The present disclosure relates to a portable cutting machine called, for example, a rear handle saw.
A portable cutting machine called a rear handle saw is a type of handheld cutting machine. A handheld cutting machine has a base to come in contact with a workpiece and a cutting machine body supported on the upper surface of the base. A rear handle saw has a handle, gripped by a user, protruding rearward from the rear end of the base. This type of portable cutting machine has the handle away from the workpiece portion to be machined, thus providing high operability for the user in a standing or half-sitting posture.
A known rechargeable portable cutting machine has a battery pack attached as a power supply. The battery pack, which is relatively heavy, is located not to lower the operability of the cutting machine.
Japanese Unexamined Patent Application Publication No. 2014-148016 (Patent Literature 1) describes a machine in a fourth embodiment (
Japanese Unexamined Patent Application Publication No. 2018-99742 (Patent Literature 2) describes a machine having a battery pack compartment parallel to a blade. This machine has a battery pack attached between a handle and a motor housing. The battery pack is attached in a hanging posture with its attachment surface (surface having rails for attachment) facing upward.
The battery pack attachment structure described in Patent Literature 1 has the battery pack protruding from the outer wall of the machine, thus upsizing the machine. In the battery pack attachment structure described in Patent Literature 2, the battery pack extends over the center plane of the handle in the lateral direction to avoid up sizing of the machine. However, the battery pack is attached to the body in a hanging posture with the upper or attachment surface facing upward, and thus applies the full weight to the attachment portion of the body (in particular, rail receivers on which the battery pack is slid and attached). The attachment portion on the body is to be strong enough to bear the full weight of the battery pack. For a heavier battery pack, the attachment portion may use an additional structure for reinforcement.
A first aspect of the present disclosure provides a portable cutting machine, including:
an electric motor;
a base having a lower surface to come in contact with a workpiece;
a cutting machine body coupled to an upper surface of the base and accommodating the electric motor;
a handle on a rear portion of the cutting machine body and at least partially rearward from a rear end of the base;
a blade on a left or a right of the handle and rotatable with the electric motor; and
a battery attachment portion configured to receive a battery pack for powering the electric motor, the battery attachment portion including
A second aspect of the present disclosure provides a portable cutting machine, including:
an electric motor;
a cutting machine body accommodating the electric motor;
a disc-shaped blade rotatably attached to a right or a left of the cutting machine body;
a front grip on a front portion of the cutting machine body;
a rear handle on a rear portion of the cutting machine body; and
a battery attachment portion configured to receive a battery pack between the front grip and the rear handle, the battery attachment portion including
A portable cutting machine 1 according to one or more embodiments will now be described with reference to
The portable cutting machine 1 includes a cutting machine body 10 and a base 2. The cutting machine body 10 includes a circular blade 25, called a tipped saw blade, which is rotatable with an electric motor 20 as a drive source. The base 2 supports the cutting machine body 10 on the upper surface. The base 2 has a window 2a substantially rectangular and elongated in the front-rear direction. The blade 25 has a lower portion protruding below the lower surface of the base 2 through the window 2a. The workpiece W is cut with the blade 25 protruding from the lower surface of the base 2. The cutting machine body 10 includes, on its rear, a handle 40 gripped by a user. The user, facing the rear of the portable cutting machine 1, grips the handle 40 and moves the portable cutting machine 1 forward to advance cutting. In the figures, the direction in which cutting advances is referred to as a cutting direction.
The components and structure will be described herein by referring to the front-rear direction with the front being the cutting direction and the rear being where the user stays. The lateral direction is defined for the components and structure as viewed from the user. As shown in
The cutting machine body 10 includes the stationary cover 11. The stationary cover 11 covers substantially the upper half of the blade 25. The cutting machine body 10 is supported on the upper surface of the base 2 in a vertically swingable manner about a vertical swing support shaft 12 at the front of the stationary cover 11. As shown in
The cutting machine body 10 is coupled to a front tilt support 4 located on the upper surface of the base 2 with the vertical swing support shaft 12. As shown in
As shown in
The rear lateral tilt support shaft 7 is coaxial with the front lateral tilt support shaft 5. The cutting machine body 10 is tilted about the front lateral tilt support shaft 5 and the rear lateral tilt support shaft 7 to the right or left to adjust the angle of the blade 25 to cut into the workpiece W.
The depth guide 6b is an arc-shaped guide for guiding the cutting machine body to swing in the vertical direction. A body fastener screw 8 is tightened into a handle support 13 (described later) to lock the cutting machine body 10 at any vertical swing position relative to the depth guide 6b. This allows the blade 25 to protrude by a constant degree below the lower surface of the base 2 to maintain a constant cutting depth into the workpiece W.
As shown in
The locking lever 9 is vertically operable to tighten or loosen the body fastener screw 8. As shown in
As shown in
The blade 25 has the lower half substantially covered with a movable cover 14. The movable cover 14 is supported to open and close substantially about the rotation center of the blade 25. The movable cover 14 opens to uncover the circumference (cutting edge) of the blade 25. The movable cover 14 is urged to close by a spring. The movable cover 14 closed under an urging force from the spring covers substantially the lower half of the blade 25. The movable cover 14 has an open-close lever 14a on its rear. A user can manually force the movable cover 14 to open and close by gripping the open-close lever 14a. In a normal cutting operation, as shown in
As shown in
The electric motor 20 is a brushless motor with a rotor 23 rotatably supported inward from the inner circumference of a cylindrical stator 22. The electric motor 20, which does not include, for example, commutators and brushes on the rotor 23, has a smaller axial (lateral) dimension. The rotor 23 is supported on a motor shaft 24 that is supported rotatably about the axis with front and rear bearings 24b and 24c in the axial direction. The front bearing 24b is held on the gear housing 15a. The rear bearing 24c is held on the rear surface of the motor housing 21. The motor shaft 24 receives a cooling fan 27 between the front bearing 24b and the rotor 23.
As shown in
The motor shaft 24 receives a driving gear 24a at the distal end (left end). The driving gear 24a is meshed with a follower gear 16. The driving gear 24a and the follower gear 16 meshing with each other form a reduction gear train for reducing the rotation output from the electric motor 20. The follower gear 16 is integrally coupled to a spindle 17. Although not shown in the figure, the spindle 17 is rotatably supported on the gear housing 15a with two bearings arranged in the axial direction. The spindle 17 is parallel to the motor shaft 24.
The spindle 17 has the distal end protruding into the stationary cover 11 to receive the blade 25. The blade 25 is held between an outer flange 25a and an inner flange 25b in the direction orthogonal to the plane. The blade 25 held between the flanges is locked with a fastener screw 25c tightened into the distal end face of the spindle 17. This allows the blade to be axially immovable and nonrotatable about the axis relative to the spindle 17.
As shown in
The controller 33 includes a shallow rectangular aluminum case accommodating the control board 33a. The control board 33a is molded with a resin for insulation. As shown in
As shown in
The motor cooling air drawn into the motor housing 21 also flows out through outlets 15b on the front surface of the gear housing 15a.
A battery attachment portion 30 is located behind the controller compartment 32. The battery attachment portion 30 receives a single battery pack 31. The battery attachment portion 30 will be described in detail later. A D-shaped handle 40 is located behind the battery attachment portion 30. The handle 40 extends substantially parallel to the plane direction (front-rear direction) of the blade 25. The handle 40 protrudes rearward from the rear of the battery attachment portion 30. The handle 40 protrudes further rearward from the rear end of the base 2. The blade 25 is on the right or left of the handle 40 (on the left in the present embodiment).
The handle 40 has a rear portion extending in the vertical direction as a grip 41 gripped by a user. The grip 41 includes a trigger switch lever 42 on its upper portion. The user pulls the switch lever 42 with the fingers holding the grip 41 to activate the electric motor 20, which rotates the blade 25. The surface of the grip 41 and a portion around the switch lever 42 are coated with a non-slip elastomer resin.
The handle 40 has an unlock button 43 above the switch lever 42. The switch lever 42 is normally locked and cannot be pulled. The user presses the unlock button 43 with a finger to unlock the switch lever 42 at the off position, enabling the switch lever 42 to be pulled. The user stops pulling the switch lever 42 to automatically return the switch lever 42 to the locked state at the off position. This prevents the switch lever 42 from being pulled accidentally.
The stationary cover 11 has a rear portion integral with the handle support 13. The handle support 13 is a flat plate formed by die-casting, similar to the stationary cover 11. The handle support 13 in the present embodiment is integral with the stationary cover 11. The handle support 13 protrudes rearward from the rear of the stationary cover 11. The handle support 13 extends parallel to the plane direction of the blade 25. The handle support 13 receives the battery attachment portion 30 and the handle 40 coupled with screws at multiple points in the front-rear direction.
The handle 40 is coupled to the stationary cover 11 with the handle support 13 between them. Thus, the handle 40 largely protruding rearward is supported rigidly, preventing or reducing bending of the handle 40 mainly in the lateral direction.
A sub grip 45 is located above the electric motor 20. As shown in
The sub grip 45 includes, in the upper portion, a grip 45a extending substantially in the lateral direction. The user grips the grip 45a with, for example, the left hand, and grips the grip 41 of the handle 40 with the right hand to move the portable cutting machine 1. The grip 45a is parallel to the base 2, and is inclined more frontward at more leftward positions in a plan view. The user can grip the inclined grip 45a more easily with the left hand.
As shown in
The battery attachment portion 30 is behind the controller compartment 32 and in front of the handle 40 in the front-rear direction. The battery attachment portion 30 has a front wall 34 at the front and a rear wall 35 at the rear. The front and rear walls 34 and 35 are parallel to each other and extend rightward (away from the blade 25) by the same dimension. The two walls 34 and 35 have substantially the same height in the vertical direction. The front wall 34 has an upper portion connected to an upper portion of the controller compartment 32.
The battery attachment portion 30 receives a single battery pack 31 between the front and rear walls 34 and 35. As shown in
As shown in
The connection surface 31b has a lock tab 31c at the rear. The lock tab 31c is urged toward the protruding end (lock position) by a spring. The battery pack 31 includes a release button 31a behind the lock tab 31c. The release button 31a is not shown in
The battery pack 31 has the connection surface 31b for connecting to the terminal mount 36, and the connection surface 31b corresponds to an attachment surface B. The attachment surface B stands with respect to the base 2. As shown in
The battery pack 31 is slid downward with the front surface facing downward as indicated by the solid-white arrow in
When the battery pack 31 is slid downward, the positive and negative terminal slots 31e and 31f receive the positive and negative power terminals 36b and 36c. The signal terminal slots 31g receive the signal terminals 36e on the terminal mount 36. This allows power supply from the battery pack 31 to the cutting machine body 10, and also allows transmission and reception of various data signals between the battery pack 31 and the cutting machine body 10.
The release button 31a is depressed toward the lower surface 31h to cause the lock tab 31c to retract from the lock recess 36d for unlocking. The unlocked battery pack 31 can be slid upward relative to the battery attachment portion 30 for detachment. The battery pack 31 can be detached from the battery attachment portion 30 and charged with a separate charger. Thus, the battery pack 31 can be used repeatedly as a power supply.
The battery attachment portion 30 selectively receives two different battery packs: a low-capacity, small first battery pack 31S, and a high-capacity, large second battery pack 31L. The battery packs 31S and 31L with such different capacities have different lengths L and different heights H. The large second battery pack 31L has a greater length L and a greater height H than the small first battery pack 31S. The two different battery packs 31S and 31L have substantially the same width D. The distance between the front and rear walls 34 and 35 in the front-rear direction is determined in accordance with the width D. The large and small battery packs 31S and 31L each have a width D small enough to create narrow clearances between the battery pack 31S or 31L and the front and rear walls 34 and 35. The connection surface 31b is common between the second battery pack 31L and the first battery pack 31S.
The second battery pack 31L has a greater length L than the first battery pack 31S. As shown in
The second battery pack 31L has a greater height H than the first battery pack 31S. As shown in
The portable cutting machine 1 according to the first embodiment includes the battery attachment portion 30 extending over the width center G of the handle 40 in the lateral direction to an area adjacent to the blade 25. Thus, the battery pack 31 attached to the battery attachment portion 30 extends over the width center G of the handle 40 to overlap an area adjacent to the blade 25. This allows the battery pack 31 to be attached in a space-efficient manner in the lateral direction than a battery pack located on one side of the portable cutting machine 1 with respect to the width center G.
The battery pack 31 (31S, 31L) is attached or detached in the vertical direction forming an angle with the front-rear direction. The attachment surface B stands with respect to the base 2 or extends in the vertical direction (the direction of gravity). This allows the battery attachment portion 30 to receive the full weight of the attached battery pack 31 on the attachment surface B. Thus, the battery pack 31 has the full weight applied dispersedly on the rail receivers 36a and other parts. More specifically, the battery attachment portion 30 partially receives the weight of the battery pack 31 with, for example, friction caused by the battery pack 31 in contact with or engaged with the battery attachment portion 30 in the sliding direction. This avoids the battery pack 31 with the full weight applied locally on the rail receivers 36a on the battery attachment portion 30. In a known attachment structure, a battery pack is attached in a hanging posture with the sliding direction crossing the direction of gravity. In such a structure, the battery pack has the full weight applied locally on rail receivers. The battery attachment portion 30 in the present embodiment can receive the large second battery pack 31L with no or less additional reinforcement for, for example, the rail receivers 36a and parts near the rail receivers 36a.
The battery attachment portion 30 is open in the direction opposite to the blade 25, or rightward (in the direction away from the blade 25). Thus, the large second battery pack 31L is attached to protrude rightward from the front and rear walls 34 and 35. With the large second battery pack 31L, the attachment surface B is located adjacent to the blade 25 with respect to the width center G of the handle 40. Thus, the large second battery pack 31L is attached in a space-efficient manner in the lateral direction. The large second battery pack 31L extends over the width center G of the handle 40 to overlap an area adjacent to the blade 25. Thus, the large second battery pack 31L has the center of gravity closer to the width center G of the handle 40. This allows the user to move the portable cutting machine 1 by gripping the handle 40 more easily.
The battery attachment portion 30 has the walls 34 and 35 at the front and the rear. The front and rear walls 34 and 35 protect the battery pack 31 attached to the battery attachment portion 30. The front and rear walls 34 and 35 serve as a battery guard.
In the first embodiment described above, the battery pack 31 is slid in the vertical direction to be attached to or detached from the battery attachment portion 30. However, the battery pack 31 may be slid in the lateral direction to be attached or detached.
In the portable cutting machine 1 according to the second embodiment, the battery pack 31 is slid in the lateral direction (a direction crossing the blade 25) to be attached or detached. As shown in
The battery attachment portion 50 in the second embodiment has a front wall 51 at the front and a rear wall 52 at the rear. The battery attachment portion 50 has an upper wall 53 at the top and a lower wall 54 at the bottom. The front wall 51, the rear wall 52, the upper wall 53, and the lower wall 54 define a rectangular battery compartment. As shown in
As shown in
As shown in
As in the first embodiment, the battery pack 31 has the connection surface 31b or a coupling surface for connecting to the terminal mount 55. The connection surface 31b corresponds to the attachment surface B. Thus, as shown in
As shown in
The portable cutting machine 1 according to the second embodiment includes a controller compartment 60 above the battery attachment portion 50. The controller compartment 60 accommodates a controller 61 for controlling the motor. In the second embodiment, cooling air for the electric motor 20 does not flow into the controller compartment. As shown in
In the second embodiment, the battery pack 31 (31S, 31L) is slid in the lateral direction to be attached or detached. In this embodiment, the battery pack 31 (31S, 31L) is also attached to extend over the width center G of the handle 40 to overlap an area adjacent to the blade 25. Thus, the battery pack 31 (31S, 31L) extends from the right area to the left area (adjacent to the blade 25) with respect to the width center G of the handle 40. This allows the battery pack 31 to be attached in a space-efficient manner in the lateral or width direction, allowing the use of the large second battery pack 31L easily.
In the second embodiment, the large second battery pack 31L also extends over the width center G of the handle 40 to overlap an area adjacent to the blade 25. Thus, the large second battery pack 31L has the center of gravity closer to the width center G of the handle 40. This avoids poor grip on the handle 40 caused by an unbalanced weight in the lateral direction due to the large battery pack 31. With the large second battery pack 31L attached, the user can move the portable cutting machine 1 by gripping the handle 40 more easily.
In the second embodiment, the front wall 51, the rear wall 52, the upper wall 53, and the lower wall 54 surround the battery pack 31. Thus, the walls 51 to 54 serve as a guard for the attached battery pack 31 to prevent damage to the battery pack 31.
The battery attachment portion 50 in the second embodiment has the attachment surface B substantially standing with respect to the base 2. In particular, as shown in
The first and second embodiments described above may be modified further. For example, although the portable cutting machine 1 in the above embodiments has the blade 25 on the left of the handle 40 as viewed from a user, a portable cutting machine may have a blade on the right of the handle 40. Such a portable cutting machine can also include the illustrated battery attachment structure. In a portable cutting machine having a blade and a stationary cover on the right of the handle 40, the battery pack 31 (31S, 31L) extends from the left to right areas (adjacent to the blade) with respect to the width center G of the handle 40. This structure also allows the large second battery pack 31L to be attached in a space-efficient manner in the width direction. The large second battery pack 31L has the center of gravity closer to the handle 40, thus allowing good grip on the handle 40 (an equally balanced weight in the lateral direction). The portable cutting machine can thus readily use the large second battery pack 31L.
Although the attachment surface B is orthogonal to the base 2 in the above embodiments, the attachment surface B may extend diagonally to the base 2. For example, the attachment surface B may be tilted in one direction or another at an angle of up to about 45° to a plane orthogonal to the base 2. The diagonally extending attachment surface B can also receive the heavy and large second battery pack 31L without much reinforcement for, for example, the rail receivers or parts near the rail receivers. The diagonally extending attachment surface B, which allows the battery pack 31 to be attached or detached diagonally to the base 2, allows any reinforcement without compromising easy attachment or detachment in a smaller space.
Although the portable cutting machine 1 in the above embodiments selectively receives two different battery packs 31S and 31L having different heights H, the portable cutting machine 1 may selectively receive three or more different battery packs having different heights (and thus having different capacities).
The portable cutting machine 1 may further selectively receive multiple different battery packs 31 having different lengths L, different widths D, or different heights H and having the common connection surface 31b. Any of these battery packs 31 is attached to extend from one of the right and left areas from the width center G of the handle 40 to the other area, thus being compact and having an equally balanced weight.
Although the portable cutting machine 1 in the above embodiments is a rear handle saw having the handle 40 largely protruding rearward, the illustrated battery attachment structure may be used for a typical portable circular saw having a more compact handle. The portable cutting machine may include a diamond wheel or a grinding disc as a blade, instead of a tipped saw blade.
The portable cutting machine 1 in the above embodiments includes the cutting machine body 10 accommodating the electric motor 20. The portable cutting machine 1 includes the disc-shaped blade 25 rotatably attached to the right or left of the cutting machine body 10. The portable cutting machine 1 includes the front grip (sub grip 45) on a front portion of the cutting machine body 10, the rear handle (handle 40) on a rear portion of the cutting machine body 10, and the battery attachment portion 30 (50) for receiving the battery pack 31 (31S, 31L) between the front grip and the rear handle. The battery attachment portion 30 (50) has the front surface (front wall 34, 51) to face the front surface of the battery pack 31 (31S, 31L), the rear surface (rear wall 35, 52) to face the rear surface of the battery pack 31 (31S, 31L), and the lateral opening to expose the battery pack 31 (31S, 31L) in the direction away from the blade 25. The battery attachment portion 30 (50) also includes the lateral surface opposite to the lateral opening, and the rail receivers 36a (55a) on any one of the lateral surface, the front surface, and the rear surface. The rail receivers 36a (55a) receive the rails 31d on the battery pack 31 (31S, 31L) in a detachable manner.
Thus, the battery pack 31 (31S, 31L) is attachable between the front grip and the rear handle. The battery attachment portion 30 (50) has the front surface facing the front surface of the attached battery pack 31 (31S, 31L), the rear surface facing the rear surface of the battery pack 31 (31S, 31L), and the lateral opening located in the lateral direction from the battery pack 31 (31S, 31L). Thus, the battery pack 31 (31S, 31L) is attached or detached in the vertical direction or the lateral direction. The battery attachment portion 30 (50) includes the rail receivers 36a (55a) on any one of the lateral surface, the front surface, and the rear surface. In each case, the battery attachment portion 30 (50) has the attachment surface B extending in the vertical direction (or standing with respect to the base 2). Thus, portions other than the rail receivers 36a (55a), such as portions in contact with or engaged with the battery pack 31 (31S, 31L) also partially receive the full weight of the battery pack 31 (31S, 31L). This allows the battery attachment portion 30 (50) to receive a larger and heavier battery pack 31L with no or less additional reinforcement. The portable cutting machine 1 can thus avoid being upsized and becoming heavy. The battery attachment portion 30 (50) has the lateral opening to expose the battery pack 31 (31S, 31L) in the direction away from the blade 25. This allows attachment of the large second battery pack 31L that uses a large attachment space on the right or left portion.
The portable cutting machine 1 according to the first embodiment includes the battery attachment portion 30 including the rail receivers 36a on the lateral surface and the upper opening to expose the upper surface of the battery pack 31 (31S, 31L). Thus, the battery pack 31 (31S, 31L) is attached or detached in the vertical direction. The battery pack 31 (31S, 31L) is slid in the vertical direction along the rail receivers 36a to be attached to or detached from the battery attachment portion 30. The base 2 does not obstruct the attachment or detachment.
The rail receivers 36a in the first embodiment allow the battery pack 31 (31S, 31L) to be detached upward. Thus, the battery pack 31 (31S, 31L) is slid upward for detachment from the battery attachment portion 30 and slid downward for attachment to the battery attachment portion 30.
The battery attachment portion 50 in the second embodiment includes the rail receivers 55a located on the rear (or front) surface, the lower surface (lower wall 54) to cover the lower surface of the battery pack 31 (31S, 31L), and the upper surface (upper wall 53) to cover the upper surface of the battery pack 31 (31S, 31L). Thus, the battery pack 31 (31S, 31L) is attached or detached in the lateral (right-left) direction through the opening in a lateral surface other than the upper, lower, front, or rear surface.
The rail receivers 55a in the second embodiment allow the battery pack 31 (31S, 31L) to be detached through the lateral opening. Thus, the battery pack 31 (31S, 31L) is slid to and through the lateral opening to be detached from the battery attachment portion 50.
The illustrated rail receivers 36a (55a) are located to allow the battery pack 31 (31S, 31L) on the rail receivers 36a (55a) to extend over the center plane of the rear handle (handle 40) in the lateral direction. Thus, the battery pack 31 (31S, 31L) is attached to extend over the center plane (width center G) of the rear handle in the lateral direction. This allows the portable cutting machine 1 to be compact.
The illustrated battery attachment portion 30 (50) selectively receives the first battery pack 31S and the second battery pack 31L having different dimensions. Each of the first battery pack 31S and the second battery pack 31L includes the rails 31d to be attached to the common rail receivers 36a (55a). Thus, the common rail receivers 36a (55a) selectively receive the first battery pack 31S and the second battery pack 31L having different dimensions. The battery attachment portion 30 (50) with a simple structure can selectively receive the small and large battery packs 31S and 31L, with the battery packs 31S and 31L having the common rails 31d attachable to the common rail receivers 36a (55a).
In the first and second embodiments, each of the small first battery pack 31S and the large second battery pack 31L has the rail surface (connection surface 31b) including the rails 31d, the thickness (height H) orthogonal to the rail surface, and the length L along the rails 31d. The first battery pack 31S and the second battery pack 31L have different thicknesses (heights H) and/or different lengths L. The first and second battery packs 31S and 31L with different thicknesses (heights H) and/or different lengths L have the common rails 31d. The battery attachment portion 30 (50) includes the common rail receivers 36a (55a) to receive both the first and second battery packs 31S and 31L. Thus, the first and second battery packs 31S and 31L with different thicknesses (heights H) and/or different lengths L can be attached to the common battery attachment portion 30 (50). The battery attachment portion 30 (50), which has the attachment surface extending in the vertical direction (or standing with respect to the base 2), can receive any of these battery packs 31 or a larger and heavier battery pack 31L with no or less additional reinforcement. The portable cutting machine 1 can thus avoid being upsized and becoming heavy.
Number | Date | Country | Kind |
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2020-052400 | Mar 2020 | JP | national |
This application is a divisional of U.S. patent application Ser. No. 17/157,164, filed Jan. 25, 2021, which in turn claims the benefit of priority to Japanese Patent Application No. 2020-052400, filed on Mar. 24, 2020, the entire contents of which are hereby incorporated by reference.
Number | Date | Country | |
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Parent | 17157164 | Jan 2021 | US |
Child | 18137659 | US |