Abstract:
An improvement for a power tool having a motor-driven working tool for performing an operation on a workpiece includes a material sensor positioned to sense the workpiece prior to operation by the working tool. The material sensor is configured to determine a material property of the workpiece and to generate a signal in response thereto. A processor coupled between the material sensor and the motor is configured to control the motor in response to the signal generated by the material sensor.

Description:
REFERENCE TO RELATED APPLICATION AND PRIORITY CLAIM 
       [0001]    This application claims priority under 35 U.S.C. §119 to U.S. Provisional Application 61/776,873, filed Mar. 12, 2013, the disclosure of which is incorporated herein by reference in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    This disclosure relates to power tools and, more particularly, to power table saws. 
       BACKGROUND 
       [0003]    Power tools, such as power table saws, planers, miter saws, bevel saws, compound saws, circular saws, or the like have evolved through the years to incorporate various safety mechanisms, such as blade guards, automatic shut-off mechanisms and the like. The power tools have also developed from the saws or cutterheads that are turned on and off by a simple switch to variable speed saws and power tools with electronically controlled drive motors. 
         [0004]    For many power tools the mode of operation of the tool may change depending upon the material of the workpiece. For instance, certain materials may require a higher cutting blade speed than other workpiece materials to avoid the risks such as kick-back and splintering, while other workpiece materials may require a lower blade sped to avoid wear and heat damage to the cutting blade. 
         [0005]    In order to improve the cutting performance of a power tool it is desirable to know the material of the workpiece so that the operation parameters of the power tool can be adjusted accordingly. 
       SUMMARY 
       [0006]    An improvement is provided for a power tool having a motor-driven working tool for performing an operation on a workpiece. In one aspect, the improvement comprises a material sensor positioned to sense the workpiece prior to operation by the working tool. The material sensor is configured to determine a material property of the workpiece and to generate a signal in response thereto. A processor coupled between the material sensor and the motor is configured to control the motor in response to the signal generated by the material sensor. 
         [0007]    The material sensor may include one or more of sensors configured to sense different materials for the workpiece, such as wood or metal, and to sense the presence of a metal contaminant in a non-metallic workpiece. The operation of the motor is a function of the workpiece material, as detected by the material sensor and controlled by the processor. In one aspect, the processor may include a table look-up feature that obtains a motor control protocol based on signals from the material sensor(s). 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  depicts a top front perspective view of a table saw incorporating a workpiece material sensor as disclosed herein. 
           [0009]      FIG. 2  depicts a schematic side view of a material sensor for use with the table saw of  FIG. 1 . 
           [0010]      FIG. 3  depicts a schematic diagram of the circuitry and electronic control module (ECM) for material sensor of  FIG. 2 . 
       
    
    
     DETAILED DESCRIPTION 
       [0011]    For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the invention is thereby intended. It is further understood that the present invention includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the invention as would normally occur to one skilled in the art to which this invention pertains. 
         [0012]    One example of a power tool, namely a table saw, is shown in  FIGS. 1 and 2 . The power tool may also be a planer, a miter saw, a bevel saw, a compound saw, a vertical saw, a band saw, a router, a circular saw, or the like. The table saw  100  includes a table  102  that includes a work surface  104  for supporting a workpiece W ( FIG. 2 ) to be cut. The table  102  defines a slot g 14   
         [0013]    through which a working tool  108 , such as a rotary saw blade, projects. In other tools, the working tool  108  may take other forms, such as a band saw blade or a cutterhead. In the illustrate embodiment, the working tool  108  is a saw blade that is powered by a motor M mounted underneath the table  104 . The power tool may incorporate a safety feature such as a riving knife  106  and a blade guard (not shown) mounted to the riving knife. In the instance of a rotary saw, such as the table saw of  FIG. 1 , the motor may be supported on a carriage (not shown) that is movably mounted to the table to permit adjustment of the height of the blade above the work surface  104  as well as the angle of the cutting blade to the surface  104  for performing angled cuts. For instance, in a typical portable table saw, a manual crank mechanism  110  is provided that allows raising and lowering the saw blade. In some embodiments, an electronic or sensor-based height/angle adjustment assembly is provided to automatically raise or lower the saw blade upon detection of the depth of the workpiece and/or tilt the saw blade. The user may override the operation of the automatic height adjustment assembly via a user interface. A similar manual crank (not shown) may be provided to perform the angle adjustment. In certain table saws, a control module  115  ( FIG. 2 ), such as an electronic control module (ECM), may be provided to control the operation of the motor. In a typical tool the control module  115  may be provided with a user interface (not shown) that permits operator adjustment of the blade cutting speed and that allows push-button activation and de-activation of the tool. In some embodiments, the user interface may include a remote control, a touch panel, or the like. 
         [0014]    In one aspect of the present disclosure, a material sensor  120  is provided that is mounted to the underside of the work surface  104  downstream of or in immediate proximity to the tool slot  109  or more particularly the cutting zone adjacent the cutting blade  108 , as depicted in  FIG. 2 . In one embodiment the sensor  120  may be arranged to overlap part of the tool slot and may be configured to be positioned as close to the cutting blade as possible, such as by providing a beveled or curved end  122  immediately adjacent the blade. In some embodiments, the material sensor  120  is either disposed over or embedded within and preferably flush with the table top. In either case, the material sensor  120  includes an upper surface  123  configured for smooth passage of the workpiece W. The material sensor  120  is configured to sense the workpiece W through the table  102 , or to directly sense the workpiece in the case of a flush mounted sensor. In certain embodiments, the table  102  may be modified to include an opening or openings for unimpeded transmission of sensor signals to and from the material sensor  120 . The material sensor  120  may be formed from a single sensor die, a plurality of sensors in a package, or a sensor strip. 
         [0015]    The material sensor  120  may be configured to detect specific properties of the workpiece material, such as density, and/or to detect the type of material, such as wood or metal, and/or to detect the presence of inhomogeneous particles in the workpiece, such as a nail in wood. The sensor  120  can be of a variety of types such as optical, light, proximity, motion, reed type, acoustic, camera-based, imaging, IR, capacitive, piezoelectric, radar, sonar, ultrasonic, distance measuring, or the like. The material sensor may also be configured to detect the workpiece material “on the fly”, meaning as the workpiece is being advanced in the “feeding direction” ( FIG. 2 ) toward a rotating saw blade  108 . 
         [0016]    The material sensor  120  communicates with the control module  115  which is configured to process the sensor signals and make appropriate determinations regarding the operation of the cutting blade. In particular, the sensor  120  may communicate with a microprocessor  117  according to the circuit diagram of  FIG. 3 . The microprocessor receives the signal on output line  121  of the sensor and produces control signals to control the activation of relays  118  operable to control the operation of the motor M. In particular, the microprocessor  117  generates a pulse-width modulated signal to one of the relays  125 ,  126  that control the operation of the motor, namely, the activation/deactivation (relay  125  or relay  126 ) and the speed of the motor (relay  125  and relay  126 ). The microprocessor may be configured to generate a control signal to control the motor supply voltage  128  to directly vary the motor rotational speed. 
         [0017]    The material sensor  120  may include one or more of a variety of sensors, such as light, acoustic, inductive, capacitive displacement, thermal and magnetic. Each type of sensor is suitable for detecting particular properties or particular materials. For instance, a magnetic sensor can sense the ferromagnetic properties of metallic materials, such as a metallic workpiece W or a workpiece that includes a metallic component. An acoustic sensor, such as an electromagnetic acoustic transducer (EMAT) or a micro-electromechanical system (MEMS) acoustic transducer, is well suited for wood or other less dense materials. A light sensor may be limited to proximity sensing or may be calibrated to sense material based on the surface characteristics. For instance, a light sensor may be calibrated to detect the difference between a metal workpiece that may be more reflective and a wood workpiece that is less reflective. The material sensor  120  may be configured to detect the presence of inhomogeneous particles in the workpiece, such as by using a capacitive or eddy current sensor to detect a metal element (i.e., a nail) in a wood workpiece. In this instance, the material sensor may be used to screen a workpiece before a cutting operation commences, such as by running the workpiece over the material sensor  120  in a direction perpendicular to the feeding direction. 
         [0018]    The material sensor  120  may thus include a combination of the above-identified sensors ( 120   a, b , . . . ) to permit detection of all types of materials and/or inhomogeneities in the workpiece. The separate sensor  120   a, b , . . . may be arranged along or transverse to the feeding direction. In this instance, the control module  115  and more particularly the microprocessor  117  is configured to distinguish between signals provided by different sensor elements  120   a, b , . . . in the material sensor  120 . For instance, a signal from an acoustic sensor  120   a  can be interpreted by the control module to indicate that the workpiece is made of wood, given that an acoustic sensor is generally ineffective for a metallic or ceramic workpiece. A concurrent signal from a magnetic sensor  120   b  can further be interpreted to indicate that a metal element, such as a nail, is present in a non-metallic (and therefore acoustic sensible) workpiece. On the other hand, no signal from the acoustic sensor and a signal from the magnetic sensor can be interpreted to mean that the workpiece is made of metal. For a sensor  120  that incorporates multiple types of sensors, the output line  121  may include separate output lines ( 121   a, b , . . . ) for each type of sensor. The microprocessor  117  can be programmed or configured to compare the signals received on the sensor output lines  121   a, b , . . . with threshold values indicative a particular material and material density. For instance, a non-null signal  121   a  from an acoustic sensor  120   a  may signify the presence of a wood workpiece W. The magnitude of the signal  121   a  may be indicative of the density of the material. For instance, a lower magnitude is indicative of a more dense wood of the workpiece W. The operation of the cutting blade  108 , and more particularly the motor M, may be adjusted based on the density of the material, since a more dense material may require a greater blade cutting speed than a less dense material. 
         [0019]    The control module  115  and/or microprocessor  117  are adapted to control the operation of the motor M and optionally to also adjust the height of the saw blade  108  based on the material composition of the workpiece W. With respect to the blade height adjustment, the material sensor  120  may be integrated with another sensor operable to determine the thickness of the workpiece. The blade height is a function of the workpiece thickness and an optimum height above the workpiece, which optimum height may be a function of the workpiece material. In one embodiment, a look-up table is stored in a memory in the control module  115  that correlates sensor signal values with motor and saw blade control parameters. The saw blade control parameters may include the optimum dimension/height above the workpiece thickness based on material composition. The motor control parameters may include: a) regulating and/or correcting the speed of the cut shortly before approaching the material as well as during the cut; b) once the teeth are engaged into the workpiece increasing the speed to a predetermined value until the cutting operation is almost complete; c) once the workpiece has moved to a predetermined position relative to the sensor detection area (i.e., when the cut is nearly complete) gradually reducing the motor speed to the end of the cut; and d) once the workpiece has moved entirely out of the sensor area, meaning that the cut is complete (i.e., when the material sensor signal  121  is a null value), de-energizing the motor. The position of the workpiece W may be verified by proximity sensors (not shown), and/or the engagement of the workpiece by the cutting blade may be verified by sensors associated with the blade and/or motor. 
         [0020]    Adjusting the motor control parameters as a function of the workpiece material can increase tool life and enhance the safety of the cutting operation. For instance, approaching a metal workpiece generates significant stress in the cutting blade teeth and can cause fractioning of a carbide tipped blade. A lower speed at the initial engagement of the cutting blade with the workpiece increases tool life and reduces the risk of kick-back at the instant when the teeth “grab” the workpiece. Reducing the speed at the end of the cut improves the quality of the cut, reduces the generation of burrs and splinters and decreases the risk of injury to the tool operator. Automatic shut-off provides the obvious safety benefit of not requiring the operator to divert his/her attention away from the spinning saw blade or workpiece in order to de-activate the motor. It is thus contemplated that the table look-up feature of the microprocessor  117  may provide a blade speed profile that is initiated once the blade contacts the workpiece and that continues until the blade passes entirely through the workpiece. The blade speed profile is a function of the material and/or material properties (such as density). 
         [0021]    The look-up table may categorize operating parameters according to categories of materials and material densities. For instance, general categories of materials may include metal, wood, ceramic and plastic. General categories of densities may hard, medium and soft. Each general category may be associated with a predetermined motor control regimen, which may be incorporated into a table look-up as discussed above. 
         [0022]    The improved power tool  100  described herein permits “touch-less” evaluation of a workpiece to determine the material of the workpiece and to use this information to control the operation of the tool, thereby improving the efficiency and safety of the cutting operation. The improved power tool  100  may also be able to share or transfer the detected information with an external device such as a computer, a laptop, a smart phone, a tablet, a diagnostic device, or the like. The share/transfer of the detected information can be accomplished either wirelessly, wired (such as via a USB as depicted in  FIG. 3 ), touch (NFC), or the like. Since the system is microprocessor based the material sensing and tool operation control can occur interactively as the operator is advancing the workpiece toward the cutting tool or saw blade  108 . 
         [0023]    Alternatively, and perhaps preferably, the workpiece is advanced to a staging area on the table  102  immediately adjacent the material sensor  120  and held at the staging area for a predetermined time before advancing the workpiece toward the cutting tool. In this instance, the controller  115  may be configured to generate an audible or visible signal to indicate when the workpiece is properly positioned at the staging area and to indicate when it is appropriate to advance the workpiece. For instance, a red light may be energized when the workpiece is at the staging area, a yellow light may be energized as the controller evaluates the workpiece material, adjusts the blade height and commences operation of the saw blade, and a green light may be energized when it is acceptable for the operator to perform the cut. Once the cut is commenced, the cutting tool or saw blade operation can continue automatically, as described above, up to and including motor shut-down or reduction of motor speed once the cut is complete. 
         [0024]    The power tool  100  described herein contemplates a material sensor  120  that is capable of detecting a wide range of materials and material properties. The materials may be wood, metal, plastic, engineered compositions, ceramic, tile, stone and any other material capable of being cut with a power tool and susceptible to detection by a sensor. The sensor or sensors in the material sensor  120  are configured for non-destructive “touchless” detection of material and material properties, such as density. The material sensor  120  and its individual sensors  120   a, b , . . . may be affixed to the underside of the table  102  to be in close proximity to the workpiece. The sensors may be configured and calibrated to evaluate a workpiece having a maximum thickness that can be cut with the particular tool or saw blade, or may have a limited range that is less than the maximum workpiece thickness but that is still capable of accurately determining workpiece material. The material sensor  120  may also incorporate a simple proximity function to indicate whether a workpiece is at the staging area and whether the workpiece has moved past the sensor at the end of the cut. The material sensor may incorporate one or more of a variety of sensor technologies, as explained above. In the realm of optical sensors, the sensor may be an infrared sensor or a charge-coupled device (CCD) with a known sensing range. Sound-based sensors may include an ultrasonic range sensor or a Doppler effect sensor. Electrical or magnetic sensors can include capacitive (such as a wall stud sensor), capacitive displacement, Hall effect or eddy current sensors. 
         [0025]    It can be appreciated that the material sensor  120  may be used independent of any cutting operation. In this case, the operator may simply move the workpiece over the material sensor  120  in a direction perpendicular to the feeding direction ( FIG. 2 ). In one alternative, the material sensor  120  may be removable from the power tool table  102  to be manually moved over the workpiece apart from the power tool. In the case of independent evaluation of the workpiece material, the material sensor may be used to determine the location of inhomogeneities in the workpiece, such as the presence of a nail. The operator may then mark the location on the workpiece and use that mark to position the workpiece so that the cut avoids the inhomogeniety, particularly when the cutting tool is not suitable for cutting through the inhomogeniety (such as a saw blade configured for cutting wood encountering a metal nail). In some embodiments, the material sensor  120  is integrated within an external portable device such as a smart phone, tablet, a diagnostic device or the like. The user may then mount the portable device under the table top for detection of the material properties. Alternatively, the user may suspend the portable device over a structure such as a blade guard with the portable device aimed at the workpiece for detection of the material properties. 
         [0026]    In yet another embodiment, the material sensor may be mounted on a boom or fixture that can be directed over the workpiece to perform the material evaluation. A boom mounted sensor  120  may be integrated into the automatic system described above or may be used independently. The material sensor may also be coupled to the working tool itself, such as for power tools in which the working tool travels over a stationary workpiece. The material sensor is positioned relative to the tool to “see” the workpiece first before engagement by the tool so that the material sensor signal can be received and processed by the controller. 
         [0027]    The controller  115  can be configured to receive the signal(s) from the material sensor  120 , to conduct the material evaluation by evaluating the output signal(s) and to store the results in a memory. Alternatively or in addition the controller may determine the tool height adjustment and motor operating parameters from a table look-up and save these parameters for subsequent implementation. As a further alternative or addition, the controller may interface with an external device and/or a display to inform the operator of the detected material and/or describe the selected operating parameters. For instance, as shown in  FIG. 3  the microprocessor  117  may include a USB interface  130  that can be connected to a laptop or desktop computer. The external computer may be configured to allow the operator to interface directly with the microprocessor to not only receive the sensor information but also to transmit operating instructions to the microprocessor. In this instance the external computer may incorporate the table look-up described above or some other algorithm or parameter storage that provides the height adjustment and motor operation parameters. 
         [0028]    It is further contemplated that the material detection features described herein may be incorporated into a complete automation and control system for all aspects of the operation of the power tool  100 . For instance, the material sensor  120  may be integrated with components operable to: a) sense workpiece thickness in order to automatically adjust blade height; b) determine and/or automatically adjust blade bevel angle; c) determine and/or automatically adjust the position of a riving knife and/or blade guard; and/or d) detect and mitigate blade kick-back conditions. All of these components may cooperate to improve safety, convenience, performance, precision, quality and reliability of the operation of the power tool  100 . The integrated system may also provide data for external access to monitor the performance of the power tool and/or to track and record cutting operations performed with the tool. 
         [0029]    It should be appreciated that while the power tool illustrated in the figures is a portable saw, the material sensor system described herein can be used on a variety of other power tools, portable and stationary (and fixed), including bench top tools such as miter saws, band saws, coping saws, drills, etc. It should further be appreciated that the sensor  120  may be integrated into a power tool, such as in the table  102 , or may be configured to be added to an existing tool In the latter case, the sensor  120  may be affixed to the underside of the table  102  in a suitable manner, such as by an adhesive that does not otherwise interfere with the operation of the sensor. The output  121  of the sensor may be coupled to an external input for a controller or microprocessor associated with the power tool. 
         [0030]    It can also be appreciated that the location of the sensor  120  may be determined by the material of the table  102 . For instance, if the table is metallic, positioning the sensor beneath the table would frustrate the ability to sense the workpiece. However, even with a metallic table, the sensor  120  can be located to “see” the workpiece through the slot  109 . As an alternative, the sensor may be embedded within the table  102  so that the sensor is flush with the surface  104 . In many power tools, the table, or at least the work surface  104 , is formed of a non-metallic material, such as a plastic, which does not interfere with the metal and wood sensors described herein. 
         [0031]    The present disclosure contemplates a power tool having a motor driven tool with parameters of operation of the power tool that depend upon the material of the workpiece. The power tool is provided with a material sensor that determines the material of the workpiece in a non-destructive manner and then provides that information to a controller that is configured to determine the parameters of operation of the tool based on the sensed material. In a further aspect, the parameters may include blade speed and speed profile for a rotary saw power tool, and may also include blade height. In another aspect, the material sensor works interactively with the operation of the power tool during a cutting operation to rapidly sense the material and direct the motor-driven tool accordingly during a single cutting operation. The material sensor may include multiple sensors capable of sensing different materials. 
         [0032]    While the invention has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the invention are desired to be protected.