Recent patents, such as U.S. Pat. Nos. 5,285,708 and 5,375,495, disclose optical alignment systems for power saws that have circular blades. Such optical alignment systems typically utilize a single laser generator that projects a line on a workpiece to indicate the location at which one of the sides of the blade will enter the workpiece and purport to facilitate cutting the workpiece.
Because power saw blades have varying thickness, there is a need for an optical system that may be used to indicate accurately the width of the material to be removed by the blade in a cost-efficient and convenient manner.
One embodiment of the invention provides an optical system mounted on a cutter that has a base and a housing supporting a blade. The optical system may projects first and second indicator lines on the base. The optical system may also include a mechanism selectively operable to adjust the first and second lines to indicate the width of the blade.
In the accompanying Figures, there are shown present embodiments of the invention wherein like reference numerals are employed to designate like parts and wherein:
a is a left side perspective view of an embodiment of an optical system employed in the cutter embodiment of
b is a top view of the optical system of
a is a cross-sectional view of an embodiment of a laser generator holder for the optical system of
b is an exploded view of
a-12d are plan views of a portion of the cutter base for the cutter of
Referring now to the drawings for the purpose of illustrating the invention and not for the purpose of limiting the same, it is to be understood that standard components or features that are within the purview of an artisan of ordinary skill and do not contribute to the understanding of the various embodiments of the invention are omitted from the drawings to enhance clarity. Furthermore, it will be appreciated that the characterizations of various components and orientations described herein as being “vertical” or “horizontal”, “right” or “left”, “side”, “upper” or “lower”, are relative characterizations only based upon the particular position or orientation of a given component for a particular application.
An embodiment of an optical alignment system 40 for the cutter 20 may be mounted on the upper guard 28. See
In one embodiment, the right and left walls 21, 23 of the upper guard 28 may include various openings that have surface portions that slidably support the holders 46, 48. The openings may also facilitate the installation of the holders 46, 48 on the upper guard 28. For example, the left wall 23 may include circular left side openings 120 having bearing surfaces 121 that are in contact with the left ends 122 of the cylindrical portions 41, 47 of the holders 46, 48. See
After the holders 46, 48 are inserted through the right side openings 124 into the upper guard 28 between the right and left walls 21, 23, they may be rotated into operative positions in the direction of the arrows “F” and “G”. The operative position may be determined such that, for example, the laser generators 42, 44 project light that passes through openings 98 of the lower guard 30 of a cutter 20 when the blade 26 is in its uppermost position away from the base 22. See
More particularly and with reference to
The laser generators 42, 44 may comprise commercial laser generators of the type that produce a fan of light, i.e. line generators, such as those laser line generators manufactured by Sean & Stephen Corporation of Taiwan and China under Model 1894. In one embodiment, each laser generator 42, 44 may be customized to include a handle arrangement 84, such as, for example, a nut or socket attached to a barrel 85 that encloses the laser unit 89 of the laser generator 42, 44. See
To prevent accidental rotation of the laser generators 42, 44 within the holders 46, 48 respectively, frictional inserts 86 may be supported in the holders 46, 48 to frictionally contact the lateral surfaces of the laser generators 42, 44. The frictional inserts 86 may be made of foam, rubber or other material that may increase the coefficient of friction at the lateral surfaces of the laser generators 42, 44. See
Additionally, the optical lens of the laser unit 85 may be customized so that it produces a fan angle “β” of approximately 30° centrally disposed about axis B-B, instead of the 60° fan angle β of typical commercial laser line generators. See
In one embodiment, the optical alignment system 40 may also be protected by a removable cover 45 that is attached to upper blade guard 28 by fasteners 13, such as, for example, screws, or by other fastening arrangements or snap-on fittings, etc. See
In one embodiment, when the laser generators 42, 44 are powered, they project two indicator lines 62, 64 on the base 22 or on a workpiece 25 that is supported on the base 22. See
a-12d illustrate a portion of the base 22 and also show the indicator lines 62, 64. Although the workpiece 25 and the blade 26 are not shown in these Figures, the kerf 100 is depicted in dashed lines to illustrate the various adjustments of the indicator lines relative to the kerf 100.
A lateral macro-adjustment may be provided by moving the holders 46, 48 laterally to accommodate the width of the blade 26 or the kerf 100 of the cut between the left and right indicator lines 62, 64, which are then laterally displaced with respect to kerf 100, as shown in
A lateral micro-adjustment of the indicator lines 62, 64 may be provided by supporting the laser generators 42, 44 on beams or sleeves 88 cantilevered from the holders 46, 48. See
A micro-adjustment actuator 94, in the form of a screw or similar fastener, may be received in an opening 140 of the holder 46, 48. The micro adjustment actuator 94 may operate to exert force on the second end tab 92 of the sleeve 88 to cause the sleeve 88 to deflect and move in the directions indicated by arrows C relative to the respective axis A1-A1, A2-A2 of the holder 46, 48. The deflection of the sleeve 88 causes the respective laser generator 42, 44 to move in like manner, such that the respective indicator line 62, 64 is displaced parallel to itself. See
The micro-adjustment actuator 94 may be operated by rotating, for example, a hex nut 96. The sleeve 88 and the micro-adjustment actuator 94 may also be calibrated such that one full turn of the nut 96 corresponds to a predetermined amount of displacement. For example, in one embodiment, one full turn of the nut 96 corresponds to a lateral displacement of {fraction (1/32)}″. Those of ordinary skill in the art will appreciate that one or more micro-adjustment operations may be required to bring the indicator lines 62, 64 onto the planes corresponding with the sides 50, 52 of the blade 26 depending on the proximity provided by a preceding macro-adjustment.
A biasing stopper 95 may be provided against the second end tab 92 of the sleeve 88 to bias the second end tab 92 toward a predetermined position, for example in contact with an inner surface 99 of the respective holder 46, 48. The stopper 95 may be made from any resilient material, such as, for example, rubber. It will be appreciated that other biasing arrangements or devices may be used, including, for example, ordinary coil springs. The biasing stopper 95 may be secured by a fastener 136, such as a set screw, or other supporting arrangement. The sleeve 88 may include a cavity 138 for receiving the frictional insert 86.
The laser light of the laser generators 42, 44 may pass through a bottom surface 31 of the lower guard 30, if such lower guard 30 is provided. The bottom surface 31 of the lower guard 30 may be constructed from materials having acceptable optical transmission properties, such as, for example, glass or polymer having a transparency index that minimizes distortion and/or dispersion of the laser light. Alternatively, the bottom surface 31 of the lower guard 30 may be provided with one or more openings 98, for example, a series of slits or louvers. See
The openings 98, may be oriented substantially perpendicularly to a periphery 33 of the lower guard 30, as shown in
In one embodiment, the shape of the openings 98 may be determined by drawing radial lines 142 emanating from a point “X” of the upper blade guard 28. Point X may be located, for example, midway between the first and second laser generators 42, 44. The angle “y” between two adjacent radial lines 142 that define the lateral sides of the openings 98 may be adjusted to achieve a desire length and spacing of the dashes of the indicator lines 62, 64. See
By operating the adjustment mechanisms described above, each of the indicator lines 62, 64 may be adjusted such that it is parallel to the first or second sides 50, 52 of the blade 26. Moreover, each indicator line 62, 64 may be manipulated to be tangent to one of the sides 50, 52 of the blade 26, or to fall within the width of the blade 26 (or the kerf 100), and therefore, within the width of the material to be removed by the blade 26. In the latter case, i.e., when the indicator lines 62, 64 are adjusted to fall within the kerf 100, certain portions of the indicator line 62, 64 may be obstructed by the blade 26 such that the indicator line 62, 64 may appear to be interrupted, i.e. having blank or shadowed portions.
In operation, the optical system 40 may be powered to project two indicator lines 62, 64 near the sides 102, 104 of the kerf 100, as shown in
As explained in connection with
Further, for a cutter such as a miter saw, as the upper guard 28 is lowered to bring the blade 26 in cutting position, the lower guard 30 rotates to expose the blade 26. Accordingly, as the blade 26 is lowered, the indicator lines 62, 64 may change from dashed to solid as they no longer pass through the lower guard 30. Additionally, the indicator lines 62, 64 may also project on the side surface of the workpiece 25, indicating, for example, a straight or slanted cut and guiding vertical or slanted orientations of the blade 26. See
Providing two laser generators 42, 44 with multiple and selectively operable adjustment mechanisms greatly facilitates the operation of cutting a workpiece 25 along a predetermined line and removing a predetermined amount of material. Such cutting operations may be performed accurately and conveniently using a variety of blades of different widths and teeth arrangements.
It will be understood that although the optical alignment system was described in reference to laser generators, other light sources capable of projecting distinctive indicator lines on the workpiece may be utilized in the spirit of the invention in connection parallelism, macro- and micro-adjustment mechanisms.
Whereas particular embodiments of the invention have been described herein for the purpose of illustrating the invention and not for the purpose of limiting the same, it will be appreciated by those of ordinary skill in the art that numerous variations of the details, materials and arrangement of parts may be made within the principle and scope of the invention without departing from the spirit invention. The preceding description, therefore, is not meant to limit the scope of the invention. Rather the scope of the invention is to be determined only by the appended claims and their equivalents.
Number | Date | Country | |
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Parent | 10174731 | Jun 2002 | US |
Child | 11033502 | Jan 2005 | US |