Point-Cloud Staircase Panel Cutting for Precise Surface Installation
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Solution Overview
Problem
Current methods for installing staircase flooring are labor-intensive and imprecise, leading to wobbly, noisy, and aesthetically unpleasing results due to the difficulty in accurately measuring and fitting custom parts to complex staircase geometries.
Innovation Solution
A system comprising a measuring device for precise surface measurement, a designating system for generating construction plans, and a cutting device for automated material cutting, allowing for efficient and accurate creation and installation of customizable panels, particularly for staircases, by scanning surfaces to generate point cloud measurements and producing custom parts with sub-millimeter accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement and cutting methods are used for staircase flooring, then flexibility and adaptability to complex geometries are maintained, but measurement precision and manufacturing accuracy deteriorate
Solution Approach 1:
The patent replaces manual mechanical measurement tools with a digital measuring device that captures point cloud data of staircase surfaces. This substitution enables precise digital measurement of complex geometries without requiring complex manual measurement procedures, directly resolving the contradiction between measurement precision and device complexity.
Solution Approach 2:
The patent creates a digital copy (point cloud model) of the physical staircase surface. This digital replica preserves all geometric details while enabling precise measurement and analysis without the complexity of physical measurement tools, allowing accurate virtual planning before physical fabrication.
2Productivity
If custom parts are manually modified to fit each step, then adaptability to complex geometries is achieved, but productivity and installation time deteriorate
Solution Approach 1:
The patent performs all measurement, planning, and cutting operations before installation. The measuring device captures staircase geometry, the designating system generates precise cutting plans, and the cutting device prepares all components in advance with sub-millimeter accuracy. This preliminary preparation eliminates time-consuming on-site modifications while maintaining high precision.
Solution Approach 2:
The patent changes the state of material from raw to precisely cut components through automated cutting. The cutting device transforms material parameters (shape, size, position) according to digital plans, achieving high manufacturing precision and productivity simultaneously by eliminating manual modification steps.
3Reliability
If imprecise measurement and cutting are used, then device complexity and installation time are reduced, but installation quality and safety deteriorate
Solution Approach 1:
The patent replaces imprecise manual measurement and cutting with automated digital systems. The measuring device captures precise point cloud data, the designating system optimizes cutting plans, and the cutting device executes cuts with sub-millimeter accuracy. This automation ensures high installation quality while reducing total installation time through efficient workflow.
Solution Approach 2:
The patent implements feedback through digital modeling and verification. The point cloud measurement provides feedback on actual staircase geometry, the designating system uses this feedback to generate accurate cutting plans, and the system verifies that cut components will fit precisely before installation begins, ensuring high reliability.
4Loss of substance
If traditional paneling methods are used, then material waste is increased due to imprecise cutting, but device complexity is reduced
Solution Approach 1:
The patent replaces traditional mechanical cutting with automated digital cutting systems guided by point cloud data. The measuring device captures precise surface geometry, the designating system optimizes material usage patterns, and the cutting device executes precise cuts that minimize waste while accommodating complex geometries efficiently.
Solution Approach 2:
The patent changes cutting parameters from approximate manual dimensions to precise digital specifications. The system determines optimal cut positions, angles, and sequences based on actual measured geometry and material properties, minimizing material waste through optimized nesting and cutting patterns.
Data Source
AI summary
A system and method for automating construction that includes collecting a multi-dimensional point cloud measurement of at least one construction structure that includes at least one surface; generating a construction plan from the multi-dimensional point cloud measurement, wherein the construction plan defines an assembly arrangement of a set of parts; from the construction plan, automatically generating a cut list for a subset of parts; communicating the cut list to a cutting device; and at the cutting device, cutting a set of materials according to the cut list.