Abstract:
The present invention relates to feedback systems that are used with power tools to provide the user with sensory feedback information allowing the user to determine the position of an adjustable portion of a power tool with respect to a stationary portion of a power tool or with respect to a workpiece without having to refer to a scale or manual measuring device. This feedback information may make it easier and faster for the user to determine the orientation or location of an adjustable portion of a power tool or determine the orientation or location of the workpiece with respect to an operational member of the power tool allowing the user to concentrate his thinking on executing the operation instead of concentrating on set up.

Description:
FIELD 
       [0001]    The present disclosure relates to power tools, and more particularly to feedback systems for adjustment mechanisms found on power tools. 
       BACKGROUND AND SUMMARY OF THE INVENTION 
       [0002]    The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. 
         [0003]    Many power tools, both portable and stationary, include adjustment mechanisms to assist the user adjusting the operational member of a power tool or in aligning the workpiece with the operational member of the power tool. For example, table saws include fences to help the user align the workpiece with the saw blade so that the workpiece can be cut at the desired location. Another example is the cutterhead adjustment handle on a planer. The cutterhead adjustment handle is used to lower the planer head to the desired height to perform the planing operation on the workpiece. 
         [0004]    Traditionally, users look at scales or similar measuring implements provided on the power tool to determine the position of an operational member or to determine the position of the workpiece with respect to the operational member of the power tool. Alternatively, users may simply measure the workpiece with respect to operational member of the power tool using a manual measuring device such as measuring tape. 
         [0005]    The present disclosure provides feedback systems that are used with power tools to provide the user with sensory feedback information allowing the user to determine the position of an adjustable portion of a power tool with respect to a stationary portion of a power tool or with respect to a workpiece without having to refer to a scale or manual measuring device. This makes it very easy and fast for the user to determine the orientation or location of an adjustable portion of a power tool or determine the orientation or location of the workpiece with respect to an operational member of the power tool allowing the user to concentrate his thinking on executing the operation instead of concentrating on set up. 
         [0006]    Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
           [0008]      FIG. 1  is a perspective view of a planer including a feedback system according to the principles of the present disclosure; 
           [0009]      FIG. 2  is a perspective view of a table saw including a feedback system according to the principles of the present disclosure; 
           [0010]      FIG. 3  is a perspective view of a drill press including a feedback system according to the principles of the present disclosure; 
           [0011]      FIG. 4  is a cross-sectional view of a portion of any one of the power tools shown in  FIGS. 1-3  detailing a feedback system according to the principles of the present disclosure; 
           [0012]      FIG. 5  is a cross-sectional view of a portion of any one of the power tools shown in  FIGS. 1-3  detailing a feedback system according to the principles of the present disclosure; 
           [0013]      FIG. 6  is a cross-sectional view of a portion of any one of the power tools shown in  FIGS. 1-3  detailing a feedback system according to the principles of the present disclosure; 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0014]    The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. 
         [0015]    With reference to  FIG. 1 , an exemplary planer mechanism constructed in accordance with the teachings of the present invention is generally indicated by reference numeral  10 . Planer mechanism  10  may include a base assembly  20 , at least two (and preferably four) support columns  30 , and a carriage assembly  40  mounted unto the support columns  30 . Carriage assembly  40  may carry a motor, a cutterhead driven by the motor and/or feed rollers driven by the motor, as is well known in the art. 
         [0016]    Persons skilled in the art will recognize that carriage assembly  40  may threadably engage support columns  30 . Persons skilled in the art are directed to U.S. Pat. No. 6,601,621, which is incorporated herein by reference, for further information on how the carriage assembly  40  is mounted unto the support columns  30  to allow adjustment of the distance between carriage assembly  40  and base assembly  20 . Nonetheless, persons skilled in the art will recognize that base assembly  20  may be movably mounted unto support columns  30  to allow adjustment of the distance between carriage assembly  40  and base assembly  20 . 
         [0017]    Adjustment of carriage assembly  40  relative to the base assembly  20  is accomplished by the user rotating handle assembly  50 . Traditionally, the user would use cutterhead height adjustment knob  60  and scale  70  to determine the distance carriage assembly  40  has traveled and the relative distance between the cutterhead (not shown) and the workpiece (not shown). However, as discussed below, the present invention preferably provides a sensory feedback system that can be used, for example, to replace the need for referring to scales or adjustment knobs or to augment the use of scales or knobs to determine the distance carriage assembly  40  has traveled and the relative distance between the cutterhead and the workpiece. Although only the example of the carriage assembly  40  is discussed, persons skilled in the art will recognize that the sensory feedback systems can be used with any adjustment mechanisms in the planer  10 . 
         [0018]    Turning to  FIG. 2 , an exemplary table saw mechanism constructed in accordance with the teachings of the present invention is generally indicated by reference numeral  100 . Exemplary table saw  100  may have a table  110  including tracks  115  and  125  for receiving fences, a base assembly  120 , including legs  130 , supporting the table  110 , and a front panel  140  connected to the base assembly  120 , legs  130  and/or table  110 . A saw assembly  150  may be pivotally attached underneath the table  110 . Saw assembly  150  carries a rotatable cutting tool, such as blade  155 . Saw assembly  150  may include a cradle (not shown). 
         [0019]    As part of the adjustment mechanisms employed by exemplary table saw  100 , the angle of blade relative to table  110  may be changed. In a preferred embodiment, the cradle may be provided with a bevel sector gear (not shown) thereon. The bevel sector gear has a rack (not shown) which meshes with a worm drive (not shown) disposed on bevel shaft (not shown), which is rotated via bevel crank wheel  160 . When bevel crank wheel  160  is rotated, the bevel shaft and its worm drive rotate. The worm drive meshes with the rack, causing the cradle and blade  155  to rotate, thus changing the bevel angle of blade  155  relative to table  110 . For further discussion of the bevel angle adjustment mechanism, persons skilled in the art are directed to U.S. Pat. No. 6,530,303, which is incorporated herein by reference. 
         [0020]    Customarily, the user would use scale  170  to determine the bevel angle of blade  155  relative to table  110 . However, as discussed below, the present invention preferably provides a sensory feedback system that can be used, for example, to replace the need for referring to scales or to augment the use of scales to determine the bevel angle of blade  155 . Although only the example of the blade  155  bevel angle is discussed, persons skilled in the art will recognize that the sensory feedback systems can be used with any adjustment mechanisms in the table saw  100 , including those, for example, that permit adjustments to the height of blade  155  with respect to table  110  and those that permit adjustments to fences  180  and  190  on table  110  of table saw  100 . 
         [0021]    Referring to  FIG. 3 , an exemplary drill press mechanism constructed in accordance with the teachings of the present invention is generally indicated by reference numeral  200 . Drill press  200  preferably includes main column  210 , base  220  and head  230 . Column  210  preferably has a hollow cylindrical shape and fits within an opening formed in base  220  and is supported by base  220  to extend substantially vertically. Head  230  preferably includes an opening which receives column  210  and is supported thereby. A chuck  240  and rotatable handle  250  for raising or lowering the chuck  240  preferably extend from head  230 . In addition, in a preferred embodiment, a drive mechanism for the chuck  240  is disposed within head  230 . 
         [0022]    The exemplary embodiment of drill press  200  also preferably includes cylindrical casting  260  disposed about column  210 . Cylindrical casting  260  provides an interface between worktable assembly  270  and column  210  of drill press  200 . In a preferred embodiment, cylindrical casting  260  may translate vertically along column  210  or may rotate about column  210  allowing worktable assembly  270  to translate or rotate about column  210 . In addition, cylindrical casting  260  provides a mechanism  280  to allow the user to rotate worktable assembly  270  with respect to column  210 . 
         [0023]    Conventionally, the user would use a scale preferably located on cylindrical casting  260  to determine the angle of worktable  270  relative to column  210 . However, as discussed below, the present invention preferably provides a sensory feedback system that can be used, for example, to replace the need for referring to scales or to augment the use of scales to determine the angle of worktable  270 . Although only the example of the adjustments to worktable  270  is discussed, persons skilled in the art will recognize that the sensory feedback systems can be used with any adjustment mechanisms in the drill press  200 , including, for example, those that permit adjustments to the chuck  240  with respect to the worktable  270 . 
         [0024]    Turning to  FIGS. 4-6 , several exemplary feedback mechanisms are shown. Each of these exemplary feedback mechanisms can be used with any adjustment mechanism found on a power tool, including those that were just discussed. 
         [0025]    With reference to  FIG. 4 , a first preferred feedback system  300  is shown. As discussed above, feedback system  300  can be used with a power tool adjustment mechanism. Feedback system  300  preferably includes a stationary portion  310 . Stationary portion  310  may be any portion of a power tool that receives a portion of a power tool adjustment mechanism. For example, looking at the above discussed power tools, carriage assembly  40  of planer  10  may include stationary potion  310 , front panel  140  of table saw  100  may include stationary portion  310 , and cylindrical casting  260  of drill press  200  may include stationary portion  310 . 
         [0026]    Feedback system  300  also preferably includes an actuation portion  320  having at least one notch  330 , but preferably a plurality of notches  330 . In a preferred embodiment, notches  330  are formed such that they are located at a predetermined distance from each other. Actuation portion  320  may be any portion of the power tool adjustment mechanism that couples to a power tool adjustment mechanism user interface. For example, looking at the above discussed power tools, rotating handle assembly  50  of planer  10  may couple with actuation portion  320 , bevel crank wheel  160  of table saw  100  may couple with actuation portion  320 , and adjustment mechanism  280  of drill press  200  may couple with actuation portion potion  320 . 
         [0027]    In a preferred embodiment, feedback system  300  also includes at least one biasing member  340  and at least one detent member  350 . Biasing member  340  preferably is coupled with stationary portion  310  at one end and coupled with detent member  350  at the other end. Detent member  350  preferably is configured and dimensioned to engage notches  330  on actuation portion  320 . In another preferred embodiment, notches  330  could be located on stationary portion  310  and detent member  350  and biasing member  340  could be located on actuation portion  320 . 
         [0028]    In an exemplary use, when the user manipulates the power tool adjustment mechanism, for example, rotating handle assembly  50  of planer  10 , rotating bevel crank wheel  160  of table saw  100 , or rotating adjustment mechanism  280  of drill press  200 , actuation portion  320  of feedback system  300  is actuated. In a preferred embodiment, when actuated, actuation portion  320  rotates with respect to stationary portion  310  allowing detent member  350  to engage and disengage from notches  330 . More specifically, detent member  350 , which in a preferred embodiment is a ball detent, is biased towards actuation portion  350  by biasing portion  340 , which in a preferred embodiment is a spring. As actuation portion  320  rotates, detent member  350  abuts an outer surface of actuation portion  320  until engaging one of the notches  330 . As actuation portion  320  continues to rotate, detent member  350  will disengage from notch  330  and again abut the outer surface of actuation portion  320  until the next notch  330 . The engagement and disengagement of detent member  350  with notch  330  will provide the user with tactile and audible feedback. Additionally, since the notches  330  are placed at predetermined locations, each engagement and disengagement of detent member  350  with notch  330  can be tied to a certain amount of adjustment of the power tool adjustment mechanism thereby indicating to the user how much adjustment has been done without the need to refer to a scale. For example, each engagement and disengagement of detent member  350  with notch  330  can indicate 0.X degree of beveling of blade  155  on table saw  100 . 
         [0029]    In another preferred embodiment, the depth of notches  330  can be varied giving the user additional tactile and audible feedback. For example, if there are four notches  330  on actuation portion  320 , one notch  330  may be larger than the other notches, so when detent member  350  engages and disengages the larger notch  330 , that can indicate something in addition to what the remaining notches  330  indicate. Turning back to the table saw  100  example, the larger notch  330  feedback could indicate X degree of beveling of blade  155  on table saw  100  while the remaining notches  330  could indicate 0.X degree of beveling. 
         [0030]    Turning to  FIG. 5 , a second preferred feedback system  400  is shown. As discussed above, feedback system  400  can be used with a power tool adjustment mechanism. Feedback system  400  preferably includes a stationary portion  410  having at least one, but preferably a plurality of biasing arms  415  that are configured and dimensioned to engage a plurality of engagement members  425 , discussed below. Stationary portion  410  may be any portion of a power tool that operationally engages a portion of a power tool adjustment mechanism. For example, looking at the above discussed power tools, carriage assembly  40  of planer  10  may include stationary potion  410 , track  115  of table saw  100  may include stationary portion  410 , and cylindrical casting  260  of drill press  200  may include stationary portion  410 . 
         [0031]    Feedback system  400  also preferably includes an actuation portion  420  having a plurality of engagement members  425 . In a preferred embodiment, engagement members  425  are formed such that they are located at a predetermined distance from each other. Actuation portion  420  may be any portion of the power tool adjustment mechanism that couples to a power tool adjustment mechanism user interface. For example, looking at the above discussed power tools, rotating handle assembly  50  of planer  10  may couple with actuation portion  420 , Fences  180  or  190  of table saw  100  may couple with actuation portion  420 , and adjustment mechanism  280  of drill press  200  may couple with actuation portion potion  420 . In another preferred embodiment, stationary portion  410  may include engagement members  425  and actuation portion  420  may include biasing arms  425 . 
         [0032]    In an exemplary use, when the user manipulates the power tool adjustment mechanism, for example, rotating handle assembly  50  of planer  10 , sliding fence  180  on table  110  of table saw  100 , or rotating adjustment mechanism  280  of drill press  200 , actuation portion  420  of feedback system  400  is actuated. In a preferred embodiment, when actuated, actuation portion  420  moves with respect to stationary portion  410  allowing biasing arms  415  to engage and disengage engagement members  425 . As actuation portion  420  moves, biasing arms  415  also move and continue to abut engagement members  425  until tips  435  of biasing arms  415  abut engagement members  425 . Continued movement of actuation portion  420  after this point results in biasing arms  415  disengaging from engagement members  425  and moving into recesses  430  until continued movement re-engages biasing arms  415  with engagement members  425 . The engagement and disengagement of biasing arms  415  with engagement members  425  will provide the user with tactile and audible feedback. Additionally, since the engagement members  425  are placed at predetermined locations, each engagement and disengagement of biasing arms  415  with engagement members  425  can be tied to a certain amount of adjustment of the power tool adjustment mechanism thereby indicating to the user how much adjustment has been done without the need to refer to a scale. For example, each engagement and disengagement biasing arms  415  with engagement members  425  can indicate X.X inches of movement of fence  180  on table saw  100 . 
         [0033]    Turning to  FIG. 6 , a third preferred feedback system  500  is shown. As discussed above, feedback system  500  can be used with a power tool adjustment mechanism. Feedback system  500  preferably includes a stationary portion  510  having at least one, but preferably a plurality of grooves  515 . In a preferred embodiment, grooves  515  are formed such that they are located at a predetermined distance from each other. Stationary portion  510  may be any portion of a power tool that operationally engages a portion of a power tool adjustment mechanism. For example, looking at the above discussed power tools, carriage assembly  40  of planer  10  may include stationary potion  510 , track  115  of table saw  100  may include stationary portion  510 , and cylindrical casting  260  of drill press  200  may include stationary portion  510 . 
         [0034]    Feedback system  500  also preferably includes an actuation portion  520  having at least one, but preferably a plurality of detent members  525 . Detent members  525  are preferably located in cavities  530 , which are longer than the length of detent members  525  thereby allowing detent members  525  to translate within the cavities  530 . In a preferred embodiment, detent members  525  preferably are configured and dimensioned to engage grooves  515  on stationary portion  510 . In another preferred embodiment, grooves  515  could be located on actuation portion  510  and detent member  525  could be located on stationary portion  510 . 
         [0035]    In an exemplary use, when the user manipulates the power tool adjustment mechanism, for example, rotating handle assembly  50  of planer  10 , moving fence  180  of table saw  100 , or rotating adjustment mechanism  280  of drill press  200 , actuation portion  520  of feedback system  500  is actuated. In a preferred embodiment, when actuated, actuation portion  520  moves with respect to stationary portion  510  allowing detent member  525  to engage and disengage from grooves  515 . More specifically, as actuation portion  520  is moved, detent members  525  abut an outer surface of stationary portion  510  until engaging one of the grooves  515 . As actuation portion  520  continues to move, detent members  525  will disengage from grooves  515  and again abut the outer surface of stationary portion  510  until the next groove  515 . The engagement and disengagement of detent members  525  with grooves  515  will provide the user with tactile and audible feedback. Additionally, since the grooves  515  are placed at predetermined locations, each engagement and disengagement of detent members  525  with grooves  515  can be tied to a certain amount of adjustment of the power tool adjustment mechanism thereby indicating to the user how much adjustment has been done without the need to refer to a scale. For example, each engagement and disengagement of detent member  525  with grooves  515  can indicate X.X inches of movement of fence  180  on table saw  100 . 
         [0036]    The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the spirit of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. Furthermore, although only select power tools were described with respect to the present invention, it should be understood that the present invention is applicable to any power tool that includes an adjustment mechanism.