US20030233921A1 - Cutter with optical alignment system - Google Patents
Cutter with optical alignment system Download PDFInfo
- Publication number
- US20030233921A1 US20030233921A1 US10/174,731 US17473102A US2003233921A1 US 20030233921 A1 US20030233921 A1 US 20030233921A1 US 17473102 A US17473102 A US 17473102A US 2003233921 A1 US2003233921 A1 US 2003233921A1
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- US
- United States
- Prior art keywords
- blade
- cutter
- holder
- housing
- indicator
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D59/00—Accessories specially designed for sawing machines or sawing devices
- B23D59/001—Measuring or control devices, e.g. for automatic control of work feed pressure on band saw blade
- B23D59/002—Measuring or control devices, e.g. for automatic control of work feed pressure on band saw blade for the position of the saw blade
- B23D59/003—Indicating the cutting plane on the workpiece, e.g. by projecting a laser beam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/24—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves
- B23Q17/2404—Arrangements for improving direct observation of the working space, e.g. using mirrors or lamps
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/04—Processes
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/768—Rotatable disc tool pair or tool and carrier
- Y10T83/7684—With means to support work relative to tool[s]
- Y10T83/7688—Plural tool elements successively actuated at same station
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/768—Rotatable disc tool pair or tool and carrier
- Y10T83/7684—With means to support work relative to tool[s]
- Y10T83/7722—Support and tool relatively adjustable
- Y10T83/7726—By movement of the tool
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/768—Rotatable disc tool pair or tool and carrier
- Y10T83/7684—With means to support work relative to tool[s]
- Y10T83/773—Work-support includes passageway for tool [e.g., slotted table]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/768—Rotatable disc tool pair or tool and carrier
- Y10T83/7755—Carrier for rotatable tool movable during cutting
- Y10T83/7788—Tool carrier oscillated or rotated
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/828—With illuminating or viewing means for work
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/828—With illuminating or viewing means for work
- Y10T83/839—Mirror or lens
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/849—With signal, scale, or indicator
- Y10T83/853—Indicates tool position
Definitions
- Recent patents such as U.S. Pat. Nos. 5,285,708 and 5,375,495, disclose optical alignment systems for power saws that have circular blades. Such optical alignment systems typically utilize a single laser generator that projects a line on a workpiece to indicate the location at which one of the sides of the blade will enter the workpiece and purport to facilitate cutting the workpiece.
- One embodiment of the invention provides an optical system mounted on a cutter that has a base and a housing supporting a blade.
- the optical system may projects first and second indicator lines on the base.
- the optical system may also include a mechanism selectively operable to adjust the first and second lines to indicate the width of the blade.
- FIG. 1 is a perspective view of an embodiment of the cutter according to the invention.
- FIG. 2 is a partially exploded view of a portion of the cutter of FIG. 1;
- FIG. 3 a is a left side perspective view of an embodiment of an optical system employed in the cutter embodiment of FIG. 1;
- FIG. 3 b is a top view of the optical system of FIG. 3 a;
- FIG. 4 a is a cross-sectional view of an embodiment of a laser generator holder for the optical system of FIG. 3 a;
- FIG. 4 b is an exploded view of FIG. 4 a;
- FIG. 5 is a right side perspective view of the optical system of FIG. 3 a;
- FIG. 6 is a right side perspective and partially exploded view of the optical system of FIG. 3 a with one laser generator holder removed;
- FIG. 7 is a partially exploded right side perspective view of the optical system of FIG. 3 a with both laser generator holders removed;
- FIG. 8 is a left side perspective and partially exploded view of the optical system of FIG. 3 a with one laser generator holder removed;
- FIG. 9 is a right side perspective view of an embodiment of a cover for the optical system of FIG. 3 a;
- FIG. 10 is a partial perspective view of the cutter of FIG. 1 showing two indicator lines injected by the optical system of FIG. 3 a in one configuration on a workpiece prior to cutting;
- FIG. 11 is an enlarged partial perspective view of the blade of the cutter of FIG. 1 showing two indicator lines projected by the optical system of FIG. 3 a in another configuration on a workpiece prior to cutting;
- FIGS. 12 a - 12 d are plan views of a portion of the cutter base for the cutter of FIG. 1 diagrammatically showing various adjustments of the indicator lines of the optical system of FIG. 3 a;
- FIG. 13 is a perspective view of the projection of the indicator lines 62 , 64 of the optical system of FIG. 3 a for a slanted cut of the cutter of FIG. 1;
- FIG. 14 is a perspective view of an embodiment of a laser generator for the optical system of FIG. 3 a.
- FIG. 15 is a side view of an embodiment of a lower guard for the cutter of FIG. 1.
- FIGS. 1 and 2 are partial perspective views of an embodiment of a cutter 20 having a base 22 and a housing 24 .
- the housing 24 supports a blade 26 that is rotatable about an axis A-A by a conventional electric motor (not shown) and may include an upper blade guard 28 and movable lower blade guard 30 .
- the blade 26 has two lateral sides 50 , 52 , which define the width of the cut made by the blade 26 . See FIG. 2. Accordingly, if the blade 26 has carbide tooth inserts, as in common in some applications, the outermost surfaces of such inserts define the width of the cut and comprise the lateral sides 50 , 52 of the blade 26 .
- the cutter 20 may be any circular saw, such as, for example, a miter saw, a table saw, a radial arm saw, a cutoff saw, a hand-held circular saw, a frame and trim saw, a compound and slide miter saw, etc., although other non-circular cutters may also be used.
- a miter saw such as, for example, a miter saw, a table saw, a radial arm saw, a cutoff saw, a hand-held circular saw, a frame and trim saw, a compound and slide miter saw, etc.
- an embodiment of an optical alignment system 40 for the cutter 20 may be mounted on the upper guard 28 . See FIGS. 2 - 9 .
- the optical alignment system 40 may include first and second laser generators 42 , 44 mounted on respective first and second holders 46 , 48 .
- Each of the holders 46 , 48 may have a cylindrical portion 41 , 47 , with a respective axis A 1 -A 1 , A 2 -A 2 , which is parallel to the axis A-A of the blade 26 when the holder 46 , 48 is installed on the upper guard 28 .
- the holders 46 , 48 may also include lateral adjustment portions 51 , 57 and may be slidably supported on the upper blade guard 28 such that they can be laterally displaced relative to the blade 26 along their respective axes A 1 -A 1 , A 2 -A 2 in the lateral directions represented by arrows “D” and “E”.
- the right and left walls 21 , 23 of the upper guard 28 may include various openings that have surface portions that slidably support the holders 46 , 48 .
- the openings may also facilitate the installation of the holders 46 , 48 on the upper guard 28 .
- the left wall 23 may include circular left side openings 120 having bearing surfaces 121 that are in contact with the left ends 122 of the cylindrical portions 41 , 47 of the holders 46 , 48 . See FIG. 7.
- the right wall 21 may include right side openings 124 that are sized and shaped to receive the holders 46 , 48 .
- the openings 124 may also include bearing surfaces 123 that are in bearing contact with the right ends 126 of cylindrical portions 41 , 47 of the holders 46 , 48 .
- the holders 46 , 48 After the holders 46 , 48 are inserted through the right side openings 124 into the upper guard 28 between the right and left walls 21 , 23 , they may be rotated into operative positions in the direction of the arrows “F” and “G”.
- the operative position may be determined such that, for example, the laser generators 42 , 44 project light that passes through openings 98 of the lower guard 30 of a cutter 20 when the blade 26 is in its uppermost position away from the base 22 . See FIG. 1.
- the holders 46 , 48 may be rotated in the direction opposite to the directions represented by the arrows F and G for removal from the upper blade guard 28 . It will be appreciated that the laser generators 42 , 43 may first be removed from the holders 46 , 48 during the installation or removal of the holders 46 , 48 into and out of the upper blade guard 28 .
- the first and second laser generators 42 , 44 may be mounted on the respective holders 46 , 48 so that they are laterally offset from the blade 26 and on opposite lateral sides 50 , 52 of the blade 26 .
- the laser generators 42 , 44 may be powered by a battery or a cutter power source via electrical cables 128 .
- converters may be connected to the laser generators 42 , 44 to convert the alternate current of the cutter power source to direct current for the laser generators 42 , 44 , and to reduce the power source voltage level to the voltage level of the laser generators 42 , 44 .
- the laser generators 42 , 44 may be controlled through a dedicated switch 43 , which may be located, for example, on the upper blade guard 28 . See FIG. 2.
- the power to the laser generators 42 , 44 may be also controlled by the electric switch of the cutter 20 in certain applications, such that the laser generators 42 , 44 are powered when the cutter 20 is powered.
- the laser generators 42 , 44 may comprise commercial laser generators of the type that produce a fan of light, i.e. line generators, such as those laser line generators manufactured by Sean & Stephen Corporation of Taiwan and China under Model 1894.
- each laser generator 42 , 44 may be customized to include a handle arrangement 84 , such as, for example, a nut or socket attached to a barrel 85 that encloses the laser unit 89 of the laser generator 42 , 44 . See FIG. 14.
- frictional inserts 86 may be supported in the holders 46 , 48 to frictionally contact the lateral surfaces of the laser generators 42 , 44 .
- the frictional inserts 86 may be made of foam, rubber or other material that may increase the coefficient of friction at the lateral surfaces of the laser generators 42 , 44 . See FIGS. 4 a and 4 b.
- the optical lens of the laser unit 85 may be customized so that it produces a fan angle “D” of approximately 30° centrally disposed about axis B-B, instead of the 60° fan angle ⁇ of typical commercial laser line generators. See FIG. 14.
- the narrower fan angle produces a laser beam of greater intensity that may be visible even in direct sunlight.
- the optical alignment system 40 may also be protected by a removable cover 45 that is attached to upper blade guard 28 by fasteners 13 , such as, for example, screws, or by other fastening arrangements or snap-on fittings, etc. See FIGS. 2 and 9.
- the cover 45 may also include openings 133 that provide access to lateral adjustment features for the holders 46 , 48 , as will be described below.
- the cover 45 may be molded as one piece from polymeric material or otherwise manufactured as is known in the art.
- the laser generators 42 , 44 when the laser generators 42 , 44 are powered, they project two indicator lines 62 , 64 on the base 22 or on a workpiece 25 that is supported on the base 22 . See FIG. 10. Namely, the first laser generator 42 projects a “left” indicator line 62 and the second laser generator 44 projects a “right” indicator line 64 .
- the optical alignment system 40 may also include several adjustment mechanisms that can be used to adjust the spacing, position and orientation of the indicator lines 62 , 64 relative to each other and relative to the blade 26 , to indicate the width of the workpiece material or “kerf” 100 to be removed by the blade 26 .
- FIGS. 12 a - 12 d illustrate a portion of the base 22 and also show the indicator lines 62 , 64 .
- the kerf 100 is depicted in dashed lines to illustrate the various adjustments of the indicator lines relative to the kerf 100 .
- FIG. 12 a illustrates the right indicator line 62 and the left indicator line 64 in a non-parallel relationship.
- a parallelism adjustment may be provided by rotating each laser generator 42 , 44 about its own longitudinal axis B-B to cause the respective indicator line 62 , 64 to become parallel to a respective lateral side of the blade 26 , defining the kerf 100 . See FIGS. 11, 12 a, and 12 b.
- the handle 84 attached to each laser generator 42 , 44 may be used to facilitate the rotation of the laser generators 42 , 44 about their longitudinal axes B-B.
- a lateral macro-adjustment may be provided by moving the holders 46 , 48 laterally to accommodate the width of the blade 26 or the kerf 100 of the cut between the left and right indicator lines 62 , 64 , which are then laterally displaced with respect to kerf 100 , as shown in FIGS. 12 b and 12 c.
- the first holder 46 may include a first threaded hole 66 parallel to its axis A 1 -A 1 and a second threaded hole 70 oriented orthogonally to the first hole 66 .
- FIG. 3 a the first holder 46 may include a first threaded hole 66 parallel to its axis A 1 -A 1 and a second threaded hole 70 oriented orthogonally to the first hole 66 .
- the second holder 48 may include a first threaded hole 68 parallel to its axis A 2 -A 2 and a second threaded hole 72 oriented orthogonally to the first hole 68 .
- First macro-adjustment actuators 74 , 78 in the form, for example, of screws, may extend through holes 132 , 132 ′, 134 , 134 ′ in the left and right walls 23 , 21 of the upper blade guard 28 , and may be received in the respective first holes 66 , 68 to move the respective holders 46 , 48 laterally.
- the wall holes 132 , 132 ′, 134 , 134 ′ are aligned with the first threaded holes 66 , 68 .
- Macro-adjustment fasteners 80 , 82 such as set screws, may be used to lock the macro-adjustment actuators 70 , 74 .
- a lateral micro-adjustment of the indicator lines 62 , 64 may be provided by supporting the laser generators 42 , 44 on beams or sleeves 88 cantilevered from the holders 46 , 48 . See FIGS. 4 a and 4 b.
- each laser generator 42 , 44 may be supported on its respective holder 46 , 48 inside a central opening 87 of a sleeve 88 which is received inside an opening 83 of the respective holder 46 , 48 .
- Each sleeve 88 may have first and second end tabs 90 , 92 that protrude on each side of the sleeve, and may be cantilevered from its first end tab 90 , which may be received, for example, in a cavity 91 of the respective holder 46 , 48 . It will be appreciated that other ways of supporting the laser generators 42 , 44 on cantilevered beams 88 and mounting such beams 88 on the holders 44 , 46 may be employed.
- a micro-adjustment actuator 94 in the form of a screw or similar fastener, may be received in an opening 140 of the holder 46 , 48 .
- the micro adjustment actuator 94 may operate to exert force on the second end tab 92 of the sleeve 88 to cause the sleeve 88 to deflect and move in the directions indicated by arrows C relative to the respective axis A 1 -A 1 , A 2 -A 2 of the holder 46 , 48 .
- the deflection of the sleeve 88 causes the respective laser generator 42 , 44 to move in like manner, such that the respective indicator line 62 , 64 is displaced parallel to itself. See FIG. 12 d.
- the micro-adjustment actuator 94 may be operated by rotating, for example, a hex nut 96 .
- the sleeve 88 and the micro-adjustment actuator 94 may also be calibrated such that one full turn of the nut 96 corresponds to a predetermined amount of displacement.
- one full turn of the nut 96 corresponds to a lateral displacement of ⁇ fraction (1/32) ⁇ ′′.
- one or more micro-adjustment operations may be required to bring the indicator lines 62 , 64 onto the planes corresponding with the sides 50 , 52 of the blade 26 depending on the proximity provided by a preceding macro-adjustment.
- a biasing stopper 95 may be provided against the second end tab 92 of the sleeve 88 to bias the second end tab 92 toward a predetermined position, for example in contact with an inner surface 99 of the respective holder 46 , 48 .
- the stopper 95 may be made from any resilient material, such as, for example, rubber. It will be appreciated that other biasing arrangements or devices may be used, including, for example, ordinary coil springs.
- the biasing stopper 95 may be secured by a fastener 136 , such as a set screw, or other supporting arrangement.
- the sleeve 88 may include a cavity 138 for receiving the frictional insert 86 .
- the laser light of the laser generators 42 , 44 may pass through a bottom surface 31 of the lower guard 30 , if such lower guard 30 is provided.
- the bottom surface 31 of the lower guard 30 may be constructed from materials having acceptable optical transmission properties, such as, for example, glass or polymer having a transparency index that minimizes distortion and/or dispersion of the laser light.
- the bottom surface 31 of the lower guard 30 may be provided with one or more openings 98 , for example, a series of slits or louvers. See FIG. 1.
- the openings 98 may be oriented substantially perpendicularly to a periphery 33 of the lower guard 30 , as shown in FIG. 1, or parallel to the periphery 33 .
- the indicator lines 62 , 64 are projected as dashed lines on the base 22 or on the workpiece 25 . See FIG. 10.
- the shape of the openings 98 may be determined by drawing radial lines 142 emanating from a point “X” of the upper blade guard 28 .
- Point X may be located, for example, midway between the first and second laser generators 42 , 44 .
- the angle “ ⁇ ” between two adjacent radial lines 142 that define the lateral sides of the openings 98 may be adjusted to achieve a desire length and spacing of the dashes of the indicator lines 62 , 64 . See FIG. 15.
- each of the indicator lines 62 , 64 may be adjusted such that it is parallel to the first or second sides 50 , 52 of the blade 26 . Moreover, each indicator line 62 , 64 may be manipulated to be tangent to one of the sides 50 , 52 of the blade 26 , or to fall within the width of the blade 26 (or the kerf 100 ), and therefore, within the width of the material to be removed by the blade 26 . In the latter case, i.e., when the indicator lines 62 , 64 are adjusted to fall within the kerf 100 , certain portions of the indicator line 62 , 64 may be obstructed by the blade 26 such that the indicator line 62 , 64 may appear to be interrupted, i.e. having blank or shadowed portions.
- FIG. 11 illustrates an example in which the left indicator line 62 is interrupted by the width of the blade 26 (hitting a tooth insert), while the right indicator line 64 is uninterrupted and tangent to the right side 52 of the blade 26 .
- the optical system 40 may be powered to project two indicator lines 62 , 64 near the sides 102 , 104 of the kerf 100 , as shown in FIG. 12 a.
- each laser generator 42 , 44 may be rotated about its longitudinal axis B-B until the corresponding indicator line 62 , 64 becomes parallel to the corresponding side of the kerf 100 . See FIG. 12 b.
- the macro-adjustment actuators 74 , 78 may then be operated to slide the corresponding holders 46 , 48 toward or away from the blade 26 , such that the indicator lines 62 , 64 are on each side of kerf 100 and close to the kerf sides 102 , 104 . See FIG. 12 c.
- the micro-adjustment actuators 94 may be operated to cause one or both indicator lines 62 , 64 to coincide with the outer edges of the kerf sides 102 , 104 , as shown in FIG. 12 d.
- the indicator line 62 , 64 may be partially interrupted or shadowed by a portion of the blade 26 , as described in connection with FIG. 11.
- the lower guard 30 rotates to expose the blade 26 . Accordingly, as the blade 26 is lowered, the indicator lines 62 , 64 may change from dashed to solid as they no longer pass through the lower guard 30 . Additionally, the indicator lines 62 , 64 may also project on the side surface of the workpiece 25 , indicating, for example, a straight or slanted cut and guiding vertical or slanted orientations of the blade 26 . See FIG. 13.
- Providing two laser generators 42 , 44 with multiple and selectively operable adjustment mechanisms greatly facilitates the operation of cutting a workpiece 25 along a predetermined line and removing a predetermined amount of material. Such cutting operations may be performed accurately and conveniently using a variety of blades of different widths and teeth arrangements.
- optical alignment system was described in reference to laser generators, other light sources capable of projecting distinctive indicator lines on the workpiece may be utilized in the spirit of the invention in connection parallelism, macro- and micro-adjustment mechanisms.
Abstract
Description
- Recent patents, such as U.S. Pat. Nos. 5,285,708 and 5,375,495, disclose optical alignment systems for power saws that have circular blades. Such optical alignment systems typically utilize a single laser generator that projects a line on a workpiece to indicate the location at which one of the sides of the blade will enter the workpiece and purport to facilitate cutting the workpiece.
- Because power saw blades have varying thickness, there is a need for an optical system that may be used to indicate accurately the width of the material to be removed by the blade in a cost-efficient and convenient manner.
- One embodiment of the invention provides an optical system mounted on a cutter that has a base and a housing supporting a blade. The optical system may projects first and second indicator lines on the base. The optical system may also include a mechanism selectively operable to adjust the first and second lines to indicate the width of the blade.
- In the accompanying Figures, there are shown present embodiments of the invention wherein like reference numerals are employed to designate like parts and wherein:
- FIG. 1 is a perspective view of an embodiment of the cutter according to the invention;
- FIG. 2 is a partially exploded view of a portion of the cutter of FIG. 1;
- FIG. 3a is a left side perspective view of an embodiment of an optical system employed in the cutter embodiment of FIG. 1;
- FIG. 3b is a top view of the optical system of FIG. 3a;
- FIG. 4a is a cross-sectional view of an embodiment of a laser generator holder for the optical system of FIG. 3a;
- FIG. 4b is an exploded view of FIG. 4a;
- FIG. 5 is a right side perspective view of the optical system of FIG. 3a;
- FIG. 6 is a right side perspective and partially exploded view of the optical system of FIG. 3a with one laser generator holder removed;
- FIG. 7 is a partially exploded right side perspective view of the optical system of FIG. 3a with both laser generator holders removed;
- FIG. 8 is a left side perspective and partially exploded view of the optical system of FIG. 3a with one laser generator holder removed;
- FIG. 9 is a right side perspective view of an embodiment of a cover for the optical system of FIG. 3a;
- FIG. 10 is a partial perspective view of the cutter of FIG. 1 showing two indicator lines injected by the optical system of FIG. 3a in one configuration on a workpiece prior to cutting;
- FIG. 11 is an enlarged partial perspective view of the blade of the cutter of FIG. 1 showing two indicator lines projected by the optical system of FIG. 3a in another configuration on a workpiece prior to cutting;
- FIGS. 12a-12 d are plan views of a portion of the cutter base for the cutter of FIG. 1 diagrammatically showing various adjustments of the indicator lines of the optical system of FIG. 3a;
- FIG. 13 is a perspective view of the projection of the
indicator lines - FIG. 14 is a perspective view of an embodiment of a laser generator for the optical system of FIG. 3a; and
- FIG. 15 is a side view of an embodiment of a lower guard for the cutter of FIG. 1.
- Referring now to the drawings for the purpose of illustrating the invention and not for the purpose of limiting the same, it is to be understood that standard components or features that are within the purview of an artisan of ordinary skill and do not contribute to the understanding of the various embodiments of the invention are omitted from the drawings to enhance clarity. Furthermore, it will be appreciated that the characterizations of various components and orientations described herein as being “vertical” or “horizontal”, “right” or “left”, “side”, “upper” or “lower”, are relative characterizations only based upon the particular position or orientation of a given component for a particular application.
- FIGS. 1 and 2 are partial perspective views of an embodiment of a
cutter 20 having abase 22 and ahousing 24. Thehousing 24 supports ablade 26 that is rotatable about an axis A-A by a conventional electric motor (not shown) and may include anupper blade guard 28 and movablelower blade guard 30. Theblade 26 has twolateral sides blade 26. See FIG. 2. Accordingly, if theblade 26 has carbide tooth inserts, as in common in some applications, the outermost surfaces of such inserts define the width of the cut and comprise thelateral sides blade 26. Thecutter 20 may be any circular saw, such as, for example, a miter saw, a table saw, a radial arm saw, a cutoff saw, a hand-held circular saw, a frame and trim saw, a compound and slide miter saw, etc., although other non-circular cutters may also be used. The manufacture and operation of such saws are known in the art and, therefore, they will not be described herein beyond what is necessary for a person of ordinary skill in the art to make and use the various embodiments of the subject invention. - An embodiment of an
optical alignment system 40 for thecutter 20 may be mounted on theupper guard 28. See FIGS. 2-9. In one embodiment, theoptical alignment system 40 may include first andsecond laser generators second holders holders cylindrical portion blade 26 when theholder upper guard 28. Theholders lateral adjustment portions upper blade guard 28 such that they can be laterally displaced relative to theblade 26 along their respective axes A1-A1, A2-A2 in the lateral directions represented by arrows “D” and “E”. - In one embodiment, the right and
left walls upper guard 28 may include various openings that have surface portions that slidably support theholders holders upper guard 28. For example, theleft wall 23 may include circularleft side openings 120 havingbearing surfaces 121 that are in contact with theleft ends 122 of thecylindrical portions holders right wall 21 may includeright side openings 124 that are sized and shaped to receive theholders openings 124 may also include bearingsurfaces 123 that are in bearing contact with the right ends 126 ofcylindrical portions holders - After the
holders right side openings 124 into theupper guard 28 between the right and leftwalls laser generators openings 98 of thelower guard 30 of acutter 20 when theblade 26 is in its uppermost position away from thebase 22. See FIG. 1. Theholders upper blade guard 28. It will be appreciated that thelaser generators holders holders upper blade guard 28. - More particularly and with reference to FIG. 3a, the first and
second laser generators respective holders blade 26 and on oppositelateral sides blade 26. Thelaser generators electrical cables 128. In the latter case, converters may be connected to thelaser generators laser generators laser generators laser generators dedicated switch 43, which may be located, for example, on theupper blade guard 28. See FIG. 2. The power to thelaser generators cutter 20 in certain applications, such that thelaser generators cutter 20 is powered. - The
laser generators laser generator handle arrangement 84, such as, for example, a nut or socket attached to abarrel 85 that encloses thelaser unit 89 of thelaser generator - To prevent accidental rotation of the
laser generators holders frictional inserts 86 may be supported in theholders laser generators laser generators - Additionally, the optical lens of the
laser unit 85 may be customized so that it produces a fan angle “D” of approximately 30° centrally disposed about axis B-B, instead of the 60° fan angle β of typical commercial laser line generators. See FIG. 14. The narrower fan angle produces a laser beam of greater intensity that may be visible even in direct sunlight. - In one embodiment, the
optical alignment system 40 may also be protected by aremovable cover 45 that is attached toupper blade guard 28 by fasteners 13, such as, for example, screws, or by other fastening arrangements or snap-on fittings, etc. See FIGS. 2 and 9. Thecover 45 may also includeopenings 133 that provide access to lateral adjustment features for theholders cover 45 may be molded as one piece from polymeric material or otherwise manufactured as is known in the art. - In one embodiment, when the
laser generators indicator lines workpiece 25 that is supported on thebase 22. See FIG. 10. Namely, thefirst laser generator 42 projects a “left”indicator line 62 and thesecond laser generator 44 projects a “right”indicator line 64. Theoptical alignment system 40 may also include several adjustment mechanisms that can be used to adjust the spacing, position and orientation of the indicator lines 62, 64 relative to each other and relative to theblade 26, to indicate the width of the workpiece material or “kerf” 100 to be removed by theblade 26. - FIGS. 12a-12 d illustrate a portion of the
base 22 and also show the indicator lines 62, 64. Although theworkpiece 25 and theblade 26 are not shown in these Figures, thekerf 100 is depicted in dashed lines to illustrate the various adjustments of the indicator lines relative to thekerf 100. FIG. 12a illustrates theright indicator line 62 and theleft indicator line 64 in a non-parallel relationship. A parallelism adjustment may be provided by rotating eachlaser generator respective indicator line blade 26, defining thekerf 100. See FIGS. 11, 12a, and 12 b. Thehandle 84 attached to eachlaser generator laser generators - A lateral macro-adjustment may be provided by moving the
holders blade 26 or thekerf 100 of the cut between the left and right indicator lines 62, 64, which are then laterally displaced with respect tokerf 100, as shown in FIGS. 12b and 12 c. To facilitate such adjustment, as can be seen in FIG. 3a, thefirst holder 46 may include a first threadedhole 66 parallel to its axis A1-A1 and a second threadedhole 70 oriented orthogonally to thefirst hole 66. Likewise, As can be seen in FIG. 4b, thesecond holder 48 may include a first threadedhole 68 parallel to its axis A2-A2 and a second threadedhole 72 oriented orthogonally to thefirst hole 68. Firstmacro-adjustment actuators holes right walls upper blade guard 28, and may be received in the respectivefirst holes respective holders holes Macro-adjustment fasteners macro-adjustment actuators - A lateral micro-adjustment of the indicator lines62, 64 may be provided by supporting the
laser generators sleeves 88 cantilevered from theholders laser generator respective holder central opening 87 of asleeve 88 which is received inside anopening 83 of therespective holder sleeve 88 may have first andsecond end tabs first end tab 90, which may be received, for example, in acavity 91 of therespective holder laser generators cantilevered beams 88 and mountingsuch beams 88 on theholders - A
micro-adjustment actuator 94, in the form of a screw or similar fastener, may be received in an opening 140 of theholder micro adjustment actuator 94 may operate to exert force on thesecond end tab 92 of thesleeve 88 to cause thesleeve 88 to deflect and move in the directions indicated by arrows C relative to the respective axis A1-A1, A2-A2 of theholder sleeve 88 causes therespective laser generator respective indicator line - The
micro-adjustment actuator 94 may be operated by rotating, for example, ahex nut 96. Thesleeve 88 and themicro-adjustment actuator 94 may also be calibrated such that one full turn of thenut 96 corresponds to a predetermined amount of displacement. For example, in one embodiment, one full turn of thenut 96 corresponds to a lateral displacement of {fraction (1/32)}″. Those of ordinary skill in the art will appreciate that one or more micro-adjustment operations may be required to bring the indicator lines 62, 64 onto the planes corresponding with thesides blade 26 depending on the proximity provided by a preceding macro-adjustment. - A biasing
stopper 95 may be provided against thesecond end tab 92 of thesleeve 88 to bias thesecond end tab 92 toward a predetermined position, for example in contact with aninner surface 99 of therespective holder stopper 95 may be made from any resilient material, such as, for example, rubber. It will be appreciated that other biasing arrangements or devices may be used, including, for example, ordinary coil springs. The biasingstopper 95 may be secured by afastener 136, such as a set screw, or other supporting arrangement. Thesleeve 88 may include acavity 138 for receiving thefrictional insert 86. - The laser light of the
laser generators bottom surface 31 of thelower guard 30, if suchlower guard 30 is provided. Thebottom surface 31 of thelower guard 30 may be constructed from materials having acceptable optical transmission properties, such as, for example, glass or polymer having a transparency index that minimizes distortion and/or dispersion of the laser light. Alternatively, thebottom surface 31 of thelower guard 30 may be provided with one ormore openings 98, for example, a series of slits or louvers. See FIG. 1. - The
openings 98, may be oriented substantially perpendicularly to aperiphery 33 of thelower guard 30, as shown in FIG. 1, or parallel to theperiphery 33. When theopenings 98 are oriented perpendicularly to theperiphery 33 of thelower guard 30, the indicator lines 62, 64 are projected as dashed lines on the base 22 or on theworkpiece 25. See FIG. 10. - In one embodiment, the shape of the
openings 98 may be determined by drawingradial lines 142 emanating from a point “X” of theupper blade guard 28. Point X may be located, for example, midway between the first andsecond laser generators adjacent radial lines 142 that define the lateral sides of theopenings 98 may be adjusted to achieve a desire length and spacing of the dashes of the indicator lines 62, 64. See FIG. 15. - By operating the adjustment mechanisms described above, each of the indicator lines62, 64 may be adjusted such that it is parallel to the first or
second sides blade 26. Moreover, eachindicator line sides blade 26, or to fall within the width of the blade 26 (or the kerf 100), and therefore, within the width of the material to be removed by theblade 26. In the latter case, i.e., when the indicator lines 62, 64 are adjusted to fall within thekerf 100, certain portions of theindicator line blade 26 such that theindicator line left indicator line 62 is interrupted by the width of the blade 26 (hitting a tooth insert), while theright indicator line 64 is uninterrupted and tangent to theright side 52 of theblade 26. - In operation, the
optical system 40 may be powered to project twoindicator lines sides kerf 100, as shown in FIG. 12a. Using thehandle 84, eachlaser generator corresponding indicator line kerf 100. See FIG. 12b. Themacro-adjustment actuators corresponding holders blade 26, such that the indicator lines 62, 64 are on each side ofkerf 100 and close to the kerf sides 102, 104. See FIG. 12c. Finally, themicro-adjustment actuators 94 may be operated to cause one or bothindicator lines - As explained in connection with FIG. 11, it is also possible, if desired, to bring the
indicator line kerf 100, for example against the inner edge of one of the kerf sides 102, 104. In such case, thecorresponding indicator line blade 26, as described in connection with FIG. 11. - Further, for a cutter such as a miter saw, as the
upper guard 28 is lowered to bring theblade 26 in cutting position, thelower guard 30 rotates to expose theblade 26. Accordingly, as theblade 26 is lowered, the indicator lines 62, 64 may change from dashed to solid as they no longer pass through thelower guard 30. Additionally, the indicator lines 62, 64 may also project on the side surface of theworkpiece 25, indicating, for example, a straight or slanted cut and guiding vertical or slanted orientations of theblade 26. See FIG. 13. - Providing two
laser generators workpiece 25 along a predetermined line and removing a predetermined amount of material. Such cutting operations may be performed accurately and conveniently using a variety of blades of different widths and teeth arrangements. - It will be understood that although the optical alignment system was described in reference to laser generators, other light sources capable of projecting distinctive indicator lines on the workpiece may be utilized in the spirit of the invention in connection parallelism, macro- and micro-adjustment mechanisms.
- Whereas particular embodiments of the invention have been described herein for the purpose of illustrating the invention and not for the purpose of limiting the same, it will be appreciated by those of ordinary skill in the art that numerous variations of the details, materials and arrangement of parts may be made within the principle and scope of the invention without departing from the spirit invention. The preceding description, therefore, is not meant to limit the scope of the invention. Rather the scope of the invention is to be determined only by the appended claims and their equivalents.
Claims (34)
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
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US10/174,731 US20030233921A1 (en) | 2002-06-19 | 2002-06-19 | Cutter with optical alignment system |
CA 2432108 CA2432108A1 (en) | 2002-06-19 | 2003-06-12 | Cutter with optical alignment system |
CNA031490042A CN1494979A (en) | 2002-06-19 | 2003-06-19 | Cutter with optical alignment system |
TW92116656A TWI228442B (en) | 2002-06-19 | 2003-06-19 | Cutter with optical alignment system |
US10/632,561 US20060101969A1 (en) | 2002-06-19 | 2003-07-31 | Optical alignment system |
US11/033,502 US7926398B2 (en) | 2002-06-19 | 2005-01-11 | Cutter with optical alignment system |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US10/174,731 US20030233921A1 (en) | 2002-06-19 | 2002-06-19 | Cutter with optical alignment system |
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US11/033,502 Continuation US7926398B2 (en) | 2002-06-19 | 2005-01-11 | Cutter with optical alignment system |
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US10/632,561 Abandoned US20060101969A1 (en) | 2002-06-19 | 2003-07-31 | Optical alignment system |
US11/033,502 Expired - Fee Related US7926398B2 (en) | 2002-06-19 | 2005-01-11 | Cutter with optical alignment system |
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US10/632,561 Abandoned US20060101969A1 (en) | 2002-06-19 | 2003-07-31 | Optical alignment system |
US11/033,502 Expired - Fee Related US7926398B2 (en) | 2002-06-19 | 2005-01-11 | Cutter with optical alignment system |
Country Status (4)
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US (3) | US20030233921A1 (en) |
CN (1) | CN1494979A (en) |
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Also Published As
Publication number | Publication date |
---|---|
US20050126356A1 (en) | 2005-06-16 |
US20060101969A1 (en) | 2006-05-18 |
CN1494979A (en) | 2004-05-12 |
CA2432108A1 (en) | 2003-12-19 |
TW200405847A (en) | 2004-04-16 |
TWI228442B (en) | 2005-03-01 |
US7926398B2 (en) | 2011-04-19 |
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