Patent Application
20120037276
1. Field of the Invention
This invention relates generally to a portable sawmill using a chainsaw for sawing logs into dimensional lumber. More specifically it relates to a sawmill using a chainsaw in a combination mounting and saw attachment framework that allows of a selectively chosen cutting of a log with the blade of the chainsaw being held in either a vertical or a horizontal planar attitude and the blade oriented for a longitudinal cutting along a length of the log; the mounting and attachment framework also allows of a modification for a use in sawmills other than the sawmill device of the invention by an addition of an accessory attachment section to a transverse guide rail assembly of the gantry of the invention.
2. Description of the Prior Art
A number of devices have been patented to serve these needs, including sawmills that use band saws, circular blade saws and chain saws as the cutting agent. These portable sawmills have come into greater use for the cutting of logs into lumber useable for building material as a means of eliminating the necessity of transporting harvested logs to a conventional saw mill for processing and as a means for small land holders and independent loggers to manufacture dimensional lumber from trees they have harvested.
All of the immediately following saw mills allow making only a horizontally or a vertically aligned cut—although some do have tilt mechanisms allowing of beveled cuts, none of them allow precisely cutting at opposed angles in both the vertical and the horizontal plane. The current invention presents a great improvement over these mills because, 1. with a mono-planar cutting mill, formation of a cant preparatory to creating “dimensional” lumber requires that the log be turned, leveled and stabilized three times. Once a cant is formed, further binding and turning operations are required for creating “dimensional” lumber.
These operations lead to increased risk of injury, wasted labor time, decreased accuracy of cutting to true dimensional size and potentially decreased orthogonality of cut pieces due to the difficulty of re-situating the log at exact 90.degree angles during successive turning operations.
Another deficiency of many of these mono-planar cutting mills is that and no partial depth cuts can be made.
With a mill providing a positioning of a saw blade in a bi-planar, vertical and horizontal planar attitude, and with the saw blade in an orientation for a longitudinal cutting of a log, both Cants and completed dimensional lumber cuts can be made with a parent log left in an original, and unturned position within the mill.
None of the sawmills provides a means for creation of a fine tuning of the vertical or horizontal planar attitude of the saw blade such as is provided in the current invention. The advantage of this capability as it is provided in the current invention is that such fine tuning allows of a creation of a greater orthogonality of the cut pieces of wood.
Some of the mills provide that the log to be cut rests on the base framework of the mill, others have the log resting within but not upon the mill framework. The current invention is arranged with an extensible modular base frame in which the log rests within the base framework but does not rest upon any portion of the base framework of the sawmill; with no log weight on the frame members there are reduced stresses on the framework, allowing of a use of a lighter and therefore more portable framework; and, there is a reduced chance of distortion of the framework; also, the log can absorb saw vibrations without transferring them to the mill works if the log is not on the base frame.
Another important feature found in the current invention is a dual acting remote safety switch and throttle trigger control means which utilizes a control cable controlled from a single control handle to provide a disengagement and a reactivation of a built in safety switch and an activation of a throttle control trigger of the chain saw; a full speed control from a slow idle to a full speed throttle setting is allowed; thus providing an advantage by an allowance of a use of a higher speed of rotation for cuts in a harder wood, or a slower blade rotation in a softer wood source.
A mechanically assisted gantry travel component of the present invention utilizes a two speed transmission in concert with a system of pulleys, gears and ropes to provide allowance of a slower speed more suitable for a cutting run of a blade through a log, or, a double speed for use during a non-cutting, return movement to a base end of the log; this results in a considerable saving of time in the course of a work run.
The present invention also uniquely provides an automatic control of the vertical level of the saw carriage assembly such that a series of successive cuts made in a horizontal plane of cutting can be made without a need for remeasurement or checking log caliper indicators; the major advantages include 1. improved accuracy of the thickness of sections of dimensional lumber since remeasurement errors are eliminated; 2. saving of time and labor.
An integral lateral position locking assembly of a body section of the invention allows a creation of a fixation of the saw at any given point in a right to left lateral direction across a full width of the gantry with the blade in either the vertical or horizontal cutting plane. The lock assembly is engaged and disengaged by simply tilting a handle of a toggle lock assembly. Another advantage is that while making a horizontal cut, the lock is left in a locked position during only about an inch of initial cutting following which it is unlocked, the pull of the saw blade then self-adjusts the saw against the side of the log in accord with any alteration of the log surface; this assures that a motor end of the sawblade bar is always involved in the cut, improving the quality of the cut surface. A further advantage is that with the saw against the side of the log throughout the cut, a thrust of the saw created by a rotation of the saw blade is absorbed by the log rather than being transferred to the gantry frame; this transfers less stress to the gantry and results in a diminution of vibration that in turn leads to a smoother and more accurate cut in a piece of dimensional lumber being milled.
In the following Summary Comments any distinguishing feature that has been covered by the preceding comments will not be dealt with again in the discussion of the following patents; the comments will only address major distinctions between any claimed matter in the named prior art and an aspect of the current invention in which the claimed matter of the current invention represents an improvement over the prior art.
U.S. Pat. Application No. 070234689 (DALE): Horizontal cut chain saw: SUMMARY COMMENTS: Manual Push for Travel; claims a remote throttle control—BUT no remote control of Safety switch is taught or claimed; no automatic vertical height return for successive cuts in horizontal plane; log to be cut rests on base frame of device.
U.S. Pat. No. 4,640,170 [BAKKEN] a portable horizontal cut Chain saw with both ends of the blade bar clamped within the gantry frame; Gantry has sliding foot plates for movement along a leveled ground surface—this mitigates against accuracy of cutting lumber to true dimensional sizes since absolute leveling of the land is not likely; vertical height adjustment is taught; a pair of interconnected screw drive rods having their lower ends affixed atop the two bar clamp assemblies is the height adjusting means, other than the inherent resistance of those threaded elements no provision is taught/claimed for holding the saw at a given vertical height; No automatic vertical height return for successive cuts is taught; No remote throttle and safety control switch element is taught; No mechanically assisted travel control mechanism is taught.
U.S. Pat. No. 3,926,086 [CRANE] horizontally cutting chainsaw. SUMMARY COMMENTS: A remote trigger disengagement control is taught, when the saw reaches the end of a cutting run, a detent that was manually pre-set to over-ride the chain saw safety device trigger is disengaged, the motor returns to idle speed and the safety switch is in an engaged position. No provision is taught for a range of throttle speed control by a remote throttle device; no provision is taught for remote reactivation of the safety switch and throttle trigger. A mechanically assisted travel mechanism taught does not have 2-speed gearing as does that of the incident invention, but, the rotating drive handle is at the end of the sawmill frame as opposed to the current invention where the operating handle is associated with the saw carriage section of the gantry, thereby providing immediate viewing of the log section being cut and allowing for speed control based on immediate observation of harder sections, burls, etc. The log rests on the base frame of the mill.
U.S. Pat. No. 5,243,892 [JINDRA] a vertical cut chain saw; SUMMARY COMMENTS: No provision is taught for setting and maintaining a vertical depth of cut other than a full depth cut. An extensible, modular base is taught, however, the log is supported on the end sections of the base of the sawmill. No remote throttle/safety switch is taught, nor is a mechanically assisted travel mechanism taught; the chainsaw is supported by a transversely slideable holder on a top cross piece of the saw carriage frame such that the chain saw can be positioned at various points across the width of the sawmill by a chain drive mechanism.
U.S. Pat. No. 3,889,560 [MACFADYEN] teaches a horizontal chain saw mill. SUMMARY COMMENTS: log is supported on a cross frame of the mill; the chain saw attachment means is undisclosed; means control the vertical height of the cradle and control its location across the diameter of the wood piece to allow cuts of differing thickness. The vertical control means taught involves several manually performed operations that must be performed prior to being able to use a moveable endless chain and geared rod arrangement as a means to alter and re-stabilize the level of the blade's cutting plane;
U.S. Pat. No. 5,784,941 [SANBORN] chain saw clamped vertically tip upwards within a saw carriage. SUMMARY COMMENTS: As opposed to the current invention, the setworks for adjusting the saw position for lateral position of cut is separate from the attachment means holding the saw to the carriage. A throttle activator is taught that keeps the saw motor at full cutting speed during a cutting run, an end of run device automatically returns the saw to idle speed during the return pass; no direct throttle control of the cutting speed by the operator is taught. No remote operation of the chain saw safety switch is taught. Log rests on the mill frame based member. A single speed travel mechanism is described.
U.S. Pat. No. 4,307,641 [SHAPLEIGH] horizontal cut chainsaw. SUMMARY COMMENTS: The log rests within and is supported by the mill frame. Means for altering the vertical elevation of the saw blade comprise a pair of rotatable vertically oriented adjusting screws, each surmounted by a control handle. Full through cuts are the only cuts allowed; manual sliding means of the gantry are taught, but no mechanically augmented dual speed control is taught.
U.S. Pat. No. 4,300,428 [WOODLAND] vertical cut chain saw. SUMMARY COMMENTS: log is held on the mill frame structure; the saw carriage allows lateral adjustment of the saw position but is restricted to the use of predetermined lock points using a series of laterally spaced apertures to provide the width adjustment stopping points; the current invention, advantageously allows lateral locking at any point along the full lateral width of the gantry. A pair of scissor jacks serving as the log support provide vertical control of the cut by elevation of the log itself, the saw carriage remaining at a given height; vertical or tilted angle cuts are possible, but cutting in a 90 degree opposed vertical or horizontal plane is not taught.
U.S. Pat. No. 7,444,912 [FENTON] a vertical cut circular blade mill using two cutting blades set to revolve in opposite directions. The blades are mounted on a carriage that allows inversion of the saws such that at the end of the first cut, the saw is flipped over and the opposite rotating blade can make a cut on the return movement of the saw carriage along the length of the log. SUMMARY COMMENTS: As with other blade saw mills, blade radius limits the size of log that can be cut with a device such as Fenton's while still maintaining portability of the unit; a 15″ log requiring a blade of at least 3 foot diameter, etc. Blades of this type are expensive and when they require sharpening they must be sent to special saw sharpening facilities that can handle the larger size blades. Replacement blades are not readily available at everyday retail sources. Log rests on the mill frame. The blade carriage unit remains at a given height and vertical height control is via altering the log support height.
U.S. Pat. No. 4,711,032 [RICKMERS] horizontal cutting band saw. SUMMARY COMMENTS Means of altering the vertical level of the saw blade comprise a control handle affixed to a threaded screw attached below to the mill base such that turning the handle moves the upper, saw support element to or from the base elements of the mill; making an initial cut, requires placement and leveling of a pair of externally applied leveling rails; following the first cut the leveling rails are removed and the saw carriage rides on top of the log surface itself.
U.S. Pat. No. 5,213,020 [ELGAN] band saw that cuts bi-directionally in both the horizontal and vertical cutting planes. SUMMARY COMMENTS: The log sits on lower mainframe of mill; As opposed to the hinge action of the chain saw positioning component of the current invention wherein the hinge rotation that provides for a 90.degree planar blade rotation is along the longitudinal axis of the Mill frame/Gantry, the hinge action in Elgan occurs along the transverse axis of the mill frame/gantry—so Elgan's cuts are horizontal along the length of the log but in the vertical plane the cut is transverse across a diameter of the log; the current invention allows full length horizontal and vertical cutting, allowing making multiple sections of dimensional lumber with far fewer cuts than Elgan. The vertical elevation of the saw carriage is done with a hydraulically driven pair of unending chains passing around pulleys at top and bottom of mill gantry. A hydraulic controlled chain drive is used for gantry travel along mill base.
U.S. Pat. No. 5,819,626 [LUCAS] a blade-saw mill making both horizontal and vertical cuts; SUMMARY COMMENTS: All limitations of blade saws in general apply to this device. The vertical level control means of the saw carriage is by four slidably mounted collars, mounted on uprights of the two vertical end frames of the mill framework; turning a control handle with a rope wound on a top axle of the end frame at both ends of the mill is required to move a pair of longitudinal guide rails up or down for vertical level control. No automatic sequential depth of horizontal cut is taught; no integral lateral positioning locking is taught. As with Elgan, Lucas provision for planar blade rotation occurs along the transverse axis of the mill frame/gantry creating the same problems listed prior for Elgan.
U.S. Pat. No. 4,584,918 [STUBBE] blade-saw making both horizontal and vertical cuts. SUMMARY COMMENTS: All general limitations of blade saws apply. The log is supported on the mill base frame. As an example of the limitation of log sizes cuttable by blade saws, Stubbe teaches an ability to cut logs up to a nominal dimension of six inches by six inches by using a sixteen inch blade; this requires an 85 pound 10 horsepower motor—using a 24 inch blade requires an 18 horsepower motor. Lifting and fitting such motors into place in rough terrain where they are likely to be used is one problem, another is, the effects of the heavy motor weights on the side cantilevered longitudinal rails of the mill. There is a rope and pulley vertical adjustment mechanism, however no automatic return to a selected depth of horizontal is taught. Both horizontal and vertical plane longitudinal cuts are possible; however, the saw automatically repositions such that traverse away from the operator is in the vertical plane and the return is in the horizontal plane—this means that only a partial depth cut resulting in one piece of dimensional lumber can be made with each full passage of the saw out and back—as opposed to the current invention where, following a series of horizontal cuts at a preferred dimension, each subsequent vertical pass creates multiple sections of dimensional lumber.
Band saw setups allowing of Bi-planar cutting would require interrupted cutting and removal of boards during the cutting operation in logs having a diameter greater than the width of the gap between the cutting aspect and the return aspect of the band saw blade; making multiple dimensional sections in a log of any greater diameter requires that cut wood must be removed during the sawing operation rather than following a full pass along the log; they also require at least two turnings, repositionings and levelings of the log after making an initial top cut in order to create a cant.
One suggested advantage of using a band saw is that band saws have a thinner kerf, and thus leave less waste due to blade width loss, however other sources cite that it is hard to keep a band saw blade tracking a straight line through a round log, and grain resistance can lead to boards having a wavy or undulating surface when they are cut by band saw blades. This leads to waste due to the inaccurate dimension of the finished lumber. Band saws are high maintenance and maintaining proper blade tension is critical.
Blade saw mills, even if capable of cutting both vertically and horizontally are limited to cutting logs within slightly less than their blade diameter; to cut larger logs, very large blades must be used, these larger blades require more substantial and stronger motors and frameworks, increasing the weight and difficulty of transport, set up and disassembly of such units as well as the cost of the mill.
Relative to a saw arrangement that allows cutting in only one planar arrangement, or to either a blade of band saw that allows bi-planar cutting, a chain saw arrangement that allows cutting in both the vertical and horizontal plane along the longitudinal length of a log allows for much more rapid production of dimensional lumber because a successive series of horizontal through cuts of a given thickness could be followed immediately by a series of vertical through cuts at a given desired width to create a full stack of boards at each vertical pass down the length of the log without the need to band and turn the mass of boards at any time.
Another advantage of the chain saw arrangement of the incident application is that it also allows for cutting a series of partial depth cuts at one or differing widths to be followed by a horizontal through cut at a desired thickness, thus allowing sequential creation of dimensional lumber of differing dimensions from the same log and with a minimal number of cutting passes as well as no turning of the cant or log.
The vertical level control mechanisms of all cited patents and applications fall into one of the following categories of mechanism. 1. Threaded rod and crank handle, 2. gears with threaded rod and/or pull chain, 3. threaded scissor jack log support, pulley, rope and crank handle, stationary saw platform with log platform that is vertically adjustable, hydraulic powered continuous chain rotating upper and lower pulleys with a chain affixed to a slidable frame element.
In the present invention, as will be described later the establishment of the vertical level of the cutting blade is achieved by the use of a unique stationary chain and climbing sprocket arrangement; the arrangement has a positive lock ability to hold the blade stably at any given level of vertical orientation within the sawmill apparatus. This vertical level control is functional with the saw blade being held in either a vertical or a horizontal orientation within the sawmill.
The present invention comprises a portable log cutting apparatus and system for a making of dimensional lumber from a log or other material suitable for cutting by a chainsaw; the chainsaw being held in a readily detachable but secure affixation to a body section of a chain saw attachment and positioning carriage framework assembly by a chainsaw bar attachment assembly component of the carriage framework assembly; the saw carriage framework assembly being in a situation within a gantry portion of a sawmill apparatus.
The carriage framework assembly is designed such that a hinged saw blade orientation component of a body section of said framework allows of a selectable positioning and maintenance of a planar orientation of a blade of the chain saw in either of a vertical or a horizontal planar cutting attitude, with a saw blade oriented for making a longitudinal cut along a log; thus allowing a user to make a selectively chosen horizontal or vertical cut or series of cuts in a longitudinal direction into and through the log or other suitable substrate material.
The body section of the carriage framework further providing for a moveable attachment of the carriage along a pair of transversely situated guide rails of a transverse guide rail assembly of said gantry; said transverse guide rail assembly allowing of a movement of or alternatively, a fixation of the chainsaw at a selected horizontal position within the full width of the gantry.
A vertical level control assembly allows a movement of or alternatively, a fixation of the chainsaw at a selected vertical level within a full height of the gantry of the sawmill.
Acting in combination, the saw carriage assembly the vertical level control assembly and the transverse guide rail assembly uniquely create an allowance of an ability to make either a vertically oriented cut or series of cuts, or a horizontally oriented cut or series of cuts, of a through cut or partial depth cut nature in a selectably alternating manner in a longitudinal direction along a full length of the log or other substrate material with the log or other substrate being left in an unturned and original position within the sawmill apparatus, and, further providing an ability for a making of a cant from the log with the log being left in its unturned and original position within the sawmill apparatus;
A base section of the sawmill apparatus is of a modular nature and is extensible to a full length of the log or other chainsaw cuttable material.
An automatically regulated control of a thickness of a horizontally oriented cut is afforded by a horizontal cut thickness gauge assembly and provides for a repeatable dimensional thickness of the cut pieces, and a saving of labor time by eliminating any need for remeasurement/calibration between cutting passes.
A dual acting remote throttle control allows a full speed range remote control of the chainsaw throttle while also affording a remote safety lock control function of the chainsaw.
A mechanically assisted dual speed bi-directional gantry travel mechanism is used.
The carriage assembly and a typical sawmill apparatus necessary for its use can be carried, set up and operated by one person and is transportable in a van, or a pickup vehicle.
A more complete description may be found in the appended claims.
It is an object of this invention to provide a sawmill device that allows of a bi-planar cutting in a longitudinal plane of cutting of a log or other material suitable for cutting by a chainsaw, into a series of specifically sized dimensional sectional pieces by using a chainsaw that is mounted on a carriage that allows of a cutting in both a horizontal and a vertical plane of orientation.
Another object is to provide a sawmill device in which the distorting effects of saw blade vibration are minimized, thereby helping to provide maximal accuracy of cutting lumber to dimensional size, and, in which a saw blade attachment device allows the log being cut to absorb the saw thrust, thus providing a reduction of strain on the sawmill framework.
Still another object is to provide a saw carriage and blade orientation device allowing biplanar cutting, which said device is adaptable for use on other sawmill frameworks.
It is a further object to provide a device framework that easily allows a manual changing of a planar attitude of a cutting head without the use of tools while maintaining orthogonality of a support framework of the device, and which said device provides a fine-tuning mechanism allowing of optimizing the blade cutting angle within either of a horizontal or a vertical cutting attitude.
Another object is to provide a means to remotely and fully operate both a saw throttle and a safety switch feature associated with a chain saw's throttle controls.
A further object is to provide a framework and sawmill apparatus that is easily transported in a pick up or such vehicle, and that can be set up and operated by one person.
Another object is to provide a device that minimizes the time and effort of squaring a log to form a cant prior to a cutting of a lumber or other such substrate to dimension, thus saving time and energy and providing maximal accuracy of cuts made in the opposed vertical and horizontal planes.
Another object is to provide a mounting system for the chain saw that allows a quick disconnect of the saw so that the saw can be used temporarily for purposes of a trimming or bucking of a parent wood source and then returned to the mill for use.
Another object is to provide a device allowing the use of both a relatively small or a large chain saw.
a presents an oblique view of the carriage viewed from a right superior aspect of the device in accordance with the invention; the carriage is arranged with the saw blade orientation section prepared to situate the saw blade in a horizontal cutting position.
b present a horizontal rear end view with a portion of a chain saw seen situated in a horizontal cutting attitude.
a: an exploded view of the components comprising the hinged attachment plate and the saw attachment components of the device as seen from a right rear superior oblique aspect.
b Top view: a bottom view looking up through the chainsaw bar attachment component.
a: The sawmill apparatus, including the carriage device of the current invention as seen in an end view from the rear.
b: The sawmill apparatus, including a base section, a log represented in a form of a cant; a gantry, a carriage device of the current invention as seen from a rear right superior viewing point. NOTE: the front end section is truncated but is an exact mirror image of the portion shown.
c A left rear superior oblique view of the basic gantry frame and left rear gantry subframe components only; the basic gantry frame is shown exclusive of the gantry top forward travel section components.
d: a rear view of the Gantry Control Handle subframe separated from the gantry frame.
e: a view of the Sawmill Apparatus Base Frame Section looking down from an oblique right superior vantage point.
f: A view of the base frame with a rear and a front non-log bearing section fully assembled; a right side gantry track section of a log containing section of the base frame is shown assembled but disassociated from the base frame as it would be seen prior to loading a log within a confine of the base section.
g: An exploded view of the same parts seen in
h: A detail of the interconnection of a pair of Base Frame longitudinal Guide Rails, and of two sets of the Support and Leveling Feet of the base framework
a: A right rear superior oblique view of the carriage assembly of the invention with the chainsaw attached and situated in a horizontal cutting position.
b: A right horizontal side view of the carriage assembly of the invention with the chainsaw attached and situated in a perpendicular cutting position.
a: A left rear superior oblique view of the wheel fenders and basic vertical frame members of the gantry, and of the frame members of the transverse guide rail assembly members.
b: A left rear superior oblique view depicting a portion of a set of four basic vertical gantry frame members and their relationship to the components of a stationary vertical climbing chain mechanism that raises and lowers a transverse guide rail assembly within the gantry framework.
c: A close up view of the stationary Vertical Climbing Chain gear boxes, handle and associated members of the transverse guide rail assembly.
d: Presents an oblique view from a left rear superior aspect looking down towards the gantry with the removable components of the transverse guide rail assembly that bear the saw carriage component withdrawn from the gantry, as though preparatory to a modification of the assembly for a use in a sawmill device other than that of the incident invention.
e: Presents an oblique view from a rear right superior vantage point looking down at a modified guide rail assembly, bearing the saw carriage component of this invention and situated with a set of accessory wheels of the modified guide rail assembly situated on the longitudinal rails that extend above and along a length of a log to be cut within a sawmill device other than that of this invention; the view is rotated approximately 90.degree clockwise to the view depicted in
f: presents an exploded view showing details of a portion of the carriage assembly and a set of modification connection components, including a set of wheels that allow a use of the transverse guide rail assembly in other sawmill devices.
a: A left side rear superior oblique view depicting a left wheel fender and the left end vertical gantry frame members and their relationship to the components of the left end stationary vertical climbing chain mechanism components.
b: presents a close up of the left rear vertical climbing chain sprocket, a section of the left climbing chain axle and the upper and lower climbing chain sprocket idler wheels.
c: Presents an oblique view of the left end cross chain assembly as seen from a rear right superior viewing aspect.
a: As seen from a front right superior aspect, presents an oblique view of the carriage with a vertical cutting guide assembly in place and with a foot section of the guide lowered to a level for locking the carriage at a level providing a cut of a predetermined thickness before a subsequent cut is made.
b: As seen from a front right superior aspect, presents an oblique view of the carriage assembly with the vertical cutting guide assembly in place and with a foot section of the guide elevated and locked at a level above the log as during a cutting operation.
a: presents a left side view of the saw handle and the saw handle borne components of a dual acting remote chainsaw safety switch and throttle trigger control assembly.
b: presents a view of the left gantry subframe borne components of the dual acting remote chainsaw safety switch and throttle trigger control assembly.
a: presents a schematic diagram of a Dual Speed Gear box assembly and of a connection of the Gear box assembly to a connecting gear of a Gantry Top Travel Component of a mechanically assisted travel control mechanism of the gantry as taught in this invention.
b: presents a diagrammatic top view of a set of Gantry Travel Control Axles and an associated set of gears and connecting chains.
The present invention, a combination chainsaw attachment and positioning device, 100
said chainsaw carriage assembly also allowing of a controlled and accurately maintained, variable but fixed depth of cut and variable but fixed width of cut of said chain saw in a perpendicularly oriented plane, or a horizontally oriented plane;
said ability of being able to make cuts in an alternating manner of cutting between an opposed pair of directions, perpendicular or horizontal, results in an ability to create multiple sections of dimensional lumber with a single pass of said chain saw following an appropriate number of preparatory cuts in an opposed plane of orientation, thereby allowing creation of said multiple sections of dimensional lumber with a minimal number of sawing operations.
Said chainsaw of said sawmill apparatus comprises in part a saw motor 401
said sawmill apparatus further comprises in part a gantry 510
each of which said vertical main frame supports is solidly affixed to one of a set of four vertical level adjustment assembly OC tubes (14a,14b,14c,14d, best seen in
said main frame vertical supports being held in an attachment with each other in such a manner as to form a rectangular top frame of said gantry main frame by a pair of transverse horizontal top main frame members (513,514
said longitudinal horizontal top main frame members comprising a left longitudinal horizontal top main frame member 511,
said transverse horizontal main frame members comprising a top rear transverse horizontal main frame member 513
said top rear transverse horizontal main frame member is attached at a topmost level and in a reinforced manner to said left end main frame member 510a; said reinforcement of said attachment is afforded by a roughly triangular rear left side transverse reinforcement plate 516a
a left end of said top front transverse horizontal main frame member 514 is attached at a topmost level and in a reinforced manner to said front left end main frame member 510b; said reinforcement of said attachment being afforded by a roughly triangular front left side transverse reinforcement plate 516b
a right end of said top front transverse horizontal main frame member 514 being attached at a topmost level and in a reinforced manner to said front right end main frame member 510d; said reinforcement of said attachment being afforded by a roughly triangular rear right side transverse reinforcement plate 516d
said left longitudinal horizontal top main frame member 511
said top mid gantry longitudinal horizontal frame member 531
said right longitudinal horizontal top main frame member 512
said rear left side vertical main frame support member 510a and said front left side vertical main frame support member 510b each terminating below in a welded attachment to a left side fender member 517
said rear right side vertical main frame support member 510c and said front left side vertical main frame support member 510d each terminating below in a welded attachment to a right side fender member 518
the whole being so arranged and affixed in and between each other as to form a stable superstructure situated upon and capable of being moved in a forward or a backward manner along a pair of longitudinal gantry tracks 505a,b,c,d,e,f
A pair of upper gantry travel drive axles 520,524
Said left end pillow blocks 521 and 525 being bolted to a top surface of said top left side horizontal main frame member 511 and said right end pillow blocks 523 and 527 being bolted to a top surface of said top right side horizontal main frame member 512; said mid axle pillow blocks 522 and 526 being bolted to a top surface of top mid frame horizontal main frame member 531;
a right end of said upper front gantry travel axle 520 terminates in a right front upper travel axle sprocket 530
Said rear left side vertical main frame support 510a
Said left subframe assembly 541
a gantry travel control handle assembly 89
said control handle axle 89b bears a set of three control handle axle gears (90,91,92
said low speed gear 91
a transmission axle 94
a closed loop external transmission gear chain 97
both of said transmission gears 95,96
when spoken of collectively hereinafter said set of control handle and transmission handle gears and chain interconnections being referred to as a gantry travel transmission 99
all three travel handle axle gears 90,91,92 are situated in a free rotational state on said handle axle 89b; said axle can be moved along a transverse axis within said bracket such that said gear lock pin 93
a centrally directed movement of said axle 89b
a lower end loop of a vertical continuous closed loop travel drive chain 101
said upper travel cross chain 102 serving to impart a rotational movement from said upper rear travel control axle 520 to said upper front travel control axle 524 such that both of said axles 520,524 move in a unison and a like directional rotational manner in either of a forward or a backward rotation, said rotational movement being in an accord with a rotational movement of a forward or a backward turning of said travel control handle 89a
a set of synthetic cables (103,106,109,112
a forward end of a front left gantry travel rope 103
a forward end of a front right gantry travel rope 106
a rearmost end of a rear left gantry travel rope 109
a rearmost end of a rear right gantry travel rope 112
following a selection of a gear pairing for a delivering of either of a lower speed or a higher speed of travel from said gears 90,91,92,95,96
a forward rotation of said gantry travel control handle 89a
with said gantry in a situation at a rear most end of said gantry longitudinal guide rails said front right gantry travel rope 106
a forward gantry control handle rotation serving thus to create said forward movement of said gantry by an application of a pulling action on said pair of front gantry travel ropes 103,106
a rearward gantry control handle rotation serving thus to create said rearward movement of said gantry by an application of a pulling action on said pair of rear gantry travel ropes 109, 112106
said gantry further partially comprises a transverse guide rail assembly 14
said gantry further comprising a stationary chain vertical level control assembly 14
said stationary chain vertical level control assembly thus allowing of a positioning and a locking into position of said saw for making said cuts or series of cuts in said log or other wood based substrate at an exact horizontal depth or an exact vertical width within said log or other chainsaw cuttable substrate;
said vertical level control assembly comprising in part a set of four vertically oriented stationary climbing chains 69a,b,c,d
NOTE: other than being positioned at different points in said gantry, all said chains are exactly alike, so a representative drawing 69a(b,c,d)
Said vertical level control assembly further comprising a control handle 47
an activation of a toggle lock handle 52a
said pair of power augmentation gears being connected by a continuous loop power augmentation gear drive chain 53
continuing forward from said augmentation gear 50, said left side climbing chain sprocket axle 51 next enters an attachment to and passes through a left rear stationary chain climbing sprocket 54a
NOTE: there are four such stationary chain climbing sprockets (54a,b,c,d
said sprockets are all in an affixation to one of a pair of climbing chain axles 51 or 552
Said left cross chain sprocket 57
Said right side cross chain sprocket 58 being affixed near a forward end of said right side stationary climbing chain sprocket axle 552
Continuing in a rearward direction from said cross chain sprocket 58, said axle 552 makes a passage through said climbing chain right front 54d, then passes through said right front guide bolt bracket 65d and said right rear guide bolt bracket 65c, passing next though and into an attachment with said right rear climbing chain sprocket 54c and then into a rear termination within a right side vertical level control assembly toggle lock mechanism 68
Following a release of said locks 52 or 68 of said vertical level control assembly, a rotation of said left side control handle 47a
NOTE: as with the stationary climbing chains themselves, other than being positioned at different points in said gantry, all said immediately associated climbing chain sprockets, climbing chain tension pulleys and attachment bolts and nuts are exactly alike, so a representative drawing
Each of which said stationary chains 69 (a,b,c,d)
Said transverse guide rail assembly 14
a lower pair of which said longitudinal guide rail support cross members 14h,14j
Lower guide rail cross members 14h,14j are held in a removable attachment to brackets 65a,b,c,d by a set of four pairs of O.C. tube attachment bolts 9
Said upper guide rail support cross members 14g and 14i
each of said set of brackets 65a,b,c,d
These other three sets of vertical travel guide nuts and bolts and a nature of their engagement within the relationship of the climbing chain assembly, the transverse guide rail assembly and the gantry are not described in detail because they are physically and functionally mirror images of the arrangement just described for bolt and nut sets 14k,14m, hence the description of said bolt and nut sets 14k and 14m are presented as a representative example of all such pairings.
Said transverse guide rails, guide rail support cross members and associated support brackets forming thus a rectilinear cross framework at said right and said left ends of said transverse carriage guide rails; said rectilinear cross framework serving as a support framework within which said stationary chain vertical level control climbing sprocket axles of said carriage vertical level control assembly are situated.
A head of each of bolts of said nut and bolt sets 14k, 14m
It is an object of this invention to provide a combined, modified chainsaw transverse guide rail and chainsaw carriage assembly that allows a use of this modified combination device within an existing sawmill apparatus other than that of the present invention, said existing sawmill having a pair of longitudinal carriage support rails. A conversion and modification adapter kit is necessary for a provision allowing of said use; said adaptor kit in essence comprising a wheel adaptor conversion kit.
A first step involved in allowing said use in other sawmills involves: a disconnection of a removable section of said transverse guide rail assembly 650
A conversion modification adaptation is then needed in order to create a pair of wheel assemblies 180
A right side wheel adaptor conversion plate 18g is seen in
In
A wheel axle bolt 18h
Once all four groups of attachment components shown as 18h-18p
Said chain saw carriage assembly 100a
A body assembly section 1
A set of circular transverse guide rail openings 13a,13c,13b are seen in
Each of these guide rail openings is in an internally facing attachment with an associated guide rail bushing plate 16a,16b,16c,16d
Said bushing plates providing a gliding surface for said Transverse guide rails 140, 141
Said body section further comprising in part a right side hinge plate spacer ridge 11
said body section further comprising a chain saw attachment assembly receiver cutout 15
said body section further comprising a pair of opposed depth gauge openings 17a, 17b
A hinged saw blade orientation assembly 2
a swivel lock bolt slot 31a
said hinged attachment plate 20
said hinge plate assembly also comprising a hinge-swivel lock component 74
the whole being arranged such that a release of said swivel lock locking handle allows a removal of said swivel lock bolt from an engagement within said swivel lock bolt slot located in a side element of said L shaped frame of said hinge plate assembly, allowing thus a selectable alternation of a planar attitude of said saw blade of said chain saw between a perpendicular or a horizontal alignment of said blade of said chain saw., and a creation of successive pieces of dimensional lumber while leaving a parent log in an unturned, original position within said sawmill.
a hinge alignment fine tuning assembly of said saw blade orientation component comprises in part a set of two pairs of hinge alignment fine tuning set screws 31c, 31d
said set screws being situated in either one of a pair of two pairs of threaded set screw holes 27a and 27b
A chainsaw attachment component 2
said bar clamp assembly component 36 of said chain saw attachment component being held at an adjustable distance beneath said longer side plate of said hinge frame assembly by a welded affixation at a lower, terminal end 39
said bar clamping assembly further comprising in part a pair of inverted U shaped bar clamp body sections (40a,40b
a pair of chainsaw bar clamping plates 42a,b; an upper bar clamping plate 42a
said bases of said foot plates comprise a skid assembly; which said skid assembly would be situated in a manner with a bottom aspect of said foot plates resting against a side surface of the log to be cut when said chainsaw blade is in an orientation for making a through cut in said horizontal cutting plane;
NOTE: optionally, a secondary bar nose end clamping assembly of a same design as said bar nose end vertical cut stabilization component (36
Said secondary bar clamping assembly is not described in detail because said assembly comprises exactly a same set of components and arrangement of parts as did the chainsaw bar clamping assembly 36
The further out towards said nose end of said saw blade said blade is in cutting contact with said log, the greater a tendency of said blade to vibrate and wander from a straight cutting path; this can significantly decrease the accuracy of cutting, and lead to defects such as “scoring” caused by sawbar vibration; processing a rough board to a finished commercial size can result in up to thirty percent waste. Any reduction in defects or increase in accuracy is proportionately rewarded with economic and ecological benefits.
Accordingly, said bar nose end clamping assembly by a provision of a stabilizing support of a blade tip when cutting at a depth using only a bar nose end section of the blade; provides both a reduction of sawing waste and a prevention of a downward movement of said saw blade nose end otherwise associated with a downward pull of said saw blade that otherwise might draw the blade deeper than intended; the bar nose end clamping assembly thus preventing a fluctuation of depth of cut along a length of a piece of dimensional lumber created in said sawmill apparatus.
Said adjustable bar nose end clamping assembly can be placed in a firm affixation to said saw bar at an appropriate location along a length of said saw bar, then, as needed, released by a loosening of said clamping plate adjustment bolts 75
A locking of an integral lateral positioning locking assembly mechanism 4
said lateral positioning locking assembly 4
said locking assembly further comprising a lock handle arm terminating inferiorly in a cam shaped end 43b
with said body section mounted on said transverse guide rail assembly with guide rails 140,141
Following these preparations, a forward engagement of said lock arm 43b will provide a rotation of said cam end into a compression against said lock block 43e, said front end concavity of said lock block thus being brought into a compression against said rear guide rail 140
A retraction, via a back tilting of said handle 43b down and back to a horizontal position allowing of a disengagement of said lock block from said transverse guide rail creating a release of said lock mechanism and allowing of a free movement of said carriage section in either a right or a left direction along a full width of said transverse guide rails of said gantry of said sawmill apparatus,
said lateral positioning locking assembly thus allowing of a precise controlling of a left side to a right side positioning of said saw blade relative to a left to right width of said gantry while said chainsaw is in said tip down, perpendicular orientation, as well as allowing of a precise controlling of said left side to right side positioning of said saw bar nose end at a selected distance from said right side within said left to right width of said gantry when said chain saw is in said horizontal plane of blade orientation.
Said saw carriage further comprising said removable, horizontal cut thickness gauge assembly 73
said horizontal cut thickness gauge assembly also comprising a pair of toggle clamp locking assemblies 79,80
said lower lock assembly 80 comprises a lower lock handle 80a, and a lower lock handle lock bolt and nut set 81
said upper lock assembly 79 comprises an upper lock assembly lock handle 79a
in an operation of assembly of said horizontal cut thickness gauge within said body section 1
with said vertical level control of said gantry elevated to an adequate level above said log in said sawmill apparatus, following a removal of said upper toggle lock element from said L shape element, a passage of a top end of said vertical element is allowed in a passage from below to above through said lower thickness gauge opening 17b in said bottom plate 6
said vertical element continuing upward makes a passage through said upper thickness gauge opening 17a in said top plate 5
then, following a locking of said lower gauge lock 80
initially, said affixation is performed with a holding of said gauge in a fixed position relative to said right side plate 8
said upper toggle clamp assembly 79 is kept in a fully assembled state with said bolt and nut passing though and holding said corner brace and lock handle together whether said lock mechanism is in a location within or a location removed from said gauge;
in said process of assembly of said gauge for a use in said mill, said bolt 82 is guided to a passage downward through said O.C. tube slot of said vertical gauge element and then said upper lock element is brought into a locked state with said gauge being held in a position considerably above said body of said carriage component;
In an operation of use of a fully assembled depth gauge in position in said body section:
with said gauge assembly inserted in place, and said lower toggle locking said gauge assembly at an appropriate distance above said log, and said upper toggle assembly being situated well upwards along said vertical element of said gauge assembly; and, following a making of a cant or at least one horizontal top cut in a log;
said transverse guide rail assembly of said gantry is lowered to and locked at a position such that said saw blade is situated in a horizontal cutting position and at a desired depth of cut relative to a top surface of said log or other chainsaw cuttable substrate;
said lower toggle is released and said gauge assembly is brought to a resting position against said top surface of said cant or said log and locked in place, following which said upper toggle assembly is released and brought into an appropriate adjustment on said vertical member with a horizontal component of said corner brace of said upper lock assembly in a position resting atop said top plate of said saw positioning assembly body; said upper toggle lock assembly then being brought into a locked state at that level;
said lower toggle is next brought to a release state, elevated off said log and relocked, with said upper toggle now elevated above said body section, thus keeping said depth assembly up out of the way while a first cut is made;
following a return of said saw to a starting position behind and at a base end of said log, said lower toggle is again brought to a released state and said gauge assembly is lowered until said horizontal component of said corner brace of said upper lock is resting atop said body of said saw positioning assembly body, following which said lower toggle is relocked
said transverse guide rail assembly is then lowered to a position such that said foot of said depth gauge assembly is resting lightly on top of said log, at which point said transverse guide rail assembly is locked at that vertical height;
said lower toggle of said depth cut gauge assembly is again brought to a released state and said assembly is then raised out of the way followed by are locking of said lower toggle, thus leading to a holding of said depth gauge assembly up out of a contact with said log;
following which a second cut is made, this process is repeated until all cuts have been made.
A combination chainsaw safety switch and throttle trigger control assembly 84
said remote control handle portion 84
a flexible combination safety switch control cable and throttle trigger control cable 90
an activation movement of said handle 87 leads to a retraction of said control cable 90 following which a projection of said pivotable safety switch engagement and connector element 602 compresses an integral safety switch 606
a further activation movement of said control handle 87 leads to an advancement of said throttle trigger from an idling speed to an active cutting speed position; a still further activation of said handle 87 allows of a further increase of said motor speed; a reduction of said activation of said control handle leading to a reduction of said motor speed of said chain saw; allowing thus of a complete control of a full range control of a cutting speed of said saw motor and said saw blade, ranging from an idling speed to a full speed of said motor and sawblade;
a release of said control handles leads in turn to a return of said throttle to a power level of an idling state and a return to an activation of said safety control switch.
Said set of longitudinal base section gantry tracks 505a,b,c,d,e,f
Gantry track subsections 581a and 581c comprise a pair of identically formed end frame sections, said end frame subsections representing respectively, a pre and log retention area gantry base section 581a and a post log retention area gantry base section 581c. A centrally situated modular subsection 581b
End frame subsections 581a and 581c are of an identical size and configuration so a detailed description of subsection 581a will be presented as a representation of both.
Base section end section subframe 581a
a steel alignment tab 600
Said end frame subsections 581a and 581c also each further comprise in part a set of adjustable support and leveling foot assemblies 590
Each of said foot assembly bolts 592 and 593
A set of the adjustable support and leveling feet being in a location at each corner of said end frames 581a and 581b
Note modular subsection 581c, as seen in
Modular subsection 581b
Each of said longitudinal track sections of base section 581b being of a same length and structural configuration, a description of track section 505c will be presented as representative of both rail track sections 505c and 505d; there are no end cross pieces for base subsection 581b. Longitudinal track section 505c of subsection 581a comprises an angle iron section situated with a 90.degree angle of said angle iron situated in a vertical orientation; each end of track section 505c bearing a track connecting tab 601
When an end of said track section 505c
An exact same process involving identical parts as that described immediately prior serves to connect a front end of said track section 505c
Referring again to
An interconnection between a series of track sections 505a,c,e and 505b,d,f
For a purpose of placing said log 503
An assembly of said base section 580
said gantry, can now be placed into a situation atop base subsection 581a following which said travel control ropes of said gantry can be brought into an attachment with a set of corresponding end section cleats 104/107/110/113
Note: said series of four travel rope connector cleats 104 and 107 are seen at a front end of base subsection attached to forward end cross piece 584d and cleats 110 and 113 are seen at a rear end cross piece 584a in
In an alternative manner, after a selection of and a leveling of an appropriate site for a situation of said sawmill apparatus, said base section 581a/b/c
following which said gantry, can now be placed into a situation atop base subsection 581a, following which said travel control ropes of said gantry can be brought into an attachment with a set of corresponding end section cleats 104/107/110/113
The carriage component of the invention can be modified to allow of a use of the invention within other sawmill apparatuses having a transverse guide rail component differing from that of the current invention.
In a first alternative embodiment a body assembly comprising in part an elongated, parallelepiped shaped body member, is of a design for a use with a transverse guide rail assembly having a pair of angle iron guide rails; a rear and a front guide rail each of which has one wall of the angle iron facing vertically, a pair of vertical slots near the front and the rear of the base of the body section, and, partially extended up the side walls of the body section could replace the circular holes in the side walls of the preferred embodiment described prior; the vertical slots would serve as a guide for the carriage to slide along the transverse guide rails. With said body situated with said base slots straddling said angle iron guide rails, a full width movement of said body section would be possible and a locking of an integral locking mechanism of said body section could allow a fixation at any point along said guide rails; a hinged L frame chainsaw positioning element attached to the body section would allow cutting in either of a vertical or a horizontal planar attitude.
Alternatively, a wheeled parallelepiped carriage framework component comprising in part an elongated, six faced, open sided box having a bottom subsection, a top subsection, a left side subsection, a right side subsection, a rear face subsection and a front face subsection;
In which each of which said front and rear face subsections is in an attachment with a set of at least three externally attached wheels of matching size via a set of axle bolts; said wheels being in a positional situation at three like corners of each of said rear face and front face walls; forming thus a minimally six wheeled carriage;
since said carriage is designed to provide an allowance of a selective positioning of a blade of a chainsaw in either a perpendicular or a horizontal plane of cutting orientation, for purposes of clarity said wheel pairs shall be described as wheel pair A, wheel pair B and wheel Pair C; a rolling plane of each of said wheels is in an alignment along said front and said rear faces of said carriage and along said pair of transverse guide rails of said gantry;
in a first functional pairing, with said carriage in a situation upon said guide rails such that said blade of said saw is in a planar attitude for a making of a vertically oriented cut or series of cuts, said wheel pair A is in an inoperative position off of the guide rails; wheel pairs B and C are in an operative position, both sets being in contact with the guide rails;
after a lifting of the carriage off the guide rails, and a turning through a 90.degree arc creating thus a second functional pairing, with said carriage in a situation upon said guide rails such that said blade of said saw is in a planar attitude for a making of a horizontally oriented cut or series of cuts, said wheel pair C is in an inoperative position off of the guide rails; wheel pairs B and A are in an operative position, both sets being in contact with the guide rails;
In a third alternative embodiment, for a Sliding Rail Carriage Component, carriage framework component comprising in part an elongated, six faced, open sided box having a bottom subsection, a top subsection, a left side subsection, a right side subsection, a rear face subsection and a front face subsection;
with two adjacent sides of said front and rear face subsections being in a fixed attachment atop an angle iron rail situated with the 90.degree angle in a vertical alignment and a V shaped opening facing downward; it is readily seen that a placement of one open sided inverted V rail on an angle iron guide rail would align the body section such that a cutting blade would be in a situation for making a vertical cut; a repositioning of the body section on the second V rail, which is situated at a 90.degree angle to the first V rail, would situate a cutting blade for making a horizontal cut.
