Bench Cutter Gear Case Segmentation for Compact Cutting Depth
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Solution Overview
Problem
Conventional bench cutters require large sizes and increased weight to accommodate cutting blades of large diameters for cutting thick materials, which compromises their portability and cutting capacity.
Innovation Solution
A transmission mechanism with a first gear directly driven by the drive portion, an intermediate gear reducing rotation, and a final gear integral with the spindle, allowing for reduced gear case size and increased cutting depth without the need for large gears, along with a lock pin system for easy detachment and safety features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large diameter cutting blade is used to cut thick material, then the cutting capacity is improved, but the gear case size must be increased to accommodate the large blade, which increases the overall bench cutter size and weight
Solution Approach 1:
The transmission mechanism is segmented into multiple stages: a first gear directly driven by the motor, a second gear meshed with the first gear, and a third gear meshed with the second gear and integral with the spindle. This multi-stage segmentation allows for progressive speed reduction, enabling the use of smaller diameter gears compared to a single-stage transmission that would require a large final gear to achieve the same reduction ratio.
2Productivity
If the gear case size is increased to accommodate large gears for thick material cutting, then the cutting capacity is improved, but the portability and accommodating property of the bench cutter are deteriorated
Solution Approach 1:
The patent utilizes the axial dimension along the spindle axis to arrange the multi-stage gear transmission. The first, second, and third gears are positioned at different locations along the axial direction, allowing the transmission mechanism to achieve significant speed reduction without increasing the radial size of the gear case. This dimensional arrangement enables compact gear case design while maintaining adequate cutting depth capability.
3Productivity
If a large diameter cutting blade is used, then the cutting capacity for thick material is improved, but the region available for cutting is restricted by the large gear case
Solution Approach 1:
The transmission mechanism is segmented into multiple stages: a first gear directly driven by the motor, a second gear meshed with the first gear, and a third gear meshed with the second gear and integral with the spindle. This multi-stage segmentation allows for progressive speed reduction, enabling the use of smaller diameter gears compared to a single-stage transmission that would require a large final gear to achieve the same reduction ratio.
4Productivity
If the size of the bench cutter is extended to ensure cutting capacity, then the cutting depth is improved, but the weight and complexity of the bench cutter are increased
Solution Approach 1:
The transmission mechanism is segmented into multiple stages: a first gear directly driven by the motor, a second gear meshed with the first gear, and a third gear meshed with the second gear and integral with the spindle. This multi-stage segmentation allows for progressive speed reduction, enabling the use of smaller diameter gears compared to a single-stage transmission that would require a large final gear to achieve the same reduction ratio.
Solution Approach 2:
The patent utilizes the axial dimension along the spindle axis to arrange the multi-stage gear transmission. The first, second, and third gears are positioned at different locations along the axial direction, allowing the transmission mechanism to achieve significant speed reduction without increasing the radial size of the gear case. This dimensional arrangement enables compact gear case design while maintaining adequate cutting depth capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables cutting of thick materials with a small cutting blade in a compact and lightweight bench cutter, enhancing cutting depth and reducing the size and weight of the gear case, while maintaining effective power transmission.
Implementation Method 1
a first gear directly driven by the drive portion; a final gear integrally rotated together with the spindle; and an intermediate gear portion, which is respectively meshed with the first gear and the final gear, reducing a rotation of the first gear and transmitting the reduced rotation to the final gear
Data Source
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Figure 3
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AI summary
According to an aspect of the invention, a bench cutter like a miter saw includes : a drive portion driving a cutting blade; a base portion supporting a workpiece; a cutting portion arranged on the base portion, pivotally supporting the cutting blade above the base portion, and configured to make the cutting blade come close to and separate from the base portion; and a supporting portion connected to the base portion and movably supporting the cutting portion, wherein the cutting portion includes : a transmission portion for transmitting power of the drive portion to the cutting blade; and a gear case covering the transmission mechanism and having a lower face portion opposed to an upper face of the base portion, wherein the transmission portion includes : a spindle concentrically supporting the cutting blade; and a cutting blade fixing portion having a flange for fixing the cutting blade to the spindle.