Table saw fence with adjustment mechanism

Abstract

Table saw fence with adjustment mechanism. A fence assembly configured to guide a workpiece relative to a blade of a saw device includes a fence supported by tracks for sliding movement relative to a work surface. Opposite ends of the fence are supported on the tracks via track-engaging members. The fence assembly includes a fence angle adjustment mechanism associated with a housing of one of the track-engaging members. The fence angle adjustment mechanism includes biasing elements that work in conjunction with an adjustment screw to adjust the position of the fence relative to parallelism with the blade.

Description

Technical Field

[0001] The present application relates to a fence assembly configured to guide a workpiece parallel to a blade of a saw device and a method of adjusting the alignment of a guide fence of a saw device to extend parallel to a cutting blade of the saw device using a fence angle adjustment mechanism. Background Art

[0002] Table saws of various designs include a frame and an upward-facing work surface having an opening through which a blade extends. The table saw may include a movable fence supported on one or more rails disposed on opposite sides of the work surface. The fence provides a guide surface against which the material to be cut is positioned. The fence can be positioned relative to the work surface by sliding the fence along the rails to a desired spacing from the blade and securing the fence in the desired position using a locking mechanism. During a cutting operation, the material rests on the work surface while sliding along the fence as it is cut by the saw blade. When the guide surface of the fence is arranged perpendicular to the work surface and aligned parallel to the blade, the fence enables the table saw to provide accurate, straight, and reproducible cuts. However, it can be difficult to adjust the position of the fence so that the guide surface of the fence is parallel with respect to the blade. It would be desirable to provide a fence having a fence alignment adjustment mechanism that can adjust the position of the fence so that the guide surface of the fence is parallel relative to the saw blade without losing reference to the fence's previous position and without overcorrection. It would be desirable for such a fence alignment adjustment mechanism to provide an incremental or fine adjustment mechanism for accurately and precisely adjusting the fence relative to the saw blade. Summary of the Invention

[0003] In some aspects, a fence assembly is configured to guide a workpiece relative to a blade of a saw device, and the fence assembly is supported by a track relative to a work surface of the saw device. The fence assembly includes a fence having a first fence end and a second fence end opposite the first fence end. The fence assembly includes a track engaging member coupled to the first fence end and supported on the track. The track engaging member includes a first housing. The first housing includes a body portion disposed within the fence, and a flange portion extending from an outer end of the body portion is disposed outside the fence and configured to engage the track. The fence assembly includes a fence angle adjustment mechanism associated with the track engaging member. The fence angle adjustment mechanism is configured to adjust the position of the fence relative to parallelism with the blade. The fence angle adjustment mechanism includes an outer fastener connecting the fence to the body portion. The outer fastener provides an axis of rotation for the fence during adjustment relative to parallelism with the blade. The fence angle adjustment mechanism includes an inner fastener connecting the fence to the body portion. The inner fastener is parallel to and spaced apart from the outer fastener. The guardrail angle adjustment mechanism includes an adjustment fastener connected to the body portion. The adjustment fastener is perpendicular to and spaced apart from the inner and outer fasteners. Rotation of the adjustment fastener relative to the body portion provides adjustment of the angular orientation of the guardrail about the rotational axis. Additionally, the guardrail angle adjustment mechanism includes an internal resilient member disposed between the guardrail and the body portion, the internal resilient member being configured to bias the guardrail toward a head of the adjustment fastener.

[0004] In some embodiments, the fence angle adjustment mechanism includes an outer resilient member disposed between an interior surface of the fence and an outer end of the body portion.

[0005] In some embodiments, the inner resilient member is positioned between an interior surface of the fence and an inner end of the body portion, and the inner resilient member is positioned on an opposite side of the body portion relative to the outer resilient member.

[0006] In some embodiments, the outer fastener is positioned between the midpoint of the body portion and the outer end of the body portion. The inner fastener serves as a stop and is positioned between the midpoint of the body portion and the inner end of the body portion. Additionally, an adjustment fastener is positioned between the inner fastener and the inner end of the body portion.

[0007] In some embodiments, the adjustment fastener includes a head and a shank, wherein the head is disposed externally of the guardrail. The shank protrudes from the head and extends through the guardrail and engages with the body portion. Additionally, an internal elastic member is disposed between the body portion and the guardrail and surrounds the shank of the adjustment fastener.

[0008] In some embodiments, the outer fastener extends through an outer opening in the fence and engages the body portion, and the outer opening receives the outer fastener in a guided fit.

[0009] In some embodiments, the fence angle adjustment mechanism includes an outer resilient member disposed between an interior surface of the fence and an outer end of the body portion, and the outer resilient member biases the fence against the outer fastener.

[0010] In some embodiments, the inner fastener extends through an inner opening in the fence and engages the body portion, and the inner opening receives the inner fastener with a clearance fit.

[0011] In some embodiments, the fence includes a work surface facing edge facing the work surface of the saw device and an opposing edge opposite the work surface facing edge. The outer fastener and the inner fastener extend through respective outer and inner openings in the opposing edges.

[0012] In some embodiments, the corresponding outer and inner openings in the opposing edges of the fence are aligned along a longitudinal axis of the fence, wherein the longitudinal axis of the fence extends between the fence first end and the fence second end.

[0013] In some embodiments, the fence angle adjustment mechanism includes an outer resilient member disposed between an interior surface of the fence and an outer end of the body portion, and the outer resilient member biases the fence against the outer fastener.

[0014] In some embodiments, the fence assembly includes a cutting axis corresponding to a cutting direction of the blade and a guide axis transverse to the cutting axis and parallel to the rail. The longitudinal axis of the outer fastener is perpendicular to both the cutting axis and the guide axis, and the fence rotational axis is coaxial with the longitudinal axis of the outer fastener.

[0015] In some embodiments, the longitudinal axis of the adjustment fastener extends parallel to the guide axis.

[0016] In some embodiments, the fence includes a first side perpendicular to the working surface and facing the blade, and a second side opposite the first side. At least one of the first side and the second side includes a recess, and the head of the adjustment fastener is seated in the recess.

[0017] In some embodiments, the fence includes: an edge facing the work surface, which faces the work surface of the saw device; and an opposite edge, which is opposite to the edge facing the work surface, the opposite edge including a recess, and the heads of the inner fastener and the outer fastener are disposed in the recess.

[0018] In some aspects, a method is provided for adjusting the position of a guide fence of a saw device relative to parallelism with a cutting blade of the saw device using a fence angle adjustment mechanism. The fence is supported by a track for sliding movement relative to a working surface of the saw device, and opposite ends of the fence are supported on the track via a track-engaging member. The fence angle adjustment mechanism is associated with a housing of the track-engaging member. The fence angle adjustment mechanism includes: an outer fastener connecting the fence to the housing; and an inner fastener connecting the fence to the body housing. The inner fastener is parallel to and spaced apart from the outer fastener. The fence angle adjustment mechanism includes an adjustment fastener connecting the fence to the housing. The adjustment fastener is perpendicular to and spaced apart from the inner and outer fasteners. Rotation of the adjustment fastener relative to the housing provides adjustment of the angular orientation of the fence about a rotational axis. Additionally, the fence angle adjustment mechanism includes an inner elastic member disposed between the fence and the housing. The inner elastic member is configured to bias the fence toward a head of the adjustment fastener. The method includes the following method steps: rotating both the inner fastener and the outer fastener to loosen both the inner fastener and the outer fastener; rotating the adjustment fastener to move the rear portion of the fence, wherein rotation of the adjustment fastener in a first direction moves the fence toward the shell, and rotation of the adjustment fastener in a second direction moves the fence away from the shell, wherein the second direction is opposite to the first direction; after rotating the adjustment fastener, rotating the outer fastener to tighten the outer fastener; and after rotating the outer fastener to tighten the outer fastener, rotating the inner fastener to tighten the inner fastener.

[0019] In some embodiments, the method includes the following method step, performed at least prior to the step of rotating both the inner and outer fasteners to loosen both the inner and outer fasteners: checking the alignment of the fence relative to the blade to determine if adjustment is necessary.

[0020] In some embodiments, the method includes the following method step, performed after the step of rotating the inner fastener to tighten the inner fastener: verifying that the fence is aligned with the blade.

[0021] In some aspects, a fence assembly is configured to guide a workpiece relative to a blade of a saw device. The fence assembly is supported relative to a work surface of the saw device by one or more rails. The fence assembly includes a fence. The fence includes a first end and a second end opposite the first end. The fence assembly includes a first rail-engaging member coupled to the first end of the fence and supported on a first one of the rails. The first rail-engaging member includes a first housing. The first housing has a body portion disposed within the fence and a flange portion. The flange portion extends from an outer end of the body portion, is disposed outside the fence, and is configured to engage the first one of the rails. The fence assembly includes a second rail-engaging member coupled to the second end of the fence and supported on a second one of the rails. The second rail-engaging member includes a second housing and a rail-engaging device configured to engage the second one of the rails. The fence assembly also includes a fence angle adjustment mechanism associated with the first rail-engaging member. The fence angle adjustment mechanism is configured to adjust the position of the fence relative to parallelism with the blade. The fence angle adjustment mechanism includes an outer fastener that connects the fence to the body portion. The outer fastener provides an axis of rotation of the fence during adjustment of the fence relative to parallelism with the blade. The fence angle adjustment mechanism includes an inner fastener that connects the fence to the body portion. The inner fastener is parallel to and spaced apart from the outer fastener. The fence angle adjustment mechanism includes an adjusting fastener that is connected to the body portion. The adjusting fastener is perpendicular to and spaced apart from the inner and outer fasteners. Rotation of the adjusting fastener relative to the body portion provides adjustment of the angular orientation of the fence about the axis of rotation. In addition, an inner elastic member is disposed between the fence and the body portion, and the inner elastic member is configured to bias the fence toward the head of the adjusting fastener.

[0022] In some aspects, a table saw fence includes a mechanism that allows the fence to be adjusted to achieve parallelism with the blade of the table saw. The mechanism applies a biasing force to the fence that works in conjunction with a set screw to fine-tune the fence's adjustment relative to the blade. The blade fence angle can be adjusted without losing reference to the previous position. Additionally, fine adjustments can be made without the risk of overcorrection.

[0023] A method for using a fence angle adjustment mechanism is also provided. By using this method, the position of the fence can be finely adjusted so that the guide surface of the fence is parallel to the blade. As a result, the fence enables the table saw to provide accurate, straight, and reproducible cuts. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 is a perspective view of a portion of a saw assembly showing the table top and fence assembly.

[0025] Figure 2 is a side view of the saw table top and fence assembly.

[0026] Figure 3 Is like along Figure 1 A cross-sectional view of the saw table top and fence assembly as viewed through line 3-3.

[0027] Figure 4 yes Figure 3 is surrounded by a dotted line and marked as " Figure 4 "An enlarged view of this part.

[0028] Figure 5 yes Figure 3 is surrounded by a dotted line and marked as " Figure 5 "The enlarged view of this part. Figure 5 , solid lines are used to show the handle and pivot pin in a first position, and dashed lines are used to show the handle and pivot pin in a second position.

[0029] Figure 6 This is an exploded perspective view of the fender assembly.

[0030] Figure 7 is a perspective view of the fender isolated from the fender assembly.

[0031] Figure 8 is a top perspective view of the tensioning mechanism of the fence assembly.

[0032] Figure 9 is a bottom perspective view of the tensioning mechanism of the sidewall assembly.

[0033] Figure 10 Is like along Figure 8 A cross-sectional view of the tensioning mechanism of the fence assembly as seen through line 10-10.

[0034] Figure 11 It is a front perspective view of the sliding mechanism of the fence assembly.

[0035] Figure 12 It is an exploded front perspective view of the sliding mechanism of the fence assembly.

[0036] Figure 13 It is a rear perspective view of the sliding mechanism of the tailgate assembly.

[0037] Figure 14 This is an exploded perspective view of the sliding mechanism of the fence assembly.

[0038] Figure 15 Another rear perspective view of the sliding mechanism of the tailgate assembly.

[0039] Figure 16 Is like along Figure 11A cross-sectional view of the sliding assembly as seen along line 16-16.

[0040] Figure 17 Is like along Figure 1 A cross-sectional view of the tailgate assembly as viewed along line 17-17.

[0041] Figure 18 It is a front perspective view of the handle.

[0042] Figure 19 This is a rear perspective view of the handle.

[0043] Figure 20 is a first perspective view of the cam.

[0044] Figure 21 is a second perspective view of the cam.

[0045] Figure 22 It is a rear perspective view of the cam assembled on the handle.

[0046] Figure 23 This is an exploded perspective view of the cam assembled on the handle.

[0047] Figure 24 It is a cross-sectional view of a portion of the fence assembly with the fence and the sliding mechanism cover omitted.

[0048] Figure 25 is another cross-sectional view of a portion of the fence assembly with the fence and sliding mechanism cover omitted.

[0049] Figure 26 is another cross-sectional view of a portion of the fence assembly with the fence and the sliding mechanism cover omitted.

[0050] Figure 27 is a side view of a portion of a fence assembly with the fence omitted, showing the fence tension adjustment mechanism in a first position.

[0051] Figure 28 is a side view of a portion of the fence assembly with the fence omitted, showing the fence tension adjustment mechanism in a second position.

[0052] Figure 29 is an end view of the fence assembly with the front cover, handle and tension adjustment mechanism omitted, illustrating the fence angle adjustment mechanism.

[0053] Figure 30 is a perspective cross-sectional view of the fence assembly with the front cover, handle, and tension adjustment mechanism omitted, illustrating the fence angle adjustment mechanism.

[0054] Figure 31 The tension member is omitted as follows Figure 30A perspective cross-sectional view of the fender assembly as viewed along line 31-31.

[0055] Figure 32 The tension member is omitted as follows Figure 30 A perspective cross-sectional view of the fence assembly as viewed along line 32-32.

[0056] Figure 33 The tension member is omitted as follows Figure 30 A perspective cross-sectional view of the fender assembly as viewed along line 33-33.

[0057] Figure 34 The tension member is omitted as follows Figure 30 A perspective cross-sectional view of the fender assembly as viewed along line 34-34.

[0058] Figure 35 is a perspective view of the outer end portion of the front housing, showing a portion of the fence angle adjustment mechanism.

[0059] Figure 36 is a perspective view of the inner end portion of the front housing, showing a portion of the fence angle adjustment mechanism.

[0060] Figure 37 is a schematic diagram of one end of a rail assembly illustrating the rail angle adjustment mechanism.

[0061] Figure 38 is a flow chart illustrating a method of adjusting the position of a guide fence of a saw device relative to parallelism with a cutting blade of the saw device using a fence angle adjustment mechanism. DETAILED DESCRIPTION

[0062] refer to Figures 1 to 7The saw device 1 includes a saw table top 2 and a fence assembly 30 supported on the saw device 1 such that a fence 32 overlies the saw table top 2 and extends parallel to a cutting blade 8 of the saw device 1. The saw device 1 illustrated in the figures is, for example, a table saw, although in other embodiments the saw device 1 may be configured as another type of cutting tool in which the fence assembly is used to position a workpiece (not shown) on a surface relative to the blade 8. The saw table top 2 is part of a saw table or cabinet structure (not shown) and defines a flat work surface 5 for supporting a workpiece. The saw table top 2 includes an opening 6. A blade 8 (e.g., a circular saw blade) of the saw device 1 protrudes through the opening 6, and an insert 9 is positioned in the opening 6 between the blade and the work surface 5. A motor (not shown) is positioned within the cabinet of the saw device 1 and is configured to rotate the blade 8 within the opening 6. The saw table top 2 has a pair of rails 20, 22 configured to orient the fence assembly 30 relative to the blade when positioned on the saw table top 2. The fence assembly 30 includes a fence 32, a sliding mechanism 52 located at a first end 34 of the fence 32, and a tensioning mechanism 82 located at a second end 36 of the fence 32. The fence assembly 30 includes a handle 140 that pivots between a locked position, in which the fence assembly 30 is fixed relative to the saw table top 2, and a released position, in which the fence assembly 30 is free to slide relative to the saw table top 2 along the rails 20, 22. The handle 140 is supported on the sliding mechanism 52 via a cam 200. The fence assembly 30 includes a link in the form of a tension member 120 that extends between the handle 140 and the tensioning mechanism 82. The cam 200 is part of a fence tension adjustment mechanism 190 that is configured to adjust the tension of the tension member 120. Additionally, the fence assembly 30 includes a fence angle adjustment mechanism 300 that is configured to adjust the position of the fence 32 so that the guide surface 44 of the fence 32 is parallel with the blade 8. The fence assembly 30 including the fence angle adjustment mechanism 300 will be described in detail below. A method of using the fence angle adjustment mechanism 300 will also be described in detail below.

[0063] The pair of rails 20, 22 are configured to support the fence assembly 30 relative to the saw table top 2 and include a first rail 20 and a second rail 22. The first rail 20 is located on one edge (e.g., the front edge) of the saw table top 2, and the second rail 22 is located on the opposite edge (e.g., the rear edge) of the saw table top 2. In some embodiments, the rails 20, 22 are integrally formed with the saw table top 2. In other embodiments, the rails 20, 22 are formed as separate parts, each of which is coupled to the saw table top 2 at an appropriate location. The rails 20, 22 are constructed of a rigid material (such as metal or plastic). The first rail 20 and the second rail 22 have the same shape, and the shape of the rails 20, 22 enables the fence assembly 30 to be easily attached to and removed from it. The shape of the rails 20, 22 also allows the fence assembly 30 to slide across the working surface 5 of the saw table top 2 for positioning by a user of the saw device 1.

[0064] The rails 20, 22 in the illustrated embodiment have a continuous outer surface such that the outer surface is formed without grooves or cavities that are typical of known rails. The outer surface includes a flat upper surface 24 for supporting the weight of the fence assembly 30 and flat side surfaces 26 to which the fence assembly 30 is clamped to attach the fence assembly 30 to the saw table top 2 ( Figure 3 ). The upper surface 24 is oriented substantially parallel to the working surface 5 of the saw table. The lateral surfaces 26 in some embodiments are oriented substantially orthogonal to the cutting direction 10, although in other embodiments the lateral surfaces 26 have a negative angle. As used herein, a lateral surface having a negative angle means that the lateral surface 26 has a flat orientation that imparts a downward force on the cooperating surfaces of the fence assembly 30 when the fence assembly 30 is arranged on the rails 20, 22 of the saw table top 2. The imparted downward force is configured to cause other surfaces of the fence assembly 30 to be urged downwardly against other surfaces of the saw table top 2 and the rails 20, 22. The interior regions of the rails 20, 22 can be solid (as shown), hollow, or include any structure that improves the manufacturability, strength, and / or durability of the rails. The rails 20, 22 traverse the width of the saw table top 2 and define a guide axis 28 that is substantially perpendicular to the cutting direction 10 of the blade 8. The fence assembly 30 is positionable relative to the blade 8 along the guide axis 28.

[0065] Railing 32( Figure 7) is configured to guide a workpiece on the saw table top 2 and position the slide mechanism 52 and the tensioning mechanism 82 relative to each other. The fence 32 is formed from a channel member or profile that, in some embodiments, defines an interior space for accommodating or positioning other components of the fence assembly. For example, in some embodiments, the fence is an elongated hollow aluminum extrusion. The fence 32 includes a longitudinal axis 37 extending between a first fence end 34 and a second fence end 36.

[0066] The fence includes side portions 44, 46 extending between the fence first end 34 and the fence second end 36. The first side portion 44 faces the blade 8 and defines a substantially flat guide surface for guiding the workpiece. When the fence assembly 30 is accurately positioned relative to the blade 8, the side portion 44 provides a flat guide surface that is substantially parallel to the cutting direction 10 of the blade to provide accurate cutting of the workpiece. In use, the workpiece rests on the saw table working surface 5 while adjacent to the guide surface (e.g., the side portion 44). The workpiece is cut by advancing the workpiece against the blade 8, which includes sliding the workpiece on the saw table working surface 5 and along the side portion 44.

[0067] The second side portion 46 faces away from the blade and is spaced apart from the first side portion 44. Elongated side grooves 45, 47 are provided in the first and second side portions 44, 46. In the illustrated embodiment, the side grooves 45, 47 extend between the fence first end 34 and the fence second end 36.

[0068] The fence includes an edge 42 facing the work surface 5 and an opposite edge 40 facing away from the work surface 5. Figure 1 , the edge 42 facing the work surface corresponds to the bottom edge of the fence 32, while the opposing edge 40 corresponds to the top edge of the fence 32. The fence edges 40, 42 join the first side portion 44 to the second side portion 46. Elongated edge grooves 35, 41 are provided in the bottom edge 42 and the top edge 40. In the illustrated embodiment, the edge grooves 35, 41 extend between the fence first end 34 and the fence second end 36, and the edge groove 35 provided in the bottom edge 42 has a larger cross-sectional area than the edge groove 41 provided in the top edge 40. The edge groove 35 provided in the bottom edge 42 defines a hollow interior space 48 of the fence 32 and receives a portion of the sliding mechanism 52 therein, as discussed below.

[0069] refer to Figure 4 and Figures 8 to 10The tensioning mechanism 82 cooperates with the slide mechanism 52 and the handle 140 to apply tension to the tension member 120, which causes the fence assembly 30 to be clamped to the saw table top 2. The tensioning mechanism 82 includes a rear housing 84 fixed to the fence second end 36 and a lever 100 pivotally attached to the rear housing 84 at its first end 102 via a lever pivot pin 108. In addition, the tensioning mechanism includes a wheel 114 rotatably secured to the second end 104 of the lever 100, wherein the second end 104 is opposite the lever first end 102.

[0070] Rod 100 is a rigid structure having a rectangular cross-section and further includes a rod opening 110 that receives a tension member 120. Rod opening 110 is positioned approximately midway between rod first end 102 and rod second end 104. Tension member 120 is coupled to rod 100 via a pivot pin 109 that extends through rod 100 at a location corresponding to rod opening 110.

[0071] The wheels 114 are secured to the rod second end 104 for rotation about a wheel rotation axis 118 provided by a fastener 116 threaded into the rod 100. The wheel rotation axis 118 is parallel to the longitudinal axis 105 of the rod 100, wherein the rod longitudinal axis 105 extends between the rod first end 102 and the rod second end 104. In this configuration, the wheels 114 are oriented for rolling contact with the lateral surfaces 26 of the track 22 as the fence assembly 30 moves along the guide axis 28. Figure 4 , the wheel 114 has a spherical profile 119 when viewed in a plane passing through and aligned with the wheel rotation axis 118. The spherical profile 119 allows freedom in the angular orientation of the wheel rotation axis 118 relative to the contact angle of the rails 20, 22 to enable linear rolling during movement of the fence assembly 30 along the guide axis 28.

[0072] The rear housing 84 is configured to cover the rear end surface 39 of the fence 32. The rear housing 84 includes a cap portion 86 that encloses the rear end surface 39 of the fence 32, and a guide block portion 88 that projects from the cap portion 86 toward the saw table top 2 and is configured to be supported on and slide relative to the upper surface 24 of the rear rail 22. Furthermore, the rear housing 84 includes a housing stop portion 90 depending from the cap portion 86. The housing stop portion 90 faces the rear rail lateral surface 26 and is spaced therefrom. Furthermore, the wheel 114 is positioned between the housing stop portion 90 and the rear lateral surface 26. While there is sufficient space between the wheel 114 and the housing stop portion 90 for the wheel 114 to rotate freely about the wheel rotation axis 118, the housing stop portion 90 limits the range of movement of the wheel 114 away from the rear lateral surface 26. The rear housing 84 includes a central through-opening 92 defined within both the cap portion 86 and the guide block portion 88. The central through-opening 92 is shaped and sized to permit the lever 100 to pivot through the arc length defined between the rear rail lateral surface 26 and the housing stop portion 90 .

[0073] The guide block portion 88 of the rear housing 84 is positioned on the lower portion of the fence 32 proximate the fence second end 36. The guide block portion 88 projects inwardly from the cap portion 86 and has a flat lower surface 89 that is oriented substantially parallel to the upper surface 24 of the track 22. In the illustrated embodiment, the guide block portion 88 is configured to support the weight of the fence assembly 30 on the track 22 and provide a low resistance to movement as the fence assembly 30 moves along the guide axis 28. In other embodiments, the lower surface of the fence 32 may support the weight of the fence assembly 30 across the saw table top 2 and provide a low resistance to movement as the fence assembly 30 moves along the guide axis 28.

[0074] refer to Figure 5 and Figures 11 to 16 The sliding mechanism 52 includes a front housing 54 disposed at the first end 34 of the fence, and a cap 51 that closes the front face 38 of the fence 32. The cap 51 includes an elongated slot 53 that receives and allows rotational movement of the handle 140 relative to the cap 51 and the sliding mechanism 52.

[0075] The front housing 54 is a rigid structure having a T-shaped profile when viewed facing the saw table top 2. The front housing 54 includes a body portion 56 and a flange portion 58. The body portion 56 is elongated in a direction parallel to the cutting direction 10 and is disposed in the hollow interior 48 of the fence 32. In particular, the body portion 56 is shaped and sized to be received in the fence hollow interior 48 with a clearance fit and is coupled to the first end 34 of the fence 32 using fasteners 302, 312. Additionally, a side surface of the body portion 56 includes a groove 66 that extends in a direction parallel to the cutting direction 10 and opens at each end 67, 68 of the body portion 56. The groove 66 provides for receiving the tension member 120 ( Figure 16 ). The end 68 of the body portion 56 closest to the fence first end 34 and the front rail 20 (hereinafter referred to as the "outer end 68") includes a circular cutout 64 that rotatably supports the fence tension adjustment mechanism 190, as discussed further below. The end 67 of the body portion 56 farthest from the fence first end 34 and the front rail 20 is hereinafter referred to as the "inner end 67."

[0076] The flange portion 58 is disposed at an outer end 68 of the body portion 56. The flange portion 58 integrally extends from a surface of the body portion 56 that faces the saw table top and extends bilaterally from the body portion 56 along the guide axis 28. The flange portion 58 includes rail-facing surfaces 69, 70 that are shaped and dimensioned to face and engage the upper surface 24 and the lateral surfaces 26 of the first rail 20. For example, the flange portion 58 has a flat lower surface 69 and flat lateral surfaces 70 that adjoin the lower surface 69. The lower surface 69 of the flange portion 58 is oriented substantially parallel to the upper surface 24 of the rails 20, 22. The orientation of the lateral surfaces 70 of the flange portion 58 substantially corresponds to the orientation of the lateral surfaces 26 of the rails 20, 22. In use, when the handle 140 is in the locked position, the body portion 56 and the flange portion 58 are fixed relative to the fence 32 to establish alignment of the fence 32 relative to the blade via the slide mechanism 52.

[0077] The rail-facing surfaces 69, 70 each include a pair of sliding contacts 60 that are bilaterally spaced laterally from the fence 32 along the guide axis 28. In the illustrated embodiment, the sliding contacts 60 are positioned proximate the end of each of the rail-facing surfaces 69, 70. However, in other embodiments, the sliding contacts 60 may be positioned inward from the end of each of the rail-facing surfaces 69, 70, or in other positions suitable for facilitating sliding movement of the flange portion 58 along the first rail 20.

[0078] In the illustrated embodiment, the sliding contact 60 is formed separately from the flange portion 58 and is directly attached to the flange portion 58 by fasteners, adhesives, etc. The sliding contact 60 may be formed of a polymer material, such as ultra-high molecular weight polyethylene (UHMW) or In other embodiments, the sliding contacts 60 are defined by the flange portion 58 such that the sliding contacts are integrally formed from the material of the flange portion 58. The pairs of sliding contacts 60 each establish two distinct contact points between the fence assembly 30 and corresponding rails 20, 22 of the saw table top 2 to facilitate alignment of the fence assembly 30 relative to the blade. The sliding mechanism 52 is positioned in front of the saw table top 2 such that the two pairs of sliding contacts 60 cooperate with the rails 20 that are positioned closest to the user of the saw device 1.

[0079] refer to Figures 3 to 5 , the tension member 120 is an elongated rigid rod that operatively couples the sliding mechanism 52 to the tensioning mechanism 82. In the illustrated embodiment, the tension member 120 has a rectangular cross-sectional shape and is uniformly sized along its length. The tension member 120 has a first end 124 that is connected to the handle 140 via a pivot pin 160. The pivot pin 160 defines an axis of rotation of the tension member first end 124 relative to the handle 140. This axis of rotation is hereinafter referred to as the tension member connection axis 132, as discussed further below. The tension member 120 has a second end 126 opposite the first end 124. The tension member second end 126 includes an elongated through-hole (e.g., a slot) 128 that receives the pivot pin 109, whereby the tension member second end 126 is pivotally coupled to the rod 100. In use, the tension member 120 is disposed within the fence 32 and, in certain positions of the handle 140 , transmits tension from the slide mechanism 52 to the tensioning mechanism 82 , as discussed further below.

[0080] refer to Figure 5 、 Figures 18 and 19 and Figures 22 to 23 The handle 140 is supported on the front housing 54 via the cam 200. The handle 140 includes a first handle end 142 coupled to the tension member 120; a second handle end 144 opposite the first end 142; and a middle handle portion 146 disposed between the first and second handle ends 142, 144. When the handle 140 is viewed perpendicular to the guide axis 28, the second handle end 144 is wide relative to the first handle end 142 and the middle handle portion 146. The enlarged second handle end 144 is gripped by the user during operation of the handle 140 and has a rectangular shape including a planar outer surface 145 that is generally perpendicular to the side panel portions 44, 46. The handle 140 includes a longitudinal axis 151 that extends through the second handle end 144 and the middle handle portion 146 and is parallel to the outer surface 145 of the second handle end 144.

[0081] When handle 140 is viewed in a direction parallel to guide axis 28, it can be seen that handle first end 142 is offset toward fence 32 relative to handle middle portion and second ends 146, 144. Handle first end 142 has a disc shape with flat side surfaces 147, 149 that are generally parallel to fence side portions 44, 46. Thus, when handle 140 is viewed in a direction parallel to guide axis 28, handle first end 142 has a circular profile 148. Furthermore, handle first end 142 includes a channel 150 that opens along circular profile 148. Channel 150 opens toward fence 32 and extends perpendicular to guide axis 28. Channel 150 is shaped and dimensioned to receive tension member first end 124 and permits free rotation of tension member 120 relative to handle 140 regardless of its position. To this end, tension member 120 is secured to handle first end 142 via a pivot pin 160 that bridges channel 150.

[0082] The handle 140 includes a cylindrical shaft 152 that integrally and bilaterally extends from side surfaces 147, 149 of the handle first end 142. The shaft 152 is centered within the circular profile 148 defined by the handle first end 142 (e.g., the profile of the shaft 152 is concentric with the profile of the handle first end 142). The shaft 152 has a shaft diameter d1 that is smaller than the diameter d2 of the handle first end 142, thereby providing a shoulder 154 on the handle first end 142 that receives the cam 200. The shaft 152 has an outer or circumferential surface 156 that is supported on the inner bearing surface 208 of the cam 200 for rotation about a handle rotation axis 158, as discussed below. The handle rotation axis 158 is offset from the tension member connection axis 132 defined by the pivot pin 160. In the illustrated embodiment, the rotation axis 158 is closer to the fence than the tension member connection axis 132 .

[0083] The handle 140 also includes a recess 164 formed on a fence-facing surface 166 of the handle intermediate portion 146. The recess 164 is shaped and sized to receive the dial 222 of the cam 200, as discussed below. Additionally, a blind opening 168 is provided in the recess 164. The blind opening 168 is configured to engage with a fence tension adjustment screw 240, as discussed below. The handle 140 is operatively coupled to the front housing 54 of the slide mechanism 52 via the cam 200, such that the handle 140 can be rotated about the handle rotation axis 158 relative to the front housing 54 in a first locked position (illustrated using solid lines in FIG. 1 ). Figure 5 ) and a second release position (shown using a dashed line in Figure 5 ).

[0084] In the first position, the handle longitudinal axis 151 is oriented at a first angle θ1 relative to the front housing 54. In the illustrated embodiment, when the handle 140 is at the first angle θ1 relative to the front housing 54, the handle longitudinal axis 151 is oriented substantially vertically, where the term "substantially vertical" means that the first angle θ1 is within plus or minus (+ / -) five degrees of vertical.

[0085] In the first position, the tension member connection axis 132 is positioned outward (eg, further away from the fence 32 ) relative to the handle rotation axis 158 .

[0086] In the first position, a first tensioning force is applied to the rod 100 of the tensioning mechanism 82 by the tensioning member 120. The first tensioning force is sufficient to pull the wheel 114 against the rear rail 22. Additionally, the tensioning member 120 subjects the sliding mechanism 52 to an opposing or reactive force, wherein the flange portion 58 is pulled against the front rail 20 and generates a vertical friction force, whereby the tensioning mechanism 82 generates a clamping force on the saw table top 2 between the wheel 114 and the pairs of sliding contacts 60. The clamping force applies sufficient force to secure the position of the fence assembly 30 along the guide axis 28. In some embodiments, the clamping force is "sufficient force" if it resists movement of the fence assembly 30 when a side load of at least 15 pounds is applied to the fence assembly 30 in the direction of the guide axis 28.

[0087] In the second position, the handle longitudinal axis 151 is oriented at a second angle θ2 relative to the front housing 54. When the handle 140 is at the second angle θ2 relative to the front housing 54, the handle longitudinal axis 151 is oriented within a range of 45 to 90 degrees relative to vertical. In the illustrated embodiment, for example, the second angle t2 is approximately 70 degrees from vertical.

[0088] As the handle 140 rotates from the first position to the second position, the tension member connection axis 132 moves generally upward (e.g., away from the saw table top 2) and inward (e.g., toward the fence 32). In the illustrated embodiment, when the handle 140 is in the second position, the tension member connection axis 132 and the handle rotation axis 158 are located at approximately the same distance from the fence 32. Because the tension member connection axis 132 is moved closer to the fence 32, the tension applied by the tension member 120 to the tensioning and sliding mechanism is reduced relative to the tension applied in the first position. More specifically, in the second position, the tension is sufficiently reduced to allow the fence assembly to easily move along the rails 20, 22, thereby allowing the position of the fence assembly 30 relative to the saw table top 2 to be adjusted.

[0089] refer to Figure 5 、 Figure 12 、 Figure 14 and Figures 20 to 28The fence assembly 30 includes a fence tension adjustment mechanism 190 that is configured to allow a user to finely adjust the fence locking force (e.g., the amount of tension applied by the tension member 120 to the slide mechanism 52 and the tensioning mechanism 82) when the handle is in the first position. Advantageously, the fence tension adjustment mechanism 190 allows a user to compensate for cable stretch, wear-in, or over-tensioning due to, for example, tolerance build-up during manufacturing. The fence tension adjustment mechanism 190 adjusts the effective length of the tension member 120 by increasing or decreasing the effective length. This adjustability allows a user to achieve an optimal balance between locked fence resistance and the force required by the user to apply to the handle 140 to change the handle position.

[0090] The fence tension adjustment mechanism 190 includes a cam 200 that supports the handle 140 for rotation relative to the front housing 54 and a fence tension adjustment screw 240 that secures the cam 200 to the front housing.

[0091] The cam 200 is an assembly comprised of a first annular member 202 and a second annular member 204. The first annular member 202 supports the shaft 152 on one side surface 147 of the handle first end 142, and the second annular member 204 supports the shaft 152 on the other side surface 149 of the handle first end 142. The first annular member 202 is separable from the second annular member 204 to allow assembly with the shaft 152, and in use, the first annular member 202 is keyed to the second annular member 204 so as to rotate in unison therewith.

[0092] Each of the first annular member 202 and the second annular member 204 includes an inner edge that serves as an inner bearing surface 208 that rotatably supports the shaft outer surface 156. Each of the first annular member 202 and the second annular member 204 includes an outer edge that serves as an outer bearing surface 210 that is rotatably supported on the circular cutout 64 of the front housing 54. The outer bearing surface 210 has a circular profile and is centered on the rotation axis 212 of the cam 200. The inner bearing surface 208 has a circular profile, is eccentric relative to the outer bearing surface 210, and is concentric with the handle rotation axis 158.

[0093] The first annular member 202 includes a planar first handle-facing surface 203 that extends between an inner bearing surface 208 and an outer bearing surface 210 of the first annular member 202. When the cam 200 is assembled with the handle 140, the first handle-facing surface 203 abuts the first side surface 147 of the handle first end 142. Additionally, the first annular member 202 includes a first protrusion 216 that projects from the first handle-facing surface 203 toward the second annular member 204. The first protrusion 216 has an outwardly facing surface that is curved and flush with a portion of the outer bearing surface 210 of the first annular member 202.

[0094] Similarly, the second annular member 204 includes a flat second handle-facing surface 205 that extends between an inner bearing surface 208 and an outer bearing surface 210 of the second annular member 204. When the cam 200 is assembled with the handle 140, the second handle-facing surface 205 abuts the second side surface 149 of the handle first end 142. Additionally, the second annular member 204 includes a second protrusion 218 that projects from the second handle-facing surface 205 toward the first annular member 202. The second protrusion 218 has an outwardly facing surface that is curved and flush with a portion of the outer bearing surface 210 of the second annular member 204.

[0095] The second protrusion 218 includes a notch 220 that is open toward the first annular member 202 and is shaped and sized to receive the first protrusion 216. When the cam 200 is assembled with the handle 140, the first protrusion 216 is seated in the notch 220, whereby the first annular member 202 is keyed to the second annular member 204. The second protrusion 218 also includes a depending leg that serves as a dial 222. The dial 222 extends radially outward from the second protrusion 218 (e.g., away from the handle first end 142). When the cam 200 is assembled with the handle 140, the dial 222 faces the handle intermediate portion 146 and is aligned with the recess 164. The dial 222 includes a through-opening 224 that is configured to receive the fence tension adjustment screw 240 therethrough. More specifically, the through opening 224 is slidably engaged with the fence tension adjustment screw 240 , causing the dial 222 to move in unison with the axial position of the fence tension adjustment screw 240 .

[0096] Cam 200 is formed of a low friction material to facilitate rotation of cam 200 relative to front housing 54 and rotation of shaft 152 relative to cam inner bearing surface 208. For example, in some embodiments, cam 200 is formed of ultra-high molecular weight (UHMW) polyethylene (PE).

[0097] The fence tension adjustment screw 240 includes a head 242 and a threaded shank 244 extending from one end of the head 242. The threads of the shank 244 are shaped and sized to engage corresponding threads provided in a blind opening 168 located in the recess 164 of the handle intermediate portion 146. In this position, the fence tension adjustment screw 240 is located below the cam rotation axis 212.

[0098] The fence tension adjustment screw 240 is configured to adjust the rotational orientation of the cam 200 relative to the front housing 54. Specifically, adjusting the position of the fence tension adjustment screw 240 relative to the front housing 54 (e.g., by rotating the fence tension adjustment screw 240 relative to the opening 168) causes the dial 222 to move relative to the front housing 54. In turn, the movement of the dial 222 causes the rotational orientation of the cam 200 relative to the front housing 54 to change. In this regard, the cam 200 can be rotated relative to the front housing 54 via adjustment of the fence tension adjustment screw 240. Because the handle shaft 152 is eccentrically supported on the inner bearing surface 208 of the cam 200 relative to the cam rotation axis 212, changes in the rotational orientation of the cam 200 alter the position of the tension member connection axis 132 relative to the fence 32. In other words, changes in the rotational orientation of the cam 200 result in an increase or decrease in the effective length of the tension member 120.

[0099] Reducing the effective length of the tension member 120 results in an increase in the tension applied by the tension member 120. This is accomplished by rotating the fence tension adjustment screw 240 into the threaded opening 168, which moves the dial 222 closer to the front housing 54 ( Figure 27 ). This increased tension correlates to an increased locking force at the rear of the fence assembly 30 when the handle 140 is in the first locked position. The increased tension increases the effective drag on the handle 140 and requires increased input force from the user to operate the handle 140. This adjustment can be made to account for cable stretch, wear-in, etc. within the fence assembly 30.

[0100] Increasing the effective length of the tension member 120 has the opposite effect. That is, increasing the effective tension length reduces the tension applied by the tension member 120. This is accomplished by rotating the fence tension adjustment screw 240 out of the threaded opening 168, which moves the dial 222 away from the front housing 54 ( Figure 24 and Figure 28 ). This results in a reduced locking force at the rear rail 22, but also results in a reduced input force from the user to operate the handle 140. Such an adjustment may be made, for example, when tension adjustments have been made excessively and the resulting force required to operate the handle 140 becomes unreasonable for the user.

[0101] Cam 200 is capable of rotating within the fence assembly 30 within a range of at least 5 degrees and no more than 90 degrees. The tension member first end 124 is connected with some degree of rotational freedom to a location within cam 200 but eccentric to the cam's rotational axis 212. Thus, rotation of cam 200 acts as a lever to reposition the tension member connection axis 132. The greater the distance from the tension member connection axis 132 to the cam's rotational axis 212, the greater the change in position for a given degree of adjustment angle. A greater degree of adjustment angle also results in a greater change in position. A simple mechanical lever is implemented around the pivot point serving as the cam's rotational axis 212, with the two balanced ends of the lever being the locations of the tension member connection axis 132 and the actuation point of the cam 200, e.g., the location of the fence tension adjustment screw 240. As the distance between the location of the fence tension adjustment screw 240 and the tension member connection axis 132 increases, the force required to adjust the tension decreases. The location of the tension member connection axis 132 is important because eccentric tension induces a rotational torque on the adjustment member. The cam 200 is configured to support any torque induced by the tensile force.

[0102] Once an adjustment has been made to the rotational orientation of the cam 200 relative to the front housing 54, the fence tension adjustment screw 240 is used to secure (e.g., fix) the cam 200 to the front housing 54 in the desired cam rotational orientation, and the handle 140 can be moved between a first handle position and a second handle position relative to the fixed cam 200.

[0103] Because the fence tension adjustment screw 240 is positioned between the handle 140 and the front housing 54, it is located behind the handle 140 when the fence assembly 30 is viewed by a user of the saw device 1. Placing the fence tension adjustment screw 240 in this position prevents adjustment of the cam's rotational orientation when the fence assembly 30 is in the locked state and tension is high. When the fence assembly 30 is in the unlocked state and the handle 140 is in the second position, the fence tension adjustment screw 240 is exposed, thereby allowing adjustment of the cam's rotational orientation and, therefore, the tension of the tension member 120, as discussed below. In the unlocked state, tension is much lower and adjustment is easier. This configuration allows the fence tension adjustment mechanism 190 to function without having to operate under higher loads and, therefore, to be more compact due to lower strength requirements.

[0104] Because the fence tension adjustment mechanism 190, including the cam 200, and the fence tension adjustment screw 240 are disposed on the front housing 54, a user standing in front of the saw device 1 can easily access the fence tension adjustment mechanism 190. Furthermore, the fence tension adjustment mechanism 190 can be used to adjust the tension of the tension member 120 without removing the fence assembly 30 from the saw table top 2.

[0105] refer to Figures 29 to 37 The fence angle adjustment mechanism 300 is associated with the slide mechanism 52 and is configured to adjust the position of the fence 32 relative to parallelism with the blade 8. In particular, the fence angle adjustment mechanism 300 is configured to change the angle of the fence longitudinal axis 37 relative to the cutting direction 10 so that the fence 32 is parallel thereto. The fence angle adjustment mechanism 300 includes: an outer fastener 302 and an inner fastener 312 that connect the fence 32 to the body portion 56; resilient members 310, 320 that apply a biasing force on the fence 32; and a fence angle adjustment fastener 322 that is configured to allow controlled and precise adjustment of the position of the fence 32 relative to parallelism with the blade 8. The elements 302, 310, 312, 320, 322 of the fence angle adjustment mechanism 300 will now be described in detail.

[0106] An external fastener 302 extends through an external opening 43 in the top edge of the fence 32 and engages with a threaded external blind hole 50 in the body portion 56. In the illustrated embodiment, the external fastener 302 is, for example, a screw having a head 304 and a threaded shank 306 projecting from the head 304. The external opening 43 is provided in the top edge groove 41 such that the external fastener head 304 is recessed relative to the surface of the fence top edge 40. The external opening 43 is shaped and sized to be a close piloting hole for the external fastener shank 306. In other words, the external opening 43 has a piloting fit relative to the external fastener shank 306, where the term "piloting fit" means that there is little to no clearance between the external opening 43 and the external fastener shank 306, resulting in concentricity between the external fastener shank 306 and the external opening 43. The external blind hole 50 is positioned adjacent to the body portion outer end 57. More specifically, the outer blind hole 50 is positioned between the body portion outer end 57 and the body portion midpoint 55 , which is midway between the body portion outer end 57 and the body portion inner end 59 .

[0107] An inner fastener 312 extends through an inner opening 49 in the top edge of the railing 32 and engages with a threaded inner blind hole 62 in the body portion 56. In the illustrated embodiment, the inner fastener 312 is, for example, a screw having a head 314 and a threaded shank 316 projecting from the head 314. The inner opening 49 is provided in the top edge groove 41 such that the inner fastener head 314 is recessed relative to the surface of the railing top edge 40. The inner opening 49 is shaped and sized to provide a generous clearance hole for the inner fastener shank 316 (e.g., having a substantial clearance fit relative to the inner fastener shank 316), as will be discussed further below. The inner opening 49 is aligned with the outer opening 43 along the railing longitudinal axis 37. The inner blind hole 62 is positioned adjacent to the body portion inner end 59. More specifically, the inner blind hole 62 is positioned between the body portion inner end 59 and the body portion midpoint 55. With this configuration, the inner fastener 312 is spaced apart from the outer fastener 302 , and the inner fastener shank 316 is parallel to the outer fastener shank 306 .

[0108] The outer resilient member 310, for example, is a Belleville washer and is positioned between the body portion outer end 57 and the outer fastener 302. Furthermore, the outer resilient member 310 is positioned between the inner surface 31 of the fence 32 and the body portion 56. Specifically, the outer resilient member 310 is positioned between the fence first side portion 44 and the side surface of the body portion 56, whereby the outer resilient member 310 exerts a force on the fence inner surface 21 in a direction parallel to the guide axis 28 and toward the blade 8. As a result, the outer opening 43 is biased against the outer fastener shank 306. Because the outer opening 43 is a tight pilot hole and the fence 32 is biased against the outer fastener shank 306, the outer fastener 302 defines a fence rotation axis 33 that extends perpendicular to the cutting direction 10 and the guide axis 28.

[0109] The fence angle adjustment fastener 322 is configured to allow controlled and precise adjustment of the angular orientation of the fence 32 about the fence rotation axis 33. In the illustrated embodiment, the fence angle adjustment fastener 322 is a screw that includes a head 324 disposed on the exterior of the fence 32 and a shank 326 projecting from the head 324. The shank 326 extends through a side opening 29 in the second side portion 46 of the fence 32 and engages with a threaded blind hole 61 in a side of the body portion 56. The blind hole 61 is disposed between the inner blind hole 62 and the body portion inner end 59. As a result, the fence angle adjustment fastener 322 is spaced apart from the inner fastener 302 and the outer fastener 306 so as to be closer to the body portion inner end 59. The side opening 29 is provided in the side groove 47 in the fence second side portion 46 such that the fastener head 324 is recessed relative to the surface of the fence second side portion 46. The shank 326 of the fence angle adjustment fastener 322 is perpendicular to the cutting direction 10 and parallel to the working surface 5 and the guide axis 28. This can be compared to the shank 306 of the outer fastener 302, which is perpendicular to both the cutting direction 10 and the guide axis 28 and coaxial with the rotational axis 33 of the fence 32.

[0110] The inner resilient member 308 cooperates with the fence angle adjustment fastener 322 to adjust the angular orientation of the fence 32 about the fence rotation axis 33. In the illustrated embodiment, in which the inner resilient member 308 is a Belleville washer, the fastener shank 326 extends through the central opening of the inner resilient member 308, thereby enclosing the fence angle adjustment fastener shank 326. In this configuration, the inner resilient member 308 is positioned between the inner fastener 312 and the body portion inner end 59. Furthermore, the inner resilient member 308 is positioned between the interior surface 31 of the fence 32 and the body portion 56. In particular, the inner resilient member 308 is positioned between the fence second side portion 46 and the side surface of the body portion 56. With this configuration, the inner resilient member 308 is positioned on the opposite side of the body portion 56 from the outer resilient member 310 and exerts a force on the fence interior surface 21 in a direction parallel to the guide axis 28 and away from the blade 8. In other words, the inner resilient member 308 biases the fence 32 toward the adjustment fastener head 324 , which is disposed on the exterior of the fence 32 .

[0111] In use, the outer fastener 302 is located in the tightly guided outer opening 43 and defines a rotation axis 33 of the fence 32, which extends perpendicularly to the cutting direction 10 and the guide axis 28. The fence rotation axis 33 is located toward the front of the saw device 1 and provides a rotation point for adjusting the fence 32. In addition, the inner fastener 312, which is offset inwardly relative to the outer fastener 302, serves as a stop to limit the range of angular variation of the fence 32. For example, Figure 37As seen in FIG, inner fastener 312 cooperates with inner opening 49 to limit angular variation to plus or minus θ3. To this end, inner opening 49 has a relatively loose clearance connection to accommodate this range of adjustment angles. Fence angle adjustment fastener 322 is positioned closer to the second end of fence 32 than inner fastener 312, and outer resilient member 310 biases fence 32 toward fastener head 324 and creates tension in fence angle adjustment fastener 322.

[0112] The fence angle adjustment fastener 322 provides controlled adjustment of the fence angular orientation, as rotation of the fence angle adjustment fastener 322 relative to the body portion 56 provides adjustment of the angular orientation of the fence 32 about the fence rotation axis 33. The fineness or degree of controlled adjustment is determined by the selection of threads for the fastener shank 326. Tightening the fence angle adjustment fastener 322 moves the fence 32 toward the corresponding side of the body portion 56. Loosening the fence angle adjustment fastener 322 allows the internal elastic member 320 to move the fence 32 away from the corresponding side of the body portion 56.

[0113] With the fence 32 in the desired position, the torque applied by tightening the outer fasteners 302 and the inner fasteners 312 is opposed by the positive connection at the rotation point for adjusting the fence 32 and by the fence angle adjustment fasteners 322. This prevents shifting of alignment when tightening the connection after adjustment. This is particularly true when the outer fasteners 302 and the inner fasteners 312 are tightened in the order of inner and then outer, as discussed further below.

[0114] refer to Figure 38 , a method of adjusting the position of a guide fence of a saw device relative to parallelism with a cutting blade of the saw device using a fence angle adjustment mechanism will now be described.

[0115] As an initial step, a user of the saw device 1 may determine whether the fence 32 is parallel to the blade 8 by, for example, measuring the alignment of the fence 32 relative to the cutting direction 10 (step 402).

[0116] If it is determined that the fence is parallel to the cutting direction 10, no adjustment is necessary and no further steps are taken. If it is determined that the fence 32 is not parallel to the cutting direction 10, the user proceeds to adjust the position of the fence 32 according to the following method steps.

[0117] To adjust the position of the fence 32, the user must loosen the connection between the fence 32 and the body portion 56 of the front housing 54. This is accomplished by rotating both the inner fastener 312 and the outer fastener 302 to loosen both the inner fastener 312 and the outer fastener 302 (step 404).

[0118] After the inner fasteners 312 and the outer fasteners 302 have been loosened, the fence angle adjustment fastener 322 is rotated to rotate the fence 32 about the fence rotation axis 33 (step 406), thereby moving the fence second end 36 relative to the fence first end 34. In this step, rotation of the fence angle adjustment fastener 322 in a first direction (e.g., clockwise) moves the fence 32 toward the body portion 56, and rotation of the fence angle adjustment fastener 322 in a second direction (e.g., counterclockwise), which is opposite the first direction, moves the fence 32 away from the body portion 56. The fence angle adjustment fastener 322 is rotated until the fence 32 is parallel to the cutting direction 10 (e.g., until the fence longitudinal axis 37, and therefore the fence first side portion 44, are parallel to the cutting direction 10).

[0119] After rotating the fence angle adjustment fastener 322, the outer fastener 302 is rotated to tighten the outer fastener 302 (step 408).

[0120] After rotating the outer fastener 302 to tighten the outer fastener 302 , the inner fastener is rotated to tighten the inner fastener (step 410 ). When this step is completed, the fence 32 is secured to the front housing 54 .

[0121] Performing steps 408 and 410 (eg, tightening the inner fasteners 312 and the outer fasteners 302 ) does not change the position and / or orientation of the fence 32 .

[0122] As a final step, the user of the saw device 1 can check the alignment of the fence 32 relative to parallelism with the blade 8 (as indicated by the cutting direction 10) to verify that the fence 32 is aligned with the blade (step 412). If it is determined that the fence is parallel to the cutting direction 10, no further adjustments are necessary and no further steps are taken. If it is determined that the fence 32 is not parallel to the cutting direction 10, the user can return to step 404.

[0123] The method described in steps 402-412 provides advantages when compared to some conventional methods of adjusting the position of the fence relative to parallelism with the blade 8. For example, in some conventional methods, the screws connecting the fence to the housing are loosened, the position of the fence relative to the housing is adjusted to an aligned state, and the connecting screws are retightened. However, in some cases, the effect of these adjustments is that the initial reference for alignment is lost when the screws connecting the fence to the housing are loosened. This makes it difficult to gauge how much adjustment is required. Furthermore, the fence and housing may shift relative to each other when retightening the connecting screws. This is caused by the difficulty of holding the two parts in relative position while trying to also tighten the screws. Additionally, the torque transferred from the connecting screws can produce movement between the fence and the housing. Each adjustment restarts the process by loosening the connection.

[0124] In contrast, in the method described in steps 402-412, the torque applied by tightening the outer fasteners 302 and inner fasteners 312 is resisted by the positive connection at the rotation point used to adjust the fence 32 and by the fence angle adjustment fasteners 322. This prevents alignment shifts when tightening the connection after adjustment. This is particularly true when the outer fasteners 302 and inner fasteners 312 are tightened in the order of inner and then outer. Without losing reference to the previous position, the angle of the fence longitudinal axis 37 can be adjusted, and fine adjustments can be made without the risk of overcorrection.

[0125] In the illustrated embodiment, the outer elastic member 310 and the inner elastic member 320 are, for example, Belleville washers. However, it should be understood that the outer elastic member 310 and the inner elastic member 320 may have alternative embodiments. For example, in some embodiments, the outer elastic member 310 and the inner elastic member 320 may be different types of springs, such as coil springs, wave springs, leaf springs, or other suitable springs. In other embodiments, the outer elastic member 310 and the inner elastic member 320 may be blocks of closed-cell foam rubber or other suitable materials.

[0126] In the illustrated embodiment, the outer fastener 302 and the inner fastener 312 form a threaded connection to the body portion 56 of the front housing 54. However, it is contemplated that in some embodiments, the outer fastener 302 and the inner fastener 312 may be threaded into nuts that effectively connect the body portion 56 to the fence 32. In still other embodiments, one or both of the outer fastener 302 and the inner fastener 312 may be pins rather than screws. For example, the shank portions 306, 326 of the fasteners 302, 312 may be unthreaded. In some embodiments, the heads 304, 324 may also be omitted.

[0127] Although tension member 120 is described herein as a rectangular rod, tension member 120 is not limited to this configuration. In one example, in some embodiments, tension member 120 may be a cylindrical rod. In another example, in some embodiments, tension member 120 may be a cable. Cables have the benefit of providing flexibility that can accommodate bending induced by friction and maintain a useful degree of freedom in rotating components.

[0128] Although the saw table top 2 of the saw device 1 shown in the illustrated embodiment includes a pair of rails 20, 22, the saw device 1 is not limited to this configuration. For example, in some embodiments, saw devices having only one rail are contemplated. In these cases, locking can be achieved by clamping from the back side of the one rail.

[0129] Although the saw device 1 illustrated in the figures is, for example, a table saw, the saw device is not limited to being a table saw. In other embodiments, the saw device can be, for example, a band saw, a saw blade, or other types of cutting tools in which a fence assembly is used to position a workpiece relative to a blade or other cutting element on a surface.

[0130] Selective illustrative embodiments of a portable table saw and fence assembly including a fence tension adjustment mechanism have been described above in some detail. It should be understood that only the structure necessary to illustrate certain features of the table saw and fence assembly has been described herein. Other conventional structures of the portable table saw and fence assembly, as well as ancillary and auxiliary components, are assumed to be known and understood by those skilled in the art. Furthermore, while working examples of the portable table saw and fence assembly have been described above, the portable table saw and fence assembly are not limited to the working examples described above, and various design variations may be implemented without departing from the portable table saw, fence assembly, and / or fence tension adjustment mechanism as set forth in the claims.

Claims

1. A fence assembly configured to guide a workpiece parallel to a blade of a saw device, the fence assembly being supported by rails relative to a working surface of the saw device, the fence assembly comprising: The guardrail comprises: First end of the guardrail, and a second end of the guardrail, which is opposite to the first end of the guardrail; A track engaging member is coupled to the first end of the fence and supported on the track, the track engaging member comprising a first housing having a a body portion, which is disposed inside the guardrail, and a flange portion extending from an outer end of the body portion disposed exteriorly of the fence and configured to engage the rail; and a fence angle adjustment mechanism associated with the track engaging member, the fence angle adjustment mechanism being configured to adjust the fence alignment to extend parallel to the blade when the fence assembly is supported by the track, the fence angle adjustment mechanism comprising: an external fastener connecting the fence to the body portion, the external fastener providing an axis of rotation for the fence during adjustment of the fence alignment, inner fasteners connecting the guardrail to the body portion, the inner fasteners being parallel to and spaced apart from the outer fasteners, an adjustment fastener connected to the body portion, the adjustment fastener being perpendicular to and spaced apart from the inner and outer fasteners, wherein rotation of the adjustment fastener relative to the body portion provides adjustment of the angular orientation of the fence about the rotational axis, and An internal resilient member is positioned between the fence and the body portion, the internal resilient member being configured to bias the fence toward a head portion of the adjustment fastener.

2. The fence assembly according to claim 1, wherein The fence angle adjustment mechanism includes an outer resilient member disposed between an interior surface of the fence and the outer end of the body portion.

3. The fence assembly according to claim 2, wherein The inner elastic member is positioned between an inner surface of the fence and an inner end of the body portion, and the inner elastic member is positioned on an opposite side of the body portion relative to the outer elastic member.

4. The fence assembly according to claim 1, wherein the outer fastener being disposed between a midpoint of the body portion and the outer end of the body portion; The inner fastener serves as a stop and is positioned between the midpoint of the body portion and the inner end of the body portion; and The adjustment fastener is disposed between the inner fastener and the inner end of the body portion.

5. The fence assembly according to claim 1, wherein The adjustment fastener includes the head and a shank, the head being disposed outside the fence, the shank protruding from the head, extending through the fence and engaging the body portion, and The inner elastic member is positioned between the body portion and the fence and surrounds the shank of the adjustment fastener.

6. The fence assembly according to claim 1, wherein: The outer fastener extends through the outer opening in the fence and engages the body portion, and the outer opening receives the outer fastener in a guided fit.

7. The fence assembly according to claim 6, wherein: The fence angle adjustment mechanism includes an outer resilient member disposed between an interior surface of the fence and the outer end of the body portion, and the outer resilient member biases the fence against the outer fastener.

8. The fence assembly according to claim 1, wherein: The inner fastener extends through the inner opening in the fence and engages the body portion, and the inner opening receives the inner fastener with a clearance fit.

9. The fence assembly according to claim 1, wherein The guardrail comprises: a work surface facing edge facing the work surface of the saw device; and an opposing edge, which is opposite to the edge facing the work surface, and The outer and inner fasteners extend through respective outer and inner openings in the opposing edges.

10. The fence assembly according to claim 9, wherein: The respective outer and inner openings in opposing edges of the fence are aligned along a longitudinal axis of the fence, wherein the longitudinal axis of the fence extends between the fence first end and the fence second end.

11. The fence assembly according to claim 1, wherein: The fence angle adjustment mechanism includes an outer resilient member disposed between an interior surface of the fence and the outer end of the body portion, and the outer resilient member biases the fence against the outer fastener.

12. The fence assembly according to claim 1, comprising: a cutting axis corresponding to a cutting direction of the blade; as well as a guide axis transverse to the cutting axis and parallel to the track, wherein The longitudinal axis of the outer fastener is perpendicular to both the cutting axis and the guide axis, and the rotational axis of the fence is coaxial with the longitudinal axis of the outer fastener.

13. The fence assembly according to claim 12, wherein: The longitudinal axis of the adjustment fastener extends parallel to the guide axis.

14. The fence assembly of claim 1, wherein The guardrail comprises: a first side perpendicular to the working surface and facing the blade; and a second side opposite to the first side, At least one of the first side and the second side includes a recess, and The head of the adjustment fastener is seated in the recess.

15. The fence assembly of claim 1, wherein The guardrail comprises: a work surface facing edge facing the work surface of the saw device; and an opposite edge, which is opposite to the edge facing the work surface, The opposing edges include recesses, and The heads of the inner fastener and the outer fastener are seated in the recess.

16. A method of adjusting the alignment of a guide fence of a saw device to extend parallel to a cutting blade of the saw device using a fence angle adjustment mechanism, The fence is supported by a track for sliding movement relative to the working surface of the saw device, and opposite ends of the fence are supported on the track via a track engaging member, the fence angle adjustment mechanism being associated with a housing of the track engaging member, The fence angle adjustment mechanism includes: external fasteners connecting the fence to the housing, an inner fastener connecting the fence to the housing, the inner fastener being parallel to and spaced apart from the outer fastener, an adjustment fastener connecting the fence to the housing, the adjustment fastener being perpendicular to and spaced apart from the inner and outer fasteners, wherein rotation of the adjustment fastener relative to the housing provides adjustment of the angular orientation of the fence about an axis of rotation, and an inner resilient member disposed between the fence and the housing, the inner resilient member being configured to bias the fence toward the head of the adjustment fastener, The method comprises the following method steps: rotating both the inner fastener and the outer fastener to loosen both the inner fastener and the outer fastener; rotating the adjustment fastener to move a rear portion of the fence, wherein rotation of the adjustment fastener in a first direction moves the fence toward the housing and rotation of the adjustment fastener in a second direction moves the fence away from the housing, wherein the second direction is opposite the first direction, and wherein during the step of rotating the adjustment fastener, the fence moves into alignment with the cutting blade; After rotating the adjustment fastener, rotating the outer fastener to tighten the outer fastener; After rotating the outer fastener to tighten the outer fastener, rotating the inner fastener to tighten the inner fastener.

17. The method according to claim 16, comprising the following method steps performed at least before the step of rotating both the inner fastener and the outer fastener to loosen both the inner fastener and the outer fastener: Check the alignment of the fence relative to the blade to determine if adjustment is necessary.

18. The method according to claim 16, comprising the following method steps performed after the step of rotating the inner fastener to tighten the inner fastener: Verify that the fence is aligned with the blade.

19. A fence assembly configured to guide a workpiece parallel to a blade of a saw device, the fence assembly being supported relative to a working surface of the saw device by one or more rails, the fence assembly comprising: The guardrail comprises: First end of the guardrail, and a second end of the guardrail, which is opposite to the first end of the guardrail; a first track-engaging member coupled to the fence first end and supported on a first one of the tracks, the first track-engaging member comprising a first housing having: a body portion, which is disposed inside the guardrail, and a flange portion extending from an outer end of the body portion disposed exteriorly of the fence and configured to engage the first of the rails; a second track engaging member coupled to the fence second end and supported on a second one of the tracks, the second track engaging member comprising: a second housing; and a track engaging device configured to engage the second one of the tracks; and a fence angle adjustment mechanism associated with the first rail engaging member, the fence angle adjustment mechanism being configured to adjust the fence alignment to extend parallel to the blade when the fence assembly is supported by the rail, the fence angle adjustment mechanism comprising: external fasteners connecting the fence to the body portion, the external fasteners providing an axis of rotation for the fence during alignment of the fence, inner fasteners connecting the guardrail to the body portion, the inner fasteners being parallel to and spaced apart from the outer fasteners, an adjustment fastener connected to the body portion, the adjustment fastener being perpendicular to and spaced apart from the inner and outer fasteners, wherein rotation of the adjustment fastener relative to the body portion provides adjustment of the angular orientation of the fence about the rotational axis, and An internal resilient member is positioned between the fence and the body portion, the internal resilient member being configured to bias the fence toward a head portion of the adjustment fastener.

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