Roller Coaster Structural Components Additive Synthesis
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Solution Overview
Problem
Current design methods for roller coasters, regulated by the EN13814 standard, face challenges in optimizing structural components for high-speed and acceleration sensations while adhering to manufacturing constraints, particularly in incorporating the benefits of additive manufacturing without traditional production limitations.
Innovation Solution
A multi-parametric optimization method combined with robotic additive synthesis using 3D printing, which includes pre-feasibility, kinematic analysis, topological optimization, and stratigraphic analysis to create a dynamically optimized roller coaster structure with variable paths and material distribution, ensuring safety and maximizing passenger sensations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional production techniques (casting, machining by removal, electro-welded carpentry) are used, then manufacturing constraints are well-defined and production is reliable, but design freedom and material distribution capability are limited
Solution Approach 1:
The patent changes the manufacturing approach from traditional techniques to 3D additive synthesis, fundamentally altering the production parameters to enable complex geometries and optimized material distribution while maintaining manufacturing reliability through a defined digital workflow
Solution Approach 2:
The patent replaces traditional mechanical manufacturing systems (casting, machining, welding) with a digital 3D printing system, substituting physical manufacturing constraints with digital design freedom while maintaining production reliability through automated control
2Adaptability or versatility
If 3D additive synthesis is used, then material distribution freedom and design innovation are maximized, but manufacturing complexity and process control difficulty increase
Solution Approach 1:
The patent performs preliminary digital design and simulation phases before physical manufacturing, creating optimized 3D models and virtual prototypes that guide the 3D printing process, thereby reducing manufacturing complexity through advance planning
Solution Approach 2:
The patent implements iterative design cycles with feedback mechanisms, where simulation results and manufacturing constraints are continuously fed back into the design process to optimize both performance and manufacturability
3Loss of substance
If topological optimization is applied to reduce material usage, then weight and material consumption decrease, but structural complexity and design iteration requirements increase
Solution Approach 1:
The patent employs automated topological optimization algorithms that self-adjust and self-optimize the design, reducing the need for manual design iterations and simplifying the complexity management through algorithmic automation
Data Source
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AI summary
Constrained designing method with multi-parametric optimization and a cross-connected production process for the robotic additive synthesis of the mechanical and structural components of a rollercoaster, compliant with the EN13814 standard. Whereas said rollercoaster has a 3D shape, forming a closed path, with portions at various inclinations and rotations and a set of curves or spirals, where said roller coaster is subject to a variable number of degrees of freedom. The cross-connected 3D printing production process engenders constraints to the designing method, as the latter must take into account the physical limitations of the printing device, avoiding generating not printable models. FIELD OF THE INVENTION The present invention refers to a constrained method with multi-parametric optimization and the related production process for the additive robotic synthesis of mechanical and structural components of a roller coaster compliant with the EN13814 standard.