. Here, the staircase 1 is shown in a room 20 with a ceiling 21, a floor 22 and an opening 23 in the floor 22 where the staircase 1 has to be fitted. As explained earlier, in a possible previous selection screen the user may have indicated where and how in the building part 20 the building element 1 should be used or placed.

(11) In the customization screen, the user may here activate a building part customization selector 30 (here indicated “EDIT ROOM”) or a building element customization selector 31 (here indicated “EDIT STAIRCASE”). It allows the user, via user tools 2 that will be explained later, to customize the design and dimensions of the building element 1.

(12) When the user selects the building part customization selector 30, the user will be presented with user tools 2 for customization of the dimensions of the building part 20. A computer system as explained earlier is provided with a building part parametric 3D model and a building element parametric 3D model that are used in combination to visually represent the building element 1 in its use in the building part 20. The customization software further uses the building part constraint space and the building element constraint space, that each have dimensional parameters that are mutually coupled, and have one or more dimensional parameters that are mathematically coupled resulting in a coupling of these constraint spaces.

(13) Thus, when customizing the room 20 (i.e., the building part), this may result in amendments in the dimensions of the staircase 1 (i.e., the building element 1). And, in fact, if the user (tries to) amend(s) dimensional parameters of the room 20, coupling of dimensional parameters in the constraint spaces may also result in changes in the dimensional parameters of the staircase 1, which will be visualized. If the user tries to amend dimensional parameters beyond the constraint spaces, the user will receive feedback, as will be explained below.

(14) As mentioned, in FIG. 1 the user activated the building part customization selector 30, and is now able to customize the room 20. In the current embodiment, the user is presented with selectors for selecting an aspect of the room that can be amended, end when a selection is made, the user is presented with a user tool 2, here for customizing “ROOM HEIGHT”. In the current embodiment, the user tool 2 provides the user with two possibilities for amending. First is by selecting the arrow and dragging the arrow up and down for making the room 20 higher or lower. The numerical field will show the actual height. Alternatively, the user can fill out the numerical field.

(15) In FIG. 2, the user activated the building element customization selector 31. Now, the user can customize the design and dimensional parameters of the staircase 1. In the customization of the design, various design elements of the building element 1 can be selected. For instance, buttons or other selection devices or attributes can be presented that allow for instance selection of the rear ornamentation of the staircase 1. In this customizer screen, the user already changed the design of the rear side of the staircase. Note that with respect to FIG. 1, the rear of the staircase 1 changed. These presented design elements are all pre-tested and pre-evaluated. Furthermore, dimensional parameters of the building element 1 can be customized. As an example of a user tool 2, an input box 2 is presented where the user can input the length of the staircase (“STAIRCASE LENGTH”). Other dimensions of the building element can be customized in a similar manner. For instance, the width of the staircase 1, the step inset, the length of the staircase, and/or the number of steps can be customized. Again, a user tool 2 is presented again with an arrow that can be selected and the length of which can be adjusted. The user tool 2 here also has a numerical field, showing the actual value and allowing input of a new numerical value.

(16) When customizing a parameter, the program recalculated other parameters to fit these other parameters, but will also check requirements. This is possible as all the parameters are limited by minimum/maximum values and/or links to other dimensional parameters in each of the constraint spaces. Thus, if a parameter like the length of the staircase is changed, those parameters that are liked in the constraint space will directly change also, but within their limits in the constraint space. And again, this may also affect parameters of the building part 20 (room). And these parameters may also run against limits through (one of the) constraint spaces.

(17) In FIG. 2, it is also presented what happens if a user tries to customize a parameter in such a way that the building element 1 is not within the constraint space any more. If the user input in the user tool 2 would result in an design that cannot be produced, or that is not within building regulations, the building element 1 would be outside the constraint space and this will be indicated in a user feedback tool 3. The user feedback tool 3 can also be indicated which specific other parameter is outside the constraint space. Furthermore, it is possible to provide feedback to the user as to the reason why the parameter that is outside its boundaries is bounded. Here it is stated “Your staircase should be at least 4.1 m long. According the Dutch building regulations, your step depth must be at least 0.23 m, otherwise the staircase is too steep. Thus, with your current number of steps, the staircase must b at least 4.1 m long”.

(18) In FIG. 3, the user selected another design parameter to customize. Here, the user tool 2 presents “WAIST DEPTH” as dimensional parameter to be customized. Again, the user may simply insert the desired value of this parameter in the indicated value field. Alternatively, the user may select the indicated arrow and drag for instance one of the ends in order to change the parameter. In such an event, the actual value can also be indicated in value field. The change may be limited by constraints. These constraints can be defined in as constraints of the building element itself. Furthermore, constraints defined in relation to the building part can be considered. Please note that here the user again changed the design of the rear side of the staircase 1.

(19) In FIG. 4, an embodiment is schematically depicted for an implementation of an assembly for forming a building element. In this embodiment, a database with constraints 13 is provided. The constraint database 13 is functionally coupled to a customizer 4. In an embodiment, the customizer 4 outputs a production instruction 5 for a production assembly 6.

(20) In the constraint database 13, all the constraints in a design of a specific building element 1 are entered that have an impact on dimensional parameters and thus on the producibility of the building element 1. These database entries usually are numerical values, but may also be mathematical relations between parameters that are more general in nature. In the current embodiment, in the constraint database 13 the constraints are classified into constraint classes 14 that effectively determine if a design can be realized, and if there are other requirements. In addition, constraints can be added that relate to aesthetical qualities of the building element. In this example database 13, as an example various constraint classes 14 are presented:

(21) DESIGN: specific constraints that are defined by a designer;

(22) STRUCTURAL: constraints that are defined by structural requirements;

(23) LEGISLATION: constraints that are defined by or follow from legislation;

(24) PRODUCTION: constraints that follow from production machines and material that is selected;

(25) INSTALLATION: constraints defined by for instance transportation, and installation;

(26) ET CETERA: possible further types of constraints.

(27) The customizer 4 in the current embodiment has several components. It holds a building element parametric 3D model 7 of the building element 1. In this embodiment, the customizer 4 further comprises a user interface 8 that allows a use to provide user input in the user tools 2, and that provides feedback to the user via the user feedback tool 3. It further provides a visual representation.

(28) The customizer 4 furthermore holds a building element constraint space 10. In the building element constraint space 10, the various dimensional parameters of the building element 1 are mutually connected using the information from the constraint database 13, thus defining the building element constraint space 10. The building element constraint space 10 is functionally coupled to the building element parametric 3D model 7.

(29) The customizer 4 outputs the production instruction 5 for a production system 6. The production instruction 5 in an embodiment can be an instruction file for one or more production machines of a production system 6. For instance, the production instruction 6 may comprise a file that provides machine instructions for operating a 3D printer. Alternatively or additionally, the production instruction 6 may comprise in instruction file for operating for instance another CNC device, like a welding robot, a milling machine, a cutting tool, or the like.

(30) In FIGS. 5 and 6, an example is visualized of a part of a building element constraint space 10, here again for the staircase 1, and a building part constraint space 12, and the interactions between these constraint spaces and the parametric models 7, 11 and with one another. The building part in this example again is the room in which the staircase 1 is to be placed and used.

(31) The parameter “Ceiling Height”, for example, can be set by the user, but is also constrained by a set of other parameters. Some of these constraints are defined as minimum or maximum values, and these are here stored and available in the database with constraints. In FIG. 5, it is illustrated how the lower boundary of “Ceiling height” is linked to and defined by a value of the “Minimum height of a space” as set in the database with constraints 13. This value can for instance be prescribed in building regulations. The maximum value for the parameter “Ceiling height” is linked to “ceiling height (max)” which again is linked to the parameter “Floor thickness” and the parameter “span(max)” which is defined in the building element constraint space.

(32) The parameter “Span(max)” in turn is defined by a parameter “Max span of a staircase without intermediate landing” which is defined in the database with constraints 13. The parameter “Span(max)” is further coupled to the parameters “Staircase Height(max)”, “Waist Depth(min) and “Staircase Length(max)” which are all defined in the building element constraint space 10.

(33) The parameter “Staircase Height(max)” in turn is limited by parameter “Maximum slope” as defined in the database with constraints 13, and is linked to the parameter “Staircase Length (max)”. In turn, the parameter Staircase Length (max) is defined by a parameter “room Length” which is defined in the building part constraint space 12, by a parameter “Minimum free space at landing” as defined in the database with constraints 13 and as mentioned by the parameter “Staircase Height (max)”. This example of one parameter in the building part constraint space 12 already indicates two links between the building element constraint space 10 and the building part constraint space 12. There are, however, many more parameters that define the constraint spaces.

(34) In FIG. 6 it is illustrated how a change in the ceiling height in turn affects other parameters. As illustrated in FIG. 6, the modification of the parameter “Ceiling Height” affects several parameters in the building part constraint space 12: Staircase Height Number of steps (via Staircase Height) Step Height (via Number of steps) Staircase Length (via Number of steps) Waist Depth (via Number of steps)

(35) and some in the building element constraint space 10: Floor Thickness(max) Aperture Length (min) Room Length(min)
Thus, both constraint spaces are linked together via parameters and their dependencies.

(36) Some of the parameters have a simple maximum value and a minimum value, that may for instance be defined by or in one of the database constraint classes. Other parameters may have a simple maximum value and/or a minimum value that are defined in the constraint space itself or in a other constraint space. Yet other parameters are defined by, or depend on, one or more other parameters. These relations can be simple linear relations between one or more parameters, but may also be more complex mathematical relationships between parameters. Some of these dependent parameters may be defined in an other constraint space, as is illustrated above. Depending on the building element, these relations are pre-defined together with the parametric 3D model. For similar building element types, for instance staircases, many of these relationships may be identical.

(37) It will also be clear that the above description and drawings are included to illustrate some embodiments of the invention, and not to limit the scope of protection. Starting from this disclosure, many more embodiments will be evident to a skilled person. These embodiments are within the scope of protection and the essence of this invention and are obvious combinations of prior art techniques and the disclosure of this patent.

REFERENCE NUMBERS

(38) 1 building element 2 user tool 3 user feedback tool 4 customizer 5 3D production assembly instructions 6 3D production assembly 7 building element parametric 3D model 8 User interface 9 user 10 building element constraint space 11 building part parametric 3D model 12 building part constraint space 13 constraint database 14 constraint classes 15 solver 16 library with building elements and building parts 17 building element selector 18 building part selector 20 building part 21 ceiling 22 floor 23 opening in ceiling 30 building part customization selector 31 building element customization selector