Table saw with sliding table and floating carriage

Abstract

A table saw comprises a base table, a sliding table, and a carriage. The base table includes a first and a second guide rail. The sliding table is configured for movement relative to the base table. The sliding table includes a third guide rail and a fourth guide rail. The carriage comprises a support frame and at least four rollers configured for rotation relative to the support frame about corresponding axes of rotation. A first and a second roller of the at least four rollers are configured to accommodate the first and third guide rails, and a third and a fourth roller of the at least four rollers are configured to accommodate the second and fourth guide rails. The axes of rotation are substantially parallel. The carriage is configured for movement relative to both the base table and the sliding table.

Description

Area

[0001] This disclosure relates to the field of table saws and in particular to the support of a sliding table of a table saw. background

[0002] Numerous machine tools have been developed to enable the shaping of a workpiece into a desired form. One such machine tool for shaping a workpiece is the table saw. Craftsmen typically use table saws for crosscutting and rip-cutting workpieces, such as hardwood, wood products, lumber, and other materials. Table saws are available as portable or workstation units and as non-portable or stationary table saws.

[0003] Most table saws include a workpiece support surface and a cutting blade that extends through an opening in the support surface. The support surface is generally a flat surface on which a user positions the workpiece for cutting. The cutting blade, usually a circular saw blade, is configured to rotate by an electric motor located beneath the support surface. An upper portion of the blade extends through the opening in the support surface above the support surface and is configured to make contact with the workpiece. A riving knife is positioned behind the saw blade and moves along a kerf in the workpiece to prevent the workpiece from binding during a cutting operation.

[0004] The workpiece support surface on some table saws is partially defined by a sliding table section to the left of the saw blade. This sliding table section is movable relative to the saw blade and is used to support the workpiece during a cutting operation. This means that the sliding table and the workpiece are moved past the saw blade to make a cut in the workpiece. The sliding table should glide smoothly back and forth with relatively little effort. Furthermore, there should be minimal lateral play in the sliding table to ensure that the saw blade makes an accurate cut.

[0005] Known systems for supporting the sliding table do not offer sufficient cutting capacity as desired by some users. Cutting capacity is the maximum width or length of a workpiece that can be supported by the sliding table and cut by the saw blade. It is based on the distance the sliding table can be moved away from the saw blade.

[0006] Based on the above, improvements are desired that increase the cutting capacity of table saws with sliding tables and that also support the sliding table with sufficient rigidity so that the saw blade makes accurate cuts in the workpiece. Brief description

[0007] According to an exemplary embodiment of the disclosure, a table saw comprises a base table, a sliding table, and a carriage. The base table comprises a first guide rail and a second guide rail. The sliding table is configured for movement relative to the base table. The sliding table comprises a third guide rail and a fourth guide rail. The carriage comprises a support frame and at least four rollers configured for rotation relative to the support frame about corresponding axes of rotation. A first roller and a second roller of the at least four rollers are configured to accommodate the first guide rail and the third guide rail, and a third roller and a fourth roller of the at least four rollers are configured to accommodate the second guide rail and the fourth guide rail. The axes of rotation are substantially parallel.The carriage is configured for movement relative to the base table and the sliding table.

[0008] According to a further exemplary embodiment of the disclosure, a table saw comprises a base table, a sliding table, and a carriage. The base table comprises a first guide rail and a second guide rail. The sliding table is configured for movement relative to the base table. The sliding table comprises a third guide rail and a fourth guide rail. The carriage comprises a first cross member, a second cross member operatively connected to the first cross member, a first roller rotatably connected to a first end of the first cross member, a second roller rotatably connected to a first end of the second cross member, a third roller rotatably connected to a second end of the second cross member, and a fourth roller rotatably connected to a second end of the first cross member.The first and second rollers are configured to hold the first and third guide rails. The third and fourth rollers are configured to hold the second and fourth guide rails. Brief description of the characters

[0009] The features and advantages described above, as well as others, will become more readily apparent to the average professional by reference to the following detailed description and the accompanying drawings; the drawings show: Fig. 1 a portable table saw comprising a sliding table and a carriage (shown in through view) for supporting the sliding table on a base table; Fig. 2 a top view showing a section of the base table, the sliding table and the carriage (shown in through view); Fig. 3 a cross-sectional view along line III-III of Fig. 2; Fig. 4 the sled from Fig. 1; Fig. 5 a section of the sled from Fig. 1, comprising an elliptically shaped opening in a transverse member of the slide; and Fig. 6 a guide rail of the base table and a guide rail of the sliding table in engagement with a roller of the carriage. Detailed description

[0010] To further the understanding of the principles of the disclosure, reference is now made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that this is not intended to limit the scope of protection of the disclosure. It is further understood that this disclosure includes any modifications and alterations to the illustrated embodiments and further applications of the principles of the disclosure, as would normally be apparent to a person skilled in the art to which this disclosure relates.

[0011] Aspects of the disclosure are disclosed in the accompanying description. Alternative embodiments of the disclosure and their equivalents may be conceived without departing from the idea or scope of protection of the disclosure. It is noted that any discussion herein of “an embodiment,” “an exemplary embodiment,” and the like indicates that the described embodiment may include a specific feature, structure, or property, and that such a specific feature, structure, or property need not necessarily be included in every embodiment. Furthermore, references to the foregoing do not necessarily imply references to the same embodiment.Finally, regardless of whether this is explicitly described, an average person skilled in the art would easily understand that each of the special features, structures, or properties of the given embodiments can be used in conjunction or combination with those of any other embodiments discussed herein.

[0012] For the purposes of revelation, the expression “A and / or B” means (A), (B), or (A and B). For the purposes of revelation, the expression “A, B, and / or C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B, and C).

[0013] The terms “comprehensive”, “including”, “exhibiting” and the like, as used with reference to embodiments of the disclosure, are synonymous.

[0014] As in Fig. As shown in Figure 1, a table saw 100 comprises a housing 104 configured to support a base table 108 and a sliding table 112. The sliding table 112 is movable relative to the base table 108 by means of a carriage 116 positioned between the sliding table 112 and the base table 108. The carriage 116 is Fig. Figure 1 shows a through view. As revealed here, the carriage 116 allows the sliding table 112 to move smoothly and with minimal lateral play relative to the base table 108. Furthermore, the configuration of the base table 108, the sliding table 112, and the carriage 116 gives the table saw 100 a higher cutting capacity compared to other designs and configurations. Each element of the table saw 100 is described here.

[0015] The housing 104 of the table saw 100 is designed for placement on the floor or a suitable stand. The housing 104 is made of plastic or metal, and can also be made of any other similar material. The housing 104 is lightweight to allow most people to easily carry the table saw 100. The housing 104 is also referred to here as a tube base.

[0016] With continued reference to Fig. Figure 1 further comprises the table saw 100, a motor 124, a saw blade 128, and a blade guard assembly 132. The motor 124 is positioned in the housing 104 and is configured to rotate the saw blade 128 for cutting workpieces. The motor 124 is normally mains-powered; however, in some embodiments, the motor 124 is powered by a removable and rechargeable battery pack (not shown). Fig. Figure 1 shows the motor 124 in block diagram form. In an exemplary structural configuration, the motor 124 is positioned in the housing 104 under a recessed section 152 of the base table 108 on the left side of the saw blade 128.

[0017] The saw blade 128 can be removed and replaced by the user. The saw blade 128 is a circular saw blade. The user selects the type of saw blade 128 based on the material of the workpiece to be cut. The saw blade 128 extends over the base table 108 and the sliding table 112 through a corresponding opening 136 formed in the base table 108.

[0018] The blade guard assembly 132 surrounds at least part of the section of the saw blade 128 that extends above the base table 108. The blade guard assembly 132 comprises two protective pads 140 for supporting the saw blade 128.

[0019] With continued reference to Fig. 1 The base table 108 is connected to the housing 104 and partially defines a flat workpiece support surface 144 and a corresponding workpiece support plane 148 ( Fig. 3) The sliding table 112 also partially defines the workpiece support surface 144. Workpieces to be cut by the table saw 100 are positioned on the workpiece support surface 144 and moved relative to the saw blade 128. The base table 108 defines a recessed section 152, which is positioned below the workpiece support surface 144.

[0020] The base table 108 comprises a left outer guide rail 156 (i.e., a first guide rail) and a right outer guide rail 160 (i.e., a second guide rail). The outer guide rails 156 and 160 are connected to the recessed section 152 of the base table 108 and are positioned below the workpiece support surface 144. The outer guide rails 156 and 160 are linear and extend along a cutting axis 164 of the table saw 100.

[0021] As in Fig. As shown in Figure 3, the outer guide rails 156, 160 are right-angled rails with an angle of ninety degrees (90°). The outer guide rails 156, 160 are oriented such that an upper guide surface 168, defined by the outer guide rails 156, 160, is rotated at an angle of forty-five degrees (45°) to the workpiece support surface 144, and a lower guide surface 172, defined by the outer guide rails 156, 160, is rotated at an angle of one hundred and thirty-five degrees (135°) to the workpiece support surface 144. One corner of the outer guide rails 156, 160 is positioned between the upper guide surface 168 and the lower guide surface 172. In further embodiments, the angle between the upper guide surface 168 and the lower guide surface 172 ranges from thirty degrees (30°) to one hundred and forty-five degrees (145°).

[0022] With reference to Fig. In embodiment 2, the right outer guide rail 160 is fixedly connected to the base table 108, and the left outer guide rail 156 is movably connected to the base table 108. For example, the right outer guide rail 160 is connected to the base table 108 with screws, bolts, or other fasteners such that it cannot move relative to the base table 108. In further embodiments, the right outer guide rail 160 is integrally formed with the base table 108. The left outer guide rail 156 is movable relative to both the base table 108 and the right outer guide rail 160. That is, the left outer guide rail 156 is movable relative to the right outer guide rail 160, so that the outer guide rails 156 and 160 can be configured in a parallel or substantially parallel configuration.As used here, "parallel" essentially means within five degrees (5°) of parallel. The outer guide rails 156, 160 are in . Fig. 2 partially shown in view through, as a section of the outer guide rails 156, 160 is obscured by the sliding table 112. The carriage 116 is shown in Fig. 2 is also shown in a transparent view, as it is completely hidden by the sliding table 112.

[0023] When the left outer guide rail 156 is positioned at a predetermined or target position, it is locked, fastened, or clamped to the base table(s) 108, thus fixing its position relative to the base table 108 and the right outer guide rail 160. During use of the table saw 100, the left outer guide rail 156 remains in the locked configuration, preventing the outer guide rails 156 and 160 from moving during cutting operations. In exemplary embodiments of Fig. 2. The base table 108 comprises two eccentric cams 176, which are rotatable with respect to the base table 108, such that the left outer guide rail 156 is moved closer to or further away from the right outer guide rail 160 and the angle of the left outer guide rail 156 to the right outer guide rail 160 is changed. A fastener extends through the eccentric cam 176 and is tightened to fix the position of the eccentric cam 176 and the left outer guide rail 156. Additional screws, bolts, or other fasteners extending through the left outer guide rail 156 and into the base table 108 are tightened to fix the left outer guide rail 156 in the predetermined position. In further embodiments, other adjusting elements are used to adjust the position of the left outer guide rail 156, such as wedges, shims, and / or the like.Furthermore, in other embodiments the right outer guide rail 160 is also adjustable.

[0024] The adjustable left outer guide rail 156 is helpful in the manufacture and / or assembly of the table saw 100 and enables mass production of the table saw 100 without extremely precise machining. As described below, the adjustability of the left outer guide rail 156 also helps to eliminate play between the carriage 116 and the sliding table 112.

[0025] With reference to Fig. 1-3 the sliding table 112 is configured for movement relative to the base table 108. Fig. 2 and Fig. Figure 3 shows that the sliding table 112 includes a left inner guide rail 180 (i.e., a third guide rail) and a right inner guide rail 184 (i.e., a fourth guide rail). The inner guide rails 180 and 184 are shown in Fig. 2 shown in a view through. The inner guide rails 180, 184 have essentially the same configuration as the outer guide rails 156, 160 of the base table 108. In the example shown of Fig. The inner guide rails 180 and 184 are right-angled rails with an angle of ninety degrees (90°). The inner guide rails 180 and 184 each define an upper guide surface 188 ( Fig. 3) and a lower surface 192 ( Fig. 3) The angle between the guide surfaces 188, 192 corresponds to the angle between the guide surfaces 168, 172. The inner guide rails 180, 184 are linear and are parallel or substantially parallel to the outer guide rails 156, 160.

[0026] The inner guide rails 180, 184 extend from a base surface of the sliding table 112. In one embodiment, the inner guide rails 180, 184 are integrally formed with the sliding table 112. In another embodiment, the inner guide rails 180, 184 are separate components and are connected to the base of the sliding table 112 using fasteners, screws, or the like. An upper surface of the sliding table 112 defines a section of the workpiece support surface 144 and is coplanar with the workpiece support plane 148.

[0027] The sliding table 112 defines a longitudinal groove 196 which is configured to hold, for example, a miter gauge 200 ( Fig. 1) to be included. Furthermore, according to the presentation in Fig. 1. A cross-cutting support 204 is configured for connection to the sliding table 112. Any other cutting accessory can also be connected to the sliding table 112 when used for the corresponding cutting operation.

[0028] As in Fig. As shown in Figure 4, the carriage 116, which is also referred to as a floating carriage, a carriage assembly, and / or an insert, comprises a support frame 208 and at least four rollers 212 operatively connected to the support frame 208. The carriage 116 is configured for sliding movement along the outer guide rails 156, 160 and the inner guide rails 180, 184 to enable sliding movement of the sliding table 112 relative to the base table 108.

[0029] The X-shaped support frame 208 of the slide 116 comprises an upper cross member 216 (i.e., a first cross member) and a lower cross member 220 (i.e., a second cross member), configured to support the four rollers 212 and overlapping each other. The cross members 216 and 220 are operatively connected by a fastener 224. The upper cross member 216 is shaped or bent to define a recess for receiving the lower cross member 220.

[0030] In an embodiment according to the illustration in Fig. 5 defines the lower transverse member 220 as a circular opening 228 for receiving the fastener 224 and defines the upper transverse member 216 as an elliptically shaped opening 232 (i.e., an oval-shaped opening) for receiving the fastener 224. In Fig. Figure 5 shows only a shaft section of the fastener 224 and does not show the head of the fastener 224, so that both openings 228, 232 are visible. The fastener 224 comprises, for example, a bolt and a nut which, when screwed together, are configured to clamp the transverse members 216, 220 together.

[0031] In one configuration, the fastener 224 connects the cross members 216, 220 with a strength that allows movement of the lower cross member 220 relative to the upper cross member 216. That is, the fastener 224 prevents the cross members 216, 220 from detaching from each other, but allows them to move relative to each other, particularly when the sliding table 112 is moved relative to the base table 108. As in Fig. As shown in Figure 5, a first pivoting motion path 236 of the transverse members 216, 220 extends about an axis defined by the fastening element 224. A second motion path 240 extends along a principal axis of the elliptically shaped opening 232. Thus, the transverse members 216, 220 are configured for rotational and translational movement relative to each other. In a typical configuration, the angle between the transverse members 216, 220 is in the range of eighty degrees (80°) to one hundred degrees (100°). Nominally, the transverse members 216, 220 are perpendicular or substantially perpendicular. Substantially perpendicular means within five degrees (5°) of perpendicular.

[0032] In further embodiments, both openings 228, 232 are circular and the transverse members 216, 220 are configured only for rotational movement relative to each other in the pivoting motion path 236. Furthermore, in another embodiment, both openings 228, 232 are elliptically shaped, so that a translational movement occurs along the principal axes of both elliptically shaped openings.

[0033] With renewed reference to Fig. In Figure 4, the four rollers 212 are configured to rotate about corresponding axes of rotation 244, one of which is shown, relative to the support frame 208. Specifically, each roller 212 is connected to the support frame 208 by an axle 248, which is screwed into a corresponding threaded opening in the cross member 216, 220. The axle 248 does not rotate relative to the cross members 216, 220. In some embodiments, a bearing (not shown) is positioned between the rollers 212 and the axle 248. The axes 248 are parallel to each other and perpendicular to the workpiece support plane 148. The rollers 212 rotate about the axes 248 and the rotation axes 244. The rotation axes 244 of the rollers 212 are parallel or substantially parallel to each other and are perpendicular or substantially perpendicular to the workpiece support plane 148. The lower cross member 220 supports two of the rollers 212 (i.e., the first and fourth rollers), and the upper cross member 216 supports the other two rollers 212 (i.e., the first and fourth rollers).the second and the third roller). Thus, each transverse member 216, 220 supports two of the rollers 212.

[0034] As in Fig. As shown in Figure 6, the rollers 212 are configured as V-rollers with an angle of ninety degrees (90°), designed to accommodate the right-angled rails of the guide rails 156, 160, 180, 184, which also have a ninety-degree angle. The angle of the V-rollers 212 corresponds to and / or coincides with the angle of the guide rails 156, 160, 180, 184. Thus, the angle of the V-rollers 212 ranges from thirty degrees (30°) to one hundred and forty-five degrees (145°). Each roller 212 defines a corresponding roller groove 252 and a vertex 256 in which the corners of the guide rails 156, 160, 180, 184 are positioned. The vertices 256 of the rollers 212 are coplanar.

[0035] Fig. Figure 2 shows that two left rollers 212 (i.e., a first and a second roller) are configured to accommodate the left outer guide rail 156 of the base table 108 and the left inner guide rail 180 of the sliding table 112. Fig. Figure 2 also shows that two right-hand rollers 212 (i.e., a third and a fourth roller) are configured to accommodate the right outer guide rail 160 of the base table 108 and the right inner guide rail 184 of the sliding table 112. Thus, the rollers are clamped between corresponding guide rails 156, 160, 180, 184, and the cross configuration of the support frame 208 results in a robustly supported sliding table 112 that moves freely and easily along a movement axis 258 with very little lateral play. Fig. 1), which is parallel to the cutting axis 164, moves.

[0036] With renewed reference to Fig. 4. The carriage 216 is configured to support four rail wipers 260. The rail wipers 260, or guide rail wipers, are connected to a corresponding cross member 216, 220. With respect to the axis of movement 258 of the sliding table 112 and the carriage 116, the two left rollers 212 are positioned between two left rail wipers 260, and the two right rollers 212 are positioned between two right rail wipers 260.

[0037] The rail wipers 260 are positioned on the guide rails 156, 160, 180, 184 and are configured to wipe dust and foreign matter from the guide rails 156, 160, 180, 184 during movement of the sliding table 112 and the carriage 116. As shown in Fig. As shown in Figure 4, each rail wiper 260 defines a left notch 264 (i.e., a first notch) and a right notch 268 (i.e., a second notch). The notches 264 and 268 are configured to accommodate a corresponding guide rail 156, 160, 180, or 184. The angle of the notches 264 and 268 corresponds to, and / or matches, the angle of the guide rails 156, 160, 180, or 184 and the V-rollers 212. In one embodiment, the notches 264, 268 are lined with a wiping element 272, which is provided as felt or another suitable material, so that when the wiping elements 272 move along the guide rails 156, 160, 180, 184, dust and foreign matter are wiped from the guide rails 156, 160, 180, 184 without damaging or scratching the guide rails 156, 160, 180, 184.In the configuration shown, each rail wiper 260 is configured to wipe two of the guide rails 156, 160, 180, 184 simultaneously during a movement of the sliding table 112 and the carriage 116 relative to the base table 108.

[0038] The rail wipers 260 are an optional element of the carriage 116, and some embodiments of the carriage 116 do not include the rail wipers 260.

[0039] The table saw 100 is configured to provide smooth and accurate movement of the sliding table 112 relative to the base table 108 and the housing 104 of the table saw 100 during operation. With reference to Fig. 1. The sliding table 112 is movable along the axis of movement 258. A workpiece (not shown) is placed on the sliding table 112, with the sliding table 112 in a starting position ( Fig. 1) is located, and then the sliding table 112 is moved past the saw blade 128 to cut into the workpiece. Next, the sliding table 112 is pulled back to its starting position in preparation for another cutting operation. When an operator moves the sliding table 112, the carriage 116 is moved between the guide rails 156, 160, 180, 184 relative to the base table 108.

[0040] Specifically, the carriage 116 is configured for movement relative to the base table 108 and the sliding table 112 during movement of the sliding table 112, due to the structural configuration described above. That is, the carriage 116 is held between the guide rails 180, 184 of the sliding table 112 and the guide rails 156, 160 of the base table 108, but is not rigidly attached to either the sliding table 112 or the base table 108. Therefore, the carriage 116 is referred to as a "floating" carriage 116. Consequently, when the sliding table 112 is moved towards the saw blade 128 to cut a workpiece, the carriage 116 also moves towards the saw blade 128. However, as described below, the carriage 116 and the sliding table 112 move different distances along the axis of movement 258.

[0041] The floating configuration of the carriage 116 significantly increases the cutting capacity of the table saw 100 compared to other configurations with sliding workpiece support surfaces. An example cutting capacity of the table saw 100 is 400 mm, and the cutting capacity of other embodiments ranges from 250 mm to 600 mm. Because the carriage 116 is floating, when the carriage 116 moves a distance X, the sliding table 112 moves a distance 2X (i.e., twice the distance of the carriage 116). Fig. Figure 2 represents a movement range 276 of the carriage 116 and a movement range 280 of the sliding table 112. The movement range 276 of the carriage 116 is defined by the fastening element 224 in a fully retracted position (the lower part of the blade in Fig. 2) to the fastening device 224 in a fully advanced position (the upper part of the leaf in Fig. 2) measured. The range of motion 280 of the sliding table 112 is measured from a longitudinal center point 284 of the sliding table 112 in the fully retracted position to the longitudinal center point 284 in the fully advanced position. As shown, the range of motion 280 of the sliding table 112 is twice the length of the range of motion 276 of the carriage 116. The floating configuration of the carriage 116 provides this increased range of motion 280, thereby directly increasing the cutting capacity of the table saw 100. The sliding table in Fig. 2 is moved to the fully retracted position, but is not actually in the fully retracted position. That is, in Fig. 2. The sliding table 112 and the carriage 116 can be moved further downwards, as shown by comparing the position of the fastening means 224 and the center point 284 with the respective areas 276, 280.

[0042] During movement of the sliding table 112 and the carriage 116, the support frame 208 of the carriage 116 compensates for dimensional differences in the guide rails 156, 160, 180, 184, the base table 108, the sliding table 112, and other parts of the table saw 100. In particular, the fastener 224, which is positioned in the elliptically shaped opening 232, loosely connects the cross members 216, 220, so that the cross members 216, 220 can pivot and move translationally while the carriage 116 slides on the guide rails 156, 160, 180, 184. The movement of the cross members 216, 220 leads to the self-alignment of the carriage 116 and allows for the positioning and structuring of the guide rails 156, 160, 180, 184 with less precision. That is, the guide rails 156, 160, 180, 184 are designed as parallel linear rails, but machine tolerances lead to variations in a horizontal distance 288 ( Fig. 2) between the guide rails 156, 160, 180, 184. By allowing bending and pivoting of the support frame 208, the carriage 116 compensates for these variations, and the sliding table 112 is moved smoothly and accurately with respect to the base table 108 and the saw blade 128. The compensation is achieved by changing the horizontal distance 292 ( Fig. 4) between the rollers 212, as permitted by the fastening member 224 and the elliptically shaped opening 232. In other words, compensation is achieved due to a changing angle between the transverse members 216, 220, as permitted by the fastening member 224 and the elliptically shaped opening 232.

[0043] The right-angled rails forming the guide rails 156, 160, 180, 184, and the corresponding V-shaped rollers 212 provide support against vertical loads on the sliding table 112. By using right-angled rails with wide support surfaces 168, 172, 188, 192, an additional contact area is provided compared to other configurations with round rails.

[0044] In one exemplary embodiment, the guide rails 156, 160, 180, 184 are made of aluminum and the V-shaped rollers 212 are made of plastic. For an even more robust configuration, the guide rails 156, 160, 180, 184 are made of hardened steel or hardened steel plates, and the V-shaped rollers 212 are made of steel. The sliding table 112 is made of aluminum and, in one embodiment, of extruded aluminum.

[0045] Although the disclosure has been illustrated and described in detail in the drawings and the preceding description, this should be understood as an illustration and not as a limitation. It is understood that only the preferred embodiments have been presented and that all changes, modifications, and further applications that fall within the scope of the disclosure are also to be protected.

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