Patent Application
20110048205
Cross-reference is made to U.S. Utility patent application Ser. No. 12/547,818 entitled “Table Saw with Actuator Module” by Mehta et al., which was filed on Aug. 26, 2009; U.S. Utility patent application Ser. No. [Attorney Docket No. 1576-0627] entitled “Table Saw with Positive Locking Mechanism” by Chung et al., which was filed on Aug. 26, 2009; U.S. Utility patent application Ser. No. [Attorney Docket No. 1576-0628] entitled “Table Saw with Belt Stop” by Chung, which was filed on Aug. 26, 2009; U.S. Utility patent application Ser. No. [Attorney Docket No. 1576-0629] entitled “Table Saw with Alignment Plate” by Chung et al., which was filed on Aug. 26, 2009; U.S. Utility patent application Ser. No. [Attorney Docket No. 1576-0630] entitled “Table Saw with Swing Arm Support” by Chung et al., which was filed on Aug. 26, 2009; U.S. Utility patent application Ser. No. [Attorney Docket No. 1576-0631] entitled “Table Saw with Mechanical Fuse” by Oberheim, which was filed on Aug. 26, 2009; U.S. Utility patent application Ser. No. [Attorney Docket No. 1576-0632] entitled “Table Saw with Pressure Operated Actuator” by Fischer et al., which was filed on Aug. 26, 2009; U.S. Utility patent application Ser. No. [Attorney Docket No. 1576-0634] entitled “Table Saw with Reset Mechanism” by Groth et al., which was filed on Aug. 26, 2009; U.S. Utility patent application Ser. No. [Attorney Docket No. 1576-0635] entitled “Table Saw with Linkage Drop System” by Holmes et al., which was filed on Aug. 26, 2009; U.S. Utility patent application Ser. No. [Attorney Docket No. 1576-0636] entitled “Table Saw with Ratchet Mechanism” by Chung et al., which was filed on Aug. 26, 2009; and U.S. Utility patent application Ser. No. [Attorney Docket No. 1576-0637] entitled “Table Saw with Actuator Reset Mechanism” by Chung, which was filed on Aug. 26, 2009, the entirety of each of which is incorporated herein by reference. The principles of the present invention may be combined with features disclosed in those patent applications.
The present disclosure relates to power tools and more particularly to power tools with exposed shaping devices.
A number of power tools have been produced to facilitate forming a work-piece into a desired shape. One such power tool is a table saw. A wide range of table saws are available for a variety of uses. Some table saws such as cabinet table saws are very heavy and relatively immobile. Other table saws, sometimes referred to as jobsite table saws, are relatively light. Jobsite table saws are thus portable so that a worker can position the table saw at a job site. Some accuracy is typically sacrificed in making a table saw sufficiently light to be mobile. The convenience of locating a table saw at a job site, however, makes job site table saws very desirable in applications such as general construction projects.
All table saws, including cabinet table saws and job site table saws generate a significant amount of dust when used to shape a work-piece. Saw dust can present a number of deleterious effects, from respiratory difficulties to rapid ignition. In order to mitigate the amount of dust in a work area, a number of different dust collection systems have been developed. Most of these systems provide a suction near the location of dust generation and subsequently filter the dust particles or discharge the dust away from the job site.
Dust collection ports are commonly provided in the housing of table saws. In the event a dust collection system is used, the dust collection port can be used to apply a suction beneath the work-piece support surface of the table saw. If a dust collection system is not used, the air flow pattern generated by the table saw results in a discharge of saw dust from the table saw housing through the dust collection port.
Prior to discharge through the dust collection port, however, the table saw mechanisms within the table saw housing are exposed to an atmosphere laden with dust. As a result a number of moving parts, including gear systems associated with the power drive system as well as blade height and bevel systems, are exposed to the dust. The dust can thus collect on various surfaces, particularly those surfaces treated with a lubricant. As dust collects on moving parts, the function of the dust laden component may be compromised resulting in increased difficulty in using the component or even component failure.
In view of the foregoing, it would be advantageous to limit the exposure of moving components of a table saw to dust generated by the table saw. A further advantage would be realized by a system that could limit the exposure of moving components of a table saw equipped with a safety system to dust generated by the table saw.
In accordance with one embodiment, table saw includes A table saw in one embodiment includes a motor, a blade operably connected to the motor, at least a portion of the blade positioned within an enclosure, and a dust plate extending within the enclosure and positioned between the at least a portion of the blade and the motor.
In another embodiment, a table saw includes a motor, an enclosure, a dust plate substantially dividing the enclosure into a mechanism portion and a blade portion, and a blade operably connected to the motor, at least a portion of the blade positioned within the blade portion.
The accompanying drawings illustrate various embodiments of the present disclosure and together with a description serve to explain the principles of the disclosure.
Corresponding reference characters indicate corresponding parts throughout the several views. Like reference characters indicate like parts throughout the several views.
While the power tools described herein are susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit the power tools to the particular forms disclosed. On the contrary, the intention is to cover all combinations of features, modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
Referring to
A motor 116 which is powered through a switch 118 located on the base housing 102, is supported by a carriage assembly 120. The carriage assembly 120 and a stop pad 122 are supported by the frame 114. The carriage assembly 120 includes a carriage 124 to which the motor 116 is mounted and two guiderails 126/128. The position of the carriage 124 along the guiderails 126/128 is controlled by a blade height turn-wheel 130 through a gearing assembly 132 and a height adjustment rod 134. The carriage 124 fixedly supports a latch assembly 140 and pivotably supports a swing arm assembly 142.
The swing arm assembly 142, also shown in
With reference to
As shown in
The inner dust plate 500 and outer cover plate 504 are formed of a material, which does not transmit fine dust and other debris. The inner dust plate 500, however, may include openings to accommodate components proximate the blade 108. For instance the inner dust plate 500 may include an opening for a riving knife (not illustrated) and a slot 512. In most embodiments, however, openings in the inner dust plate 500 are minimized.
The slot 512 in the inner dust plate 500 is configured to enable the carriage assembly 120 to move relative the frame 114. In particular, as the carriage assembly 120 moves between an upper position and a lower position, the arbor shaft 516, which supports the blade 108, also moves between an upper position and a lower position. Accordingly, in order to prevent the inner dust plate 500 from restricting the motion of the carriage assembly 120 and, in particular, the arbor shaft 516, the inner dust plate 500 includes a slot 512. The length of the slot 512 is at least as great as the distance traveled by the arbor shaft 516 relative to the inner dust plate 500. The width of the slot 512 may be minimized to prevent dust and debris from escaping the blade space 508 through the slot 512.
To further prevent dust and debris from escaping the blade space 508 through the slot 512, the inner dust plate 500 includes a dust curtain 520, as shown in
The table saw 100 includes a dust collection port 532 to vent the blade space 508. The port 532 may be coupled to a dust collection system (not illustrated) for collecting dust and debris generated by the table saw 100. As shown in
Operation of the table saw 100 is described with reference to
Additionally, the blade wheel 156 is positioned sufficiently close to the work-piece support surface 104 that the blade 108 extends above the work-piece support surface 104 as shown in
Using the switch 118, power is then applied to the motor 116 causing the output shaft 152 and the power wheel 150 to rotate. Rotation of the power wheel 150 causes the belt 154 to rotate the blade wheel 156 and the blade 108 which is mounted on the blade wheel 156. A work-piece may then be shaped by moving the work-piece into contact with the blade 108.
As the work-piece contacts the blade 108, dust and debris are often generated. Most of the dust and debris, however, contacts only the inner surfaces of dust plate 500 and outer cover plate 504, which define the blade space 508. Accordingly, by diverting the dust and debris into the approximately closed volume of the blade space 508, the table saw 100 prevents the dust and debris from contaminating the components on the motor 116 side of the inner dust plate 500. The slot 512 formed in the inner dust plate 500 enables the height of the blade 108 to be adjusted relative to the work-piece support surface 104. The dust curtain 520 prevents the dust and debris drawn into the blade space 508 from escaping the blade space 508 through the slot 512.
Rotation of the blade 108 evacuates air from the blade space 508 creating a region of low pressure relative to the pressure on the motor 116 side of the inner dust plate 500. Accordingly, air flows from the high pressure side of the inner dust plate 500, near the motor 116, to the low pressure of the inner dust plate 500, which defines the blade space 508. The flow of air into the blade space 508 further prevents dust and debris from contaminating the components proximate the motor 116. This pressure differential may be increased by providing a suction on the dust collection port 532 with a dust collection system.
The table saw 100 includes a sensing and control circuit (not shown) which activates the solenoid 182 in response to a sensed condition. Any desired sensing and control circuit may be used for this purpose. One acceptable sensing and control circuit is described in U.S. Pat. No. 6,922,153, the entire contents of which are herein incorporated by reference. The safety detection and protection system described in the '153 patent senses an unsafe condition and provides a control signal which, in the table saw 100, is used to actuate the solenoid 182.
Upon actuation of the solenoid 182, the solenoid pin 184 is forced outwardly from the solenoid 182. When the swing arm assembly 142 is maintained in a latched position with the latch pin 166 resting on the latch ledge 170 as shown in
The shape of the latch pin 166 and the latch ledge 172 is selected such that the impact of the solenoid pin 184 on the strike plate 146 generates a force tending to push the latch pin 166 against the spring 168. The spring constant of the spring 168 and the operating characteristics of the solenoid 182 are selected such that when the solenoid pin 184 impacts the strike plate 146 the generated force is sufficient to compress the spring 168 and to force the latch pin 166 into a position whereat the swing arm assembly 142 is no longer maintained in position adjacent to the latch assembly 140 by the latch pin 166. In embodiments with a rigid latch pin 166, the generated force causes the latch hold 170 to rotate about the pivot 190 in a counterclockwise direction thereby forcing the springs 186 and 188 into further compression. When the latch hold 170 has rotated sufficiently, the latch ledge moves out from underneath the latch pin 166.
In either event, the swing arm assembly 142 is no longer supported by the latch hold 170. Consequently, the swing arm assembly 142 pivots about the power shaft 152 in the direction of the arrow 200 of
As discussed above, the slot 512 is shaped to permit movement of the arbor shaft 516 upwardly and downwardly to allow the blade 108 to be set at different blade heights. Thus, the side of the slot farthest away from the power shaft 152 may be substantially straight along a horizontal axis. The slot 512 is further shaped to permit free rotation of the swing arm assembly 142 when the swing arm assembly is no longer supported by the latch hold 170. Accordingly, the side of the slot 512 closest to the power shaft 152 is curved.
Because the latch ledge 172 is formed complementarily to the shape of the latch pin 166, the wear of the latch ledge 172 and the latch pin 166 during the de-latching described above is reduced. Accordingly, the pressure needed to effect de-latching does not change significantly over multiple actuations of the solenoid 182.
As the swing arm assembly 142 moves in the direction of the arrow 200, the rebound plate 148 of the swing arm assembly 142 rotates below the rebound ledge 178 of the latch hold 170. At this point, rotation of the latch hold 170 about the pivot 190 is no longer restrained by the swing arm assembly 142. Accordingly, the springs 186 and 188 cause the latch hold 170 to rotate into a position whereat the rebound ledge 178 is located in the swing path of the swing arm 142, that is, the path along which the swing arm 142 moves, as shown in
The configuration of
In one embodiment, the stop pad 122 is made with microcellular polyurethane elastomer (MPE). MPEs form a material with numerous randomly oriented air chambers. Some of the air chambers are closed and some are linked. Additionally, the linked air chambers have varying degrees of communication between the chambers and the orientation of the linked chambers varies. Accordingly, when the MPE structure is compressed, air in the chambers is compressed. As the air is compressed, some of the air remains within various chambers, some of the air migrates between other chambers and some of the air is expelled from the structure. One such MPE is MH 24-65, commercially available from Elastogran GmbH under the trade name CELLASTO®. In other embodiments, a foam material such as “memory foam” may be used.
Use of an MPE or other appropriate material in the stop pad 122 stops rotation of the swing arm assembly 142 without damaging the swing arm assembly 142. Prior to impacting the stop pad 122, however, the swing arm assembly 142 may be moving with sufficient force to cause the swing arm assembly to rebound off of the stop pad 122. In such a circumstance, the swing arm assembly 142 will rotate about the power shaft 152 in a counterclockwise direction. Thus, the blade 108 moves toward the work-piece support surface 104. Movement of the blade 108 above the work-piece support surface 104, however, is inhibited by the latch hold 170.
Specifically, because the springs 186 and 188 bias the latch hold 170 to a location within the swing path of the swing arm assembly 142, movement of the swing arm assembly 142 toward the work-piece support surface 104 brings the rebound plate 148 into contact with the rebound ledge 178 as shown in
The spring constants for the springs 186 and 188 are thus selected to ensure that the latch hold 170 is positioned within the swing path of the swing arm assembly 142 before the swing arm assembly 142 travels from the latched position downwardly into contact with the stop pad 122 and then upwardly to a position whereat the blade 108 is above the work-piece support surface 104. Of course, the time available for moving the latch hold 170 into the swing path can be increased by moving the stop pad 122 further away from the work-piece support surface 104 along the swing path. Such modification increases the overall height of the frame 114, particularly for embodiments with variable blade height. The increased material for the frame 114 results in increased weight. Increased size and weight are generally not desired for movable power tools. Thus, positioning the stop pad 122 closer to the work-piece support surface 104 along the swing path reduces the height of the frame 114 and the resultant weight of the table saw 100.
For some embodiments wherein the stop pad 122 is positioned closer to the work-piece support surface 104 along the swing path, such as the embodiment of
The angle and length of the stop pad 122 are selected in the embodiment of FIG. 2 to o ensure that the swing arm assembly 142 contacts the stop pad 122 at the foot 192 (see
Once the sensed condition has been cleared, the swing arm assembly 142 is reset by moving the latch hold 170 out of the swing path. This is effected by compressing the springs 188 and 186. The swing arm assembly 142 may then be rotated in a counterclockwise direction about the output shaft 152 until the rebound plate 148 is adjacent to the upper surface of the latch hold 170. The latch hold 170 is then released and the springs 188 and 186 bias the latch hold 170 about the pivot 190 into contact with the lip 164 of the swing arm assembly 142 which restricts rotation of the latch hold 170. Additionally, the swing arm assembly 142 is maintained in a latched position with the latch pin 166 resting on the latch ledge 170 as shown in
The table saw 100 thus actively monitors for an unsafe condition and initiates mitigation action automatically in the event an unsafe condition is sensed. Additionally, movement and subsequent stopping of the swing arm assembly 172 is accomplished without requiring physical contact with the blade 108. Accordingly, the blade 108 is not damaged by the mitigation action.
Moreover, because the mitigation action does not require interaction with the blade 108, the mitigation system of the table saw 100 may be used with other shaping devices such as sanding wheels, blades with varying dado blades, and molding head cutters, without requiring any modification to the mitigation system. Additionally, because the moving components of the mitigation system can be mounted on the frame 114, the mitigation system can be used with any desired blade height or bevel angle.
The mitigation system discussed with respect to the table saw 100 can be implemented using very light materials, and is thus amenable to incorporation into a variety of power tools including bench top saws and portable saws. For example, the components which are subjected to increased stress within the mitigation system, such as the solenoid pin 184, the latch hold 170, the rebound plate 148, and the strike plate 146, can be made of more durable materials including metals to withstand the impacts and stresses of activating the mitigation system. Other components, including the housings, may be fabricated from more lightweight materials to minimize the weight of the power tool.
If desired, the components of the table saw 100 may repositioned within the housing 102. By way of example,
A further example of rearranged components is shown in
The swing arm assembly 232 is maintained in the position shown in
The rebound latch 242 is pivotably mounted to the carriage assembly 234 by a pivot 272. A spring 274 biases the rebound latch 242 in a counter clockwise direction as viewed in
Operation of the power tool 230 may be substantially identical to operation of the table saw 100 through the firing of the solenoid 240. When the solenoid 240 is actuated, however, a solenoid pin 290, shown in
In
Continued movement of the solenoid pin 290 outwardly from the solenoid 240 causes the solenoid pin 290 to contact the strike plate 250 as depicted in
Once the rebound latch 242 has rotated sufficiently, the swing arm assembly 232 slides past the release 278 and into contact with the latch foot 280 as shown in
The swing arm assembly 232 then rotates into contact with the stop pad 282. In the event the swing arm assembly 232 begins to rebound off of the stop pad 282, the latch plate 252 moves into contact with the rebound ledge 276 and rotation of the swing arm assembly 232 is arrested.
The vertical arm configuration of the tool 230 may be desirable in applications wherein injury is most likely to occur as a result of movement parallel to the surface of the work-piece support surface. By way of example,
A work-piece, for purpose of this example, is moved by a user toward the blade 302 in the direction of the arrow 310. Thus, the point at which the user is most likely to come into accidental contact with the shaping device 302 is at or near the location 312.
When accelerated such as by a solenoid 182, the blade wheel 304, in a horizontal swing arm configuration, rotates from the position indicated by the blade wheel 304 to the position indicated by the blade wheel 304H1 in a first time interval. The location of the shaping device 302 associated with the blade wheel 304H1 is blade 302H1. Thus, the blade 302 has moved from the location 312 to the location 314.
During the same time interval, the blade wheel 304, in a vertical swing arm configuration, rotates from the position indicated by the blade wheel 304 to the position indicated by the blade wheel 304V1. The location of the shaping device 302 associated with the blade wheel 304V1 is blade 302V1. Thus, the blade 302 has moved from the location 312 to the location 316. Accordingly, the blade 302 is moved farther away from the contact point 312 by the vertical configuration than by the horizontal configuration.
Likewise, the blade wheel 304, in a horizontal swing arm configuration, rotates from the position indicated by the blade wheel 304H1 to the position indicated by the blade wheel 304H2 in a second time interval. The location of the shaping device 302 associated with the blade wheel 304H2 is blade 302H2. Thus, the blade 302 has moved from the location 312 to the location 316 over two time intervals.
During the second time interval, the blade wheel 304, in a vertical swing arm configuration, rotates from the position indicated by the blade wheel 304V1 to the position indicated by the blade wheel 304V2. The location of the shaping device 302 associated with the blade wheel 304V2 is blade 302V2. Thus, the blade 302 has moved from the location 312 to the location 318. Accordingly, the blade 302 moves away from the contact point 312 by about a factor of two in the vertical configuration as compared to the horizontal configuration.
Thus, in applications wherein an injury is most likely to occur at one side of the shaping device, a vertically oriented swing arm may be used to mitigate injury. Most table saw applications will fit into this scenario if a blade guard is installed.
As described above, operation of the latch pin 254 is significantly different from operation of the latch pin 166. Specifically, the latch pin 166 is operated by applying a force to the swing arm assembly 142. In contrast, the latch pin 254 is relatively immune to activation by application of force to the swing arm assembly 232. Accordingly, the latch pin 254 is a positive locking mechanism that is not susceptible to unintentional unlocking absent complete failure of the latch pin 254. The latch pin 254 may thus be used in swing arms that are positioned in any desired orientation.
A variety of positive locking mechanisms, i.e., mechanisms wherein a latch is moved prior to application of rotational force to the swing arm assembly, may be incorporated into power tools. One example of another positive locking mechanism is the latch pin 320 of
Another positive locking mechanism is the latch pin 330 of
Another positive locking mechanism is the latch pin 360 of
A positive locking mechanism may also be provided in the form of rotating latch pin such as the latch pin 380 depicted in
In operation, movement of the solenoid pin 398 causes the solenoid pin 398 to impinge the actuation ramp 386 of the latch pin 380 imparting a rotational force to the latch pin 380. The actuation ramp 386 thus converts axial force from the solenoid pin 398 to a rotational force. The rotational force overcomes the bias of the spring 396 causing the latch pin 380 to rotate in a counterclockwise direction about the pivot pin 394. The shape of the hook portion 388 and the retaining pin 390 along with the location of the hook portion 388 relative to the pivot pin 394 is selected to ensure that an upward force is not imparted onto the retaining pin 390 from the latch pin 384 during this rotation. Once the actuation ramp 386 has rotated sufficiently, the solenoid pin 398 continues to move axially into contact with the swing arm 392.
The latch pin 400 depicted in
In operation, movement of the solenoid pin 418 causes the solenoid pin 418 to impinge the actuation ramp 406 of the latch pin 400 imparting a rotational force to the latch pin 400. The rotational force overcomes the bias of the spring 416 causing the latch pin 400 to rotate in a clockwise direction about the pivot pin 414. The shape of the lip portion 408 and the retaining recess 410 along with the location of the lip portion 408 relative to the pivot pin 414 is selected to ensure that an upward force is not imparted onto the retaining recess 410 from the latch pin 404 during this rotation. Once the actuation ramp 406 has rotated sufficiently, the solenoid pin 418 continues to move axially into contact with the swing arm 412.
The solenoid pin 418 in this embodiment impinges a strike plate portion 420 which is pivotably attached to a lower swing arm housing 422 by a pivot pin 424. Spring washers 426 positioned between the strike plate portion 420 and the lower swing arm housing 422 bias the strike plate portion 420 into a position aligned with the solenoid pin 418 when the lip portion 408 is within the retaining recess 410. When the solenoid pin 418 impacts the strike plate portion 420, the spring washers 426 are compressed thereby reducing the peak force that is transferred from the strike plate portion 420 to the other components of the swing arm 412. This allows lighter materials to be used for some components of the swing arm 412 while ensuring a rapid acceleration of the swing arm 412.
The latch pin 430 depicted in
In operation, movement of the solenoid pin (not shown) causes the solenoid pin (not shown) to impinge the actuation ramp 436 of the latch pin 430 and the axial force is translated into a rotational force by the actuating ramp 436 imparting a rotational force to the latch pin 430. The rotational force overcomes the bias of the spring 446 causing the latch pin 430 to rotate in a clockwise direction about the pivot pin 444 and outwardly from the swing arm 442. Once the actuation ramp 436 has rotated sufficiently, the solenoid pin (not shown) continues to move axially into contact with a strike plate 448 on the swing arm 412.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the invention are desired to be protected.
