Abstract:
A portable band saw includes a serviceable/replaceable bumper system for allowing the band saw to be easily repaired if damaged from being dropped. An auxiliary handle is adjustably mounted to the band saw and is releasable from its position if subjected to a large force so as to avoid damage to the handle and tool housing. An adjustable guide shoe includes a toolless adjustment. The front and rear section of the band saw are disposed on opposite sides of a polymeric field case. Compression rods are used to isolate compression forces from the polymeric field case. An electric box assembly including a plastic component box is disposed between the field case and a front section of the band saw. A crash guard is mounted adjacent to the field case and includes a sight guide along an edge thereof and a rear blade guard formed integrally therewith.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 61/025,217, filed on Jan. 31, 2008. 
    
    
     FIELD 
     The present disclosure relates to various improvements to a portable band saw. 
     BACKGROUND 
     This section provides background information related to the present disclosure which is not necessarily prior art. 
     Many tradespersons, such as pipe fitters, steam fitters and electricians, routinely cut metal workpieces such as pipes, tubes and conduit with portable hand-held power saws. In some applications, such as when the end of a pipe or conduit is to be threaded, it is highly desirable that the cut be perpendicular to the axis of the workpiece so that the maximum axial deviation or runout of the cut is less than about one-thirty second of an inch. When this degree of accuracy is needed, the tradesperson was typically forced to employ a free-standing cutoff saw or a portable hand-held band saw. Free-standing cutoff saws, however, are not typically practical due to issues with their cost and size, as well as the free-standing (i.e., non-portable) nature of the saw. 
     Although portable hand-held band saws provide the tradesperson with an efficient yet portable means for cutting work pieces, these tools can be improved by improving their maintenance and damage prevention, increasing their functionality, reducing their weight and improving the accuracy of a cut made by the band saw. 
     SUMMARY 
     This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
     A portable band saw includes a serviceable/replaceable bumper system for allowing the band saw to be easily repaired if damaged from being dropped. The bumper system includes a rigid shroud removably mounted to the band saw and an elastomeric bumper mounted to said rigid shroud. 
     An auxiliary handle is adjustably mounted to the band saw and is releasable from its position if subjected to a large force so as to avoid damage to the handle and tool housing. The front section of the band saw includes at least one bore receiving a spring biased insert having at least one of a detent and a protrusion for engaging the other of a detent and a protrusion on the handle. The spring biased insert allows the handle to disengage from the insert when subjected to a large force, such as by being dropped. 
     An adjustable guide shoe is provided that includes a toolless adjustment mechanism to allow the position of the guide shoe to be easily adjusted. 
     The front and rear section of the band saw are disposed on opposite sides of a polymeric field case. Compression rods are used to isolate compression forces from the polymeric field case. 
     An electric box assembly including a plastic component box is disposed between the field case and a front section of the band saw. The plastic component box can house a control module and a light power supply. One or more routing cavities can extend from the component box and provide a covering for a wire of a wire harness connected to said control module. A light emitting diode can be mounted to a routing cavity of the component box and can be aligned with the band saw blade to cast a shadow along the cut line. 
     A crash guard is mounted adjacent to the field case for protecting the filed case from damage. The crash guard can include a sight guide along an edge thereof and a rear blade guard formed integrally therewith for shielding the user from the return blade. 
     Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       DRAWINGS 
       The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
         FIG. 1  is a perspective view of a portable band saw according to the principles of the present disclosure; 
         FIG. 2  is an exploded perspective view of the portable band saw shown in  FIG. 1 ; 
         FIG. 3  is a perspective view of the portable band saw shown in  FIG. 1  with the auxiliary handle shown in exploded view; 
         FIG. 4  is a perspective view of the portable band saw shown in  FIG. 3  illustrating the assembly of the auxiliary handle; 
         FIG. 5  is a perspective view of the portable band saw shown in  FIG. 4  with the auxiliary handle shown removed to illustrate the spring biased inserts. 
         FIG. 6  is a perspective view of the auxiliary handle; 
         FIG. 7  is a side plan view of the portable band saw showing the auxiliary handle in a forward position; 
         FIG. 8  is a side plan view of the portable band saw showing the auxiliary handle in a upright position; 
         FIG. 9  is a side plan view of the portable band saw showing the auxiliary handle in an angled position; 
         FIG. 10  is a perspective view of the portable band saw shown in  FIG. 1  with the front and rear bumpers shown in exploded view; 
         FIG. 11  is an exploded perspective view of the front shroud and bumper assembly; 
         FIG. 12  is an exploded perspective view of the bumper assembly; 
         FIG. 13  is an exploded perspective view of the rear bumper assembly; 
         FIG. 14  is a perspective view of the portable band saw with the field case removed to illustrate the compression rods and tension bolts of the present disclosure; 
         FIG. 15  is a partially exploded view of the portable band saw illustrating the electric box assembly of the present disclosure; 
         FIG. 16  is plan view of the wire harness according to the principles of the present disclosure; 
         FIG. 17  is a perspective view of the electric box assembly of the present disclosure; 
         FIG. 18  is an exploded perspective view of the electric box assembly of the present disclosure; 
         FIG. 19  is perspective view of a rear of the portable band saw according to the principles of the present disclosure; 
         FIG. 20  is a perspective view of the portable band saw shown in  FIG. 1  with the adjustable shoe shown in exploded view; 
         FIG. 21  is a perspective view of the shoe body; 
         FIG. 22  is partial cut away view illustrating the adjustable shoe according to the principles of the present disclosure; 
         FIG. 23  is a perspective view of the crash guard mounted to the field case according to the principles of the present disclosure; 
         FIG. 24  is an exploded perspective view of the crash guard and field case according to the principles of the present disclosure; 
         FIG. 25  is a rear perspective view of the crash guard mounted to the field case and receiving the blade in a rear blade guard portion according to the principles of the present disclosure; 
         FIG. 26  is top view of the field case illustrating the sight guide according to the principles of the present disclosure; 
         FIG. 27  is a perspective view of a portable band saw illustrating the light system according to the principles of the present disclosure; 
         FIG. 28  is perspective view of the light assembly according to the principles of the present disclosure; and 
         FIG. 29  is an exploded perspective view of the light assembly according to the principles of the present disclosure. 
     
    
    
     Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION 
     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. Although the following description is related generally to portable band saws, it will be understood that the systems and features of the portable band saw, as described and claimed herein, can be used with any appropriate portable tool, such as an appropriate portable cutting device, for example, a circular saw, reciprocating saw, etc. Therefore, it will be understood that the following discussions are not intended to limit the scope of the appended claims. 
     With reference to  FIG. 1 , a portable band saw  10  is shown. The portable band saw  10  can be used to cut through various metal, metal alloy and/or polymeric work-pieces. The portable band saw  10  can include a housing  12 , a power system  14 , a saw blade system  16  and a lighting system  18 . The housing  12  can enclose and/or support each of the power system  14 , the saw blade system  16  and the lighting system  18 . The power system  14  can power the saw blade system  16 , such that the saw blade system  16  can cut through the desired structure. The lighting system  18  can illuminate a work surface associated with the cutting operation of the saw blade system  16  to facilitate the operation of the portable band saw  10 . 
     With reference to  FIGS. 1 and 2 , the housing  12  can include a first or front section  20  and a second or rear section  22 , which can be joined together by a field case  21 , one or more compression rods  24  and at least one tension screw/bolt  26 . As the front section  20  and the rear section  22  of the housing  12  can be substantially similar to a housing associated with a commercially available Heavy-Duty Deep Cut Variable Speed Band Saw, model D28770, manufactured by DeWALT Industrial Tool Co. of Baltimore, Md., the front section  20  and the rear section  22  will not be discussed in great detail herein. Briefly, however, the front section  20  and rear section  22  can be composed of a metal or metal alloy material, and can comprise cast aluminum alloy or magnesium alloy, for example. The front section  20  can include a first or auxiliary handle  28 , while the rear section  22  can include a second or trigger handle  30 . Each of the front section  20  and the rear section  22  can include a bumper system  32 . 
     The auxiliary handle  28  can provide additional stability for the user of the portable band saw  10 , and can be indexed at multiple angles to enable the user to select a comfortable position for the operation of the portable band saw  10 , which can improve the ease of use of the portable band saw  10 . The auxiliary handle  28  can be coupled to the front section  20  of the housing  12  and can pivot or rotate relative to the housing  12 . With additional reference to  FIGS. 3-6 , the auxiliary handle  28  can include a knob  34  ( FIGS. 3 and 4 ), a washer  36  ( FIG. 4 ), a first insert  38  ( FIGS. 3 and 5 ), a second insert  40  ( FIGS. 3 and 5 ), a handle body  42  ( FIGS. 3 ,  4  and  6 ) and a carriage bolt  44  ( FIGS. 3 and 4 ). 
     With reference to  FIGS. 3 and 4 , the knob  34  can comprise any suitable graspable portion that can enable a user to easily rotate the knob  34  in a clockwise or counterclockwise direction while the user is holding the trigger handle  30 . The knob  34  can be rotated relative to the housing  12  in a clockwise direction to secure the auxiliary handle  28  to the housing  12 , and can be rotated in a counterclockwise direction to release the auxiliary handle  28  from the housing  12 . In this regard, the knob  34  can include a bore  34   a . The bore  34   a  can include threads, which can threadably engage mating threads  44   a  on the carriage bolt  44 . Thus, the rotation of the knob  34  relative to the housing  12  can move the knob  34  along the threads  44   a  of the carriage bolt  44  to either tighten or lock the auxiliary handle  28  on the housing  12 , or to release or loosen the auxiliary handle  28  relative to the housing  12 , and thus, enable the auxiliary handle  28  to be pivoted or indexed relative to the housing  12 . 
     With reference to  FIG. 4 , the washer  36  can be positioned between the knob  34  and the first insert  38  to distribute the tightening or compressive force from the knob  34  over a surface of the first insert  38 . With reference to  FIGS. 3 and 5 , the first insert  38  can be coupled to a first bore  46  formed in the housing  12 , and the second insert  40  can be coupled to a second bore  48  formed in the housing  12 . It should be noted that although the first bore  46  and second bore  48  are identified as separate bores, the first bore  46  and second bore  48  could comprise a single bore formed through the housing  12 . Typically, the first bore  46  can be formed opposite the second bore  48 . The first insert  38  and second insert  40  can be coupled to the first bore  46  and second bore  48  through any suitable fastening technique, such as through the use of mechanical fasteners, a press-fit, a snap fit, welding and the like. Alternatively, the inserts  38 ,  40  can be provided with flats that orient the inserts within the  46 ,  48  and springs  41  ( FIG. 5 ) can be disposed within the bores  46 ,  48  to bias the inserts toward the handle  42 . Generally, the first insert  38  and second insert  40  can be composed of a resilient material, which can comprise a metal, metal alloy, polymer or combinations thereof. For example, the first insert  38  and second insert  40  can be composed of a metal or metal alloy and a polymer can be overmolded onto the metal or metal alloy, if desired. The first insert  38  and second insert  40  can each include multiple detents  38   a ,  40   a , which can engage protrusions  42   a  formed on the handle body  42  ( FIG. 3 ). The multiple detents  38   a ,  40   a  can enable the handle body  42  to be pivoted or indexed and secured to the housing  12  in a variety of positions. The springs  41  allow the inserts  38 ,  40  to be retracted out of engagement with the protrusions  42   a  of the handle body when the handle  42  is subjected to a large force, such as by being dropped. The ability of the handle to move when subject to a large force, protects the handle  42  and housing from being damaged if dropped. 
     With reference to  FIGS. 3 and 6 , the handle body  42  can be generally U-shaped, and can include the protrusions  42   a . The protrusions  42   a  can be formed on opposite annular projections  50 . The protrusions  42   a  can be sized to engage the detents  38   a ,  40   a  to enable the handle body  42  to be secured or coupled to the housing  12  in any desired position. Generally, with reference to  FIGS. 7-9 , the handle body  42  can be angled or indexed relative to the housing  12  in any position from about zero degrees ( FIG. 7 ) to about ninety degrees ( FIG. 8 ). For example, as shown in  FIG. 9 , the handle body  42  can be coupled to the housing  12  at about forty-five degrees. With reference back to  FIG. 6 , the annular projections  50  can include throughbores  52 . The throughbores  52  can slideably engage the carriage bolt  44  to enable the handle body  42  to rotate or pivot about the carriage bolt  44  when the knob  34  is rotated accordingly, as shown in  FIGS. 3 and 4 . 
     With reference to  FIGS. 3 and 4 , the carriage bolt  44  can include the threads  44   a  and a head  44   b . The threads  44   a  can engage the bore  34   a  of the knob  34  to enable the handle body  42  to be secured to or released from the housing  12 . The head  44   b  can be sized such that the head  44   b  can apply a compressive force against one of the annular projections  50  of the handle body  42  when the auxiliary handle  28  is coupled to the housing  12 , as shown best in  FIGS. 7-9 . 
     With reference to  FIG. 1 , the trigger handle  30  can be coupled to the rear portion  22  of the housing  12 . As the trigger handle  30  can be substantially similar to a trigger handle associated with the commercially available Heavy-Duty Deep Cut Variable Speed Band Saw, model D28770, manufactured by DeWALT Industrial Tool Co. of Baltimore, Md., the trigger handle  30  will not be discussed in great detail herein. Briefly, however, the trigger handle  30  can enable the user to activate or deactivate the portable band saw  10 , and can enable the user to guide the portable band saw  10  over a work-piece. 
     The housing  12  can include the bumper system  32 , as shown in  FIG. 1 . The bumper system  32  can be coupled to the front section  20  and the rear section  22 . The bumper system  32  can protect the portable band saw  10  from inadvertent falls from various heights. Further, the bumper system  32  can be easily replaceable such that the user of the portable band saw  10  can replace the bumper system  32  himself or herself at a job site, without requiring the user to take the portable band saw  10  to a service station. The bumper system  32  can generally be configured to absorb a significant shock load, which can thereby prevent damage to the housing  12 . By preventing damage to the housing  12 , the portable band saw  10  may remain operable after a significant fall. With additional reference to  FIG. 10 , the bumper system  32  can include a front bumper  54  that can be coupled to the front section  20 , and a rear bumper  56  that can be coupled to the rear section  22 . 
     With reference to  FIGS. 10-12 , the front bumper  54  can include a shroud  54   a  and a bumper  54   b . The shroud  54   a  can be shaped to conform to a shape of the front section  20 , and can include a first or top surface  60 , a second or side surface  62  and one or more coupling features  64 . The shroud  54   a  can be a monolithic member, but could also comprise one or more members to enable partial replacement of the front bumper  54 , if desired. The shroud  54   a  can be composed of any suitable high strength material, such as a metal, metal alloy or polymer, and for example, steel. The shroud  54   a  can be coupled to the front section  20 , via any suitable mechanical fastening technique, such as through a snap-fit or the use of mechanical fasteners, for example, rivets, bolts, screws, etc. Generally, as shown in  FIG. 10 , the top surface  60  can protect a top surface  20   a  of the front section  20 , while the side surface  62  can protect an annular area  20   b  below the top surface  20   a  of the front section  20 . The coupling features  64  can couple the top surface  60  of the shroud  54   a  to the top surface  20   a  of the front section  20 , and can couple the side surface  62  to the annular area  20   b . If mechanical fasteners are employed to couple the shroud  54   a  to the housing  12 , then the coupling features  64  can comprise apertures, however, it will be understood that the coupling features  64  can comprise any desired feature to attach the shroud  54   a  to the housing  12 , such as mating projections. 
     With continuing reference to  FIGS. 10-12 , the bumper  54   b  can be shaped to conform to a shape of the side surface  62  of the shroud  54   a , and as best shown in  FIG. 12 , can include an insert  66 , a polymeric member  68  and one or more coupling features  70 . The bumper  54   b  can be a monolithic member, but could also comprise one or more members to enable partial replacement of the front bumper  54 , if desired. The insert  66  can be composed of any suitable high strength material, for example, a metal, metal alloy or polymer, such as steel. The insert  66  can provide the bumper  54   b  with added rigidity. The insert  66  can be disposed adjacent to the side surface  62  of the shroud  54   a  when the bumper  54   b  is coupled to the shroud  54   a.    
     The polymeric member  68  can be coupled adjacent to a surface  66   a  of the insert  66 . The polymeric member  68  can be coupled to the insert  66  through any suitable technique, such as by overmolding the polymeric member  68  onto the insert  66 , or by insert molding the insert  66  within the polymeric member  68 . The polymeric member  68  can be composed of any suitable shock absorbing material, for example, rubber. The coupling features  70  can couple the bumper  54   b  to the shroud  54   a . The bumper  54   b  can be coupled to the shroud  54   a , via any suitable mechanical fastening technique, such as through a snap-fit or the use of mechanical fasteners, for example, rivets, bolts, screws, etc. If mechanical fasteners are employed to couple the bumper  54   b  to the housing  12 , then the coupling features  70  can comprise apertures that extend through both the insert  66  and the polymeric member  68 , however, it will be understood that the coupling features  70  can comprise any desired feature to attach the bumper  54   b  to the housing  12 , such as mating projections. 
     With reference to  FIG. 10 , the rear bumper  56  can be coupled to the rear section  22  of the housing  12 . Generally, the rear bumper  56  can be coupled to a side  22   a  of the rear section  22 , to protect an annular area surrounding a top surface  22   b  of the rear section  22 . The rear bumper  56  can be annular, however, the rear bumper  56  can be shaped as desired to conform to the shape of the rear section  22 . The rear bumper  56  can be a monolithic member, but could also comprise one or more members to enable partial replacement of the rear bumper  56 , if desired. With reference to  FIG. 13 , the rear bumper  56  can include an insert  72 , a polymeric member  74  and one or more coupling features  76 . 
     The insert  72  can be composed of any suitable high strength material, for example, a metal, metal alloy or polymer, such as steel. The insert  72  can provide the rear bumper  56  with added rigidity. The insert  72  can be disposed adjacent to the side  22   a  of the rear section  22  when the rear bumper  56  is coupled to the rear section  22 . 
     The polymeric member  74  can be coupled adjacent to a surface  72   a  of the insert  72 . The polymeric member  74  can be coupled to the insert  72  through any suitable technique, such as by overmolding the polymeric member  74  onto the insert  72 , or by insert molding the insert  72  within the polymeric member  74 . The polymeric member  74  can be composed of any suitable shock absorbing material, for example, rubber. 
     The coupling features  76  can couple the rear bumper  56  to the rear section  22 . The rear bumper  56  can be coupled to the rear section  22 , via any suitable mechanical fastening technique, such as through a snap-fit or the use of mechanical fasteners, for example, rivets, bolts, screws, etc. If mechanical fasteners are employed to couple the rear bumper  56  to the housing  12 , then the coupling features  76  can comprise apertures that extend through both the insert  72  and the polymeric member  74 , however, it will be understood that the coupling features  76  can comprise any desired feature to attach the rear bumper  56  to the housing  12 , such as mating projections. 
     With reference to  FIG. 2 , the field case  21  can be coupled between the front section  20  and the rear section  22  of the housing  12 . Generally, the field case  21  can be composed of a polymeric material, and can house at least a portion of the power system  14 . The field case  21  can include a first bore  21   a , a second bore  21   b  and a third bore  21   c . The first bore  21   a , the second bore  21   b  and the third bore  21   c  can extend at least partially through the field case  21 . For example, the first bore  21   a  and the second bore  21   b  can be formed in the field case  21  such that a center area of the first bore  21   a  and second bore  21   b  can be devoid of the field case  21  to enable a portion of the saw blade system  16  to be coupled to the field case  21 , via the compression rods  24 , as will be discussed. The first bore  21   a  and the second bore  21   b  can be disposed at one side of the field case  21  and can be sized to receive the compression rods  24 . The third bore  21   c  can pass through a side of the field case  21  opposite the first bore  21   a  and second bore  21   b . The third bore  21   c  can be sized to receive the tension screw/bolt  26 . 
     With reference to  FIGS. 2 and 14 , the compression rods  24  can be coupled between the front section  20  and the rear section  22 . A first compression rod  24   a  can be received in the first bore  21   a , and a second compression rod  24   b  can be received in the second bore  21   b  of the field case  21 , as shown in  FIG. 14 . The front section  20  and the rear section  22  can retain the compression rods  24  within the field case  21 . The compression rods  24  can receive a compression load C that can be generally inherent in the portable band saw  10 , and thus, the compression rods  24  can relieve the field case  21  from the compression load C, which can remove the compliant nature associated with the field case  21  being composed of a polymeric material. The compression rods  24  can also couple at least a portion of the saw blade system  16  to the field case  21 , as will be discussed herein. 
     With continued reference to  FIGS. 2 and 14 , the tension screw/bolt  26  can be received through the third bore  21   c  of the field case  21 , and can extend from the front section  20  to the rear section  22 . The tension screw/bolt  26  can be threaded into a bore  80  defined in the rear section  22 , which can serve to retain the tension screw/bolt  26  within the bore  21   c . The tension screw/bolt  26  can receive a tension or tensile load T that can be generally inherent in the portable band saw  10 , and thus, the tension screw/bolt  26  can relieve the field case  21  from the tensile load T, which can remove the compliant nature associated with having the field case  21  composed of a polymeric material. 
     With reference to  FIG. 15 , the power system  14  can be encased by the housing  12 . The power system  14  can drive the saw blade system  16  to cut the work-piece. The power system  14  can include a trigger  100 , a motor  102  and a control system  104  via one or more wires  100   b  (shown in  FIG. 16 ). As the trigger  100  and motor  102  can be substantially similar to a trigger and motor associated with a commercially available Heavy-Duty Deep Cut Variable Speed Band Saw, model D28770, manufactured by DeWALT Industrial Tool Co. of Baltimore, Md., the trigger  100  and motor  102  will not be discussed in great detail herein. Briefly, however, the trigger  100  can include an actuator  100   a  that can be in communication with the control system  104 . The actuator  100   a  can protrude from the trigger handle  30  to enable a user to activate or deactivate the portable band saw  10 . Based on the input from the user, the actuator  100   a  can transmit a signal to the control system  104  to activate the motor  102 . 
     With reference to  FIG. 15 , the motor  102  can be a DC motor, such as a brushless DC motor. The motor  102  can be housed in the field case  21 , and can be responsive to and in communication with the control system  104 . The motor  102  can also be coupled to the saw blade system  16 , via an output shaft, for example, to drive the saw blade system  16 . As will be discussed, based on the input received by the actuator  100   a , the control system  104  can provide the motor  102  with an appropriate current at an appropriate voltage phase angle to drive the saw blade system  16 . 
     The control system  104  can be coupled to a first end  21   d  of the field case  21 , adjacent to the motor  102 . The control system  104  can be operable to activate and deactivate the motor  102  based on the user input received from the trigger  100 . With reference to  FIGS. 15-18 , the control system  104  can include a component box  106  ( FIGS. 15 ,  17  and  18 ), a controller  108  ( FIG. 18 ), a lighting power supply  110  ( FIG. 18 ) and a wiring harness  112  ( FIGS. 16-18 ). 
     With reference to  FIGS. 17 and 18 , the component box  106  can be composed of a polymeric material, which can serve to electrically insulate the electrical components within the component box  106  from the metallic portions of the housing  12 , such as the front section  20  and the rear section  22 . The component box  106  is received in a cavity  23  in a rear portion of the front section  20 , as illustrated in  FIGS. 10 and 15 . The component box  106  can include apertures  114 , a component cavity  116 , a first routing cavity  118 , a second routing cavity  120 , and coupling members  122 . The apertures  114  can receive mechanical fasteners, such as screws, bolts, etc. to couple the component box  106  to the field case  21 . The component cavity  116  can be generally rectangular, and can have a depth sized to receive and retain the controller  108  and the lighting power supply  110  within the component box  106 , as shown in  FIG. 17 . The first routing cavity  118  and second routing cavity  120  can be sized to enable wires from the wiring harness  112  to be routed away from the metallic portions of the housing  12 . The coupling members  122  can retain the controller  108  and the lighting power supply  110  within the component box  106 . The coupling members  122  can comprise flexible arms to enable the controller  108  and the lighting power supply  110  to be inserted into the component box  106 . 
     With reference to  FIG. 18 , the controller  108  can be in communication with and responsive to the trigger  100  and the motor  102  to enable the operation of the portable band saw  10 , as will be discussed. The controller  108  can also be in communication with and responsive to the lighting system  18  to activate or deactivate the lighting system  18 , as will also be discussed herein. It should be understood that as used herein, the term controller refers to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, or other suitable components that provide the described functionality. Further, as the controller  108  can be substantially similar to a controller associated with a commercially available Heavy-Duty Deep Cut Variable Speed Band Saw, model D28770, manufactured by DeWALT Industrial Tool Co. of Baltimore, Md., the controller  108  will not be discussed in great detail herein. Briefly, however, the controller  108  can provide a selected current at a selected voltage phase angle to the motor  102  from a field power source (not shown) based on the signal received from the actuator  100   a . The controller  108  can also provide current to the lighting system  18  from the lighting power supply  110  based on a signal received from the lighting system  18 , as will be discussed. 
     With reference to  FIG. 18 , the lighting power supply  110  can comprise any suitable power source capable of providing current to the lighting system  18 , such as a battery, capacitor, etc. The lighting power supply  110  can include members  110   a  to couple the wiring harness  112  to the component box  106 . The wiring harness  112  can include apertures formed in a projection  112   a  that can receive the members  110   a  to couple the wiring harness  112  to the component box  106 . Generally, the wiring harness  112  can be press-fit onto the members  110   a.    
     With reference to  FIG. 16 , the wiring harness  112  can include one or more controller connections  124 , a lighting connection  126 , a lighting power supply connection  128  and a feedback coil  130 . The controller connections  124 , the lighting connection  126 , the lighting power supply connection  128  and the feedback coil  130  can be overmolded with a polymeric material to form the wiring harness  112 . As the controller connections  124 , the lighting connection  126  and the lighting power supply connection  128  can be similar to the connections employed with the commercially available Heavy-Duty Deep Cut Variable Speed Band Saw, model D28770, manufactured by DeWALT Industrial Tool Co. of Baltimore, Md., the controller connections  124 , the lighting connection  126  and the lighting power supply connection  128  will not be discussed in great detail herein. The feedback coil  130  can be disposed within a center  132  of the overmolded wiring harness  112 , which can be adjacent to the motor  102  when the component box  106  is coupled to the field case  21 . The feedback coil  130  can sense the magnetic field generated by the motor  102 , and can communicate this information to the controller  108  via an appropriate one of the controller connections  124 . Based on the signal from the feedback coil  130 , the controller  108  can increase or decrease the speed of the motor  102 . By incorporating the feedback coil  130  within the center  132  of the overmolded wiring harness  112 , the feedback coil  130  can remain in the same position during the use of the portable band saw  10 , which can improve the accuracy of the signal received from the feedback coil  130 . 
     With reference to  FIG. 19 , the saw blade system  16  can be driven by the motor  102  of the power system  14 . The saw blade system  16  can include a blade  200 , one or more pulleys  202 , a shoe  204 , a crash plate system  206  and a sight guide  208 . The blade  200  can comprise a conventional band saw blade, such as a Bi-Metal Portable Band Saw Blade, model DW3891, commercially available from DeWALT Industrial Tool Co. of Baltimore, Md. The pulleys  202  can be substantially similar to pulleys associated with the commercially available Heavy-Duty Deep Cut Variable Speed Band Saw, model D28770, manufactured by DeWALT Industrial Tool Co. of Baltimore, Md., and thus, the pulleys  202  will not be discussed in great detail herein. Briefly, however, one of the pulleys  202  can be coupled to the motor  102  to drive the blade  200  around the housing  12 . 
     With reference to  FIGS. 20-22 , the shoe  204  can be positioned adjacent to the work-piece to support the work-piece during the operation of the portable band saw  10 . The shoe  204  can be configured to enable the user of the portable band saw  10  to adjust a position of the shoe  204  relative to the work-piece without requiring tools. The shoe  204  can include a shoe body  210 , a block  212 , a stud  214  and a lever  216 . 
     With reference to  FIGS. 20 and 21 , the shoe body  210  can define a first end  218 , a second end  220 , a first or front side  222  and a second or rear side  224 . The first end  218  can include one or more apertures  226  and a blade passage  228 . The apertures  226  can be sized to receive one or more mechanical fasteners  226   a , such as screws, bolts, etc., to couple the shoe body  210  to the block  212 . The blade passage  228  can enable the blade  200  to pass through the shoe body  210 . The second end  220  of the shoe body  210  can be positioned adjacent to the work-piece when the shoe  204  is coupled to the housing  12 . The front side  222  can face the front section  20  when the shoe  204  is coupled to the rear section  22 . The rear side  224  can be opposite the front side  222 , and thus, can be adjacent to the rear section  22  when the shoe  204  is coupled to the rear section  22 . The rear side  224  can also include a lip  224   a  ( FIG. 21 ). The lip  224   a  can cooperate with the block  212  to couple or clamp the shoe body  210  to the rear section  22  of the housing  12 . 
     The block  212  can be coupled to the shoe body  210  via the mechanical fasteners  226   a . The block  212  can include a projection  230 , a clamping surface  232  and mating features  234 . With reference to  FIG. 22 , the projection  230  can be generally elliptical, and can be sized to slide within a slot  236  formed in the rear section  22  of the housing  12 . As will be discussed, the block  212  can cooperate with the slot  236  to enable the shoe body  210  to be positioned and secured in any desired position along a length of the slot  236 . The slot  236  can comprise a T-slot to enable only the projection  230  of the block  212  to be received in and slide within the slot  236 . As shown in  FIG. 20 , the projection  230  can define apertures  230   a  for receipt of the mechanical fasteners  226   a  to couple the block  212  to the shoe body  210 , and thus, the apertures  230   a  can be threaded, if necessary, to mate with the mechanical fasteners  226   a.    
     With reference to  FIGS. 20 and 22 , the clamping surface  232  can cooperate with the lip  224   a  to couple or clamp the shoe  204  to the rear section  22  of the housing  12 . In this regard, the rear section  22  of the housing  12  can include a rail  238  adjacent to the slot  236  ( FIG. 22 ). When the projection  230  is positioned within the slot  236 , the lip  224   a  can abut against a first side of the rail  238  and the clamping surface  232  can abut against a second side of the rail  238  to clamp the shoe  204  to the housing  12 . With reference to  FIG. 21 , the clamping surface  232  can include a taper  232   a . The taper  232   a  can enable the block  212  to be forced tightly against the rail  238  to firmly clamp the shoe body  210  to the housing  12 . 
     With reference to  FIGS. 20-22 , the mating features  234  can be defined on a surface opposite the clamping surface  232 . The mating features  234  can include any feature capable of engaging the stud  214  in a variety of positions, such as ridges, angled projections, detents, etc. The mating features  234  can engage the stud  214  such that a force applied to the stud  214 , via the lever  216 , can be applied to the block  212  to clamp the shoe  204  to the housing  12 . Thus, the mating features  234  can cooperate with the stud  214  to lock or secure the shoe  204  in a desired vertical position relative to the housing  12 . 
     With reference to  FIGS. 20 and 22 , the stud  214  can include a first end  240  and a second end  242 . The first end  240  of the stud  214  can include at least one mating feature  240   a . The mating feature  240   a  can be configured to engage the mating features  234  on the block  212  to transmit a torque from the lever  216  to the block  212  to clamp the shoe  204  to the housing  12 . For example, if the mating features  234  of the block  212  comprise angled projections, then the mating feature  240   a  of the stud  214  can comprise a valley. The second end  242  of the stud  214  can be configured to couple the lever  216  to the stud  214 , and thus, the second end  242  can define a bore that can be threaded, keyed, notched, etc. to couple the lever  216  to the stud  214 . 
     With reference to  FIGS. 20 and 22 , the lever  216  can include a first end  216   a  that can couple the lever  216  to the stud  214 , and a second end  216   b  that can receive an input from the user of the portable band saw  10 . The first end  216   a  can be configured to mate within the bore  242   a  of the second end  242  of the stud  214 , and thus, the first end  216   a  can be threaded, keyed, notched, etc. to fixedly couple the lever  216  to the stud  214 . In addition, it should be understood that although the stud  214  and lever  216  are described herein as being discrete elements, the stud  214  and lever  216  could also be integrally formed. The second end  216   b  of the lever  216  can be sized such that the user can easily grasp the lever  216  to rotate the lever  216  clockwise or counterclockwise relative to the housing  12 . In this regard, the lever  216  can be rotated clockwise to apply the torque to the block  212 , via the stud  214 , to clamp the shoe  204  in a desired position relative to the housing  12 . The lever  216  can be rotated counterclockwise to release the torque from the block  212 , by disengaging the mating features  234  of the block  212  from the mating feature  240   a  of the stud  214 , to enable the projection  230  of the block  212  to be slid into a desired position within the slot  236 . Thus, the lever  216  can enable tool-less adjustment of the shoe  204  relative to the housing  12 , which can enable quick adjustments of the shoe  204  on a job site. 
     With reference to FIGS.  19  and  23 - 25 , the saw blade system  16  can also include the crash plate system  206 . The crash plate system  206  can protect a bottom  250  of the field case  21  from damage that may be caused by the portable band saw  10  contacting the work-piece after the cutting operation due to the inherent follow through motion of the portable band saw  10 . The crash plate system  206  can include a crash plate  252  and a blade guard  254 . The crash plate  252  and blade guard  254  can be discrete members, or can be integrally formed into a monolithic member. The crash plate  252  and blade guard  254  can be composed of any suitable high strength material, such as a metal, metal alloy or resilient polymer. The crash plate  252  can protect the field case  21  from damage, while the blade guard  254  can protect the user from a rear section  200   a  of the blade  200  ( FIG. 25 ). 
     The crash plate  252  can be configured to mate with the bottom  250  of the field case  21 , and for example, can be generally concave in shape. As shown in  FIG. 24 , the crash plate  252  can also be sized to fit in the void defined between the first bore  21   a  and second bore  21   b  of the field case  21 , so that the compression rods  24   a ,  24   b  can be used to couple the crash plate  252  to the field case  21 . It will be understood that any suitable technique could be used to couple the crash plate  252  to the field case  21 , such as welding, adhesives, mechanical fasteners, etc. The crash plate  252  can include a top surface  256 , a rear surface  258 , a first side  260 , a second side  262  and throughbores  264 . 
     With reference to  FIGS. 23 and 24 , the top surface  256  can be positioned adjacent to the field case  21 , and can be generally smooth to mate with a generally smooth exterior of the field case  21 . The rear surface  258  can be opposite the top surface  256 , and can include one or more crush ribs  258   a . The crush ribs  258   a  can absorb and distribute forces incurred when the portable band saw  10  inadvertently contacts the work-piece. The first side  260  can be coupled to the sight guide  208 , and the second side  262  can be coupled to the blade guard  254 . The throughbores  264  can be sized to slideably receive the compression rods  24  therethrough to couple the crash plate  252  to the field case  21  ( FIG. 23 ). 
     With reference to FIGS.  19  and  23 - 25 , the blade guard  254  can be coupled to or formed on the second side  262  of the crash plate  252 . As discussed, the blade guard  254  can protect or guard the user from the rear portion  200   a  of the blade  200  ( FIG. 25 ), and can also shield the blade  200  from debris or objects adjacent to the work-piece. The blade guard  254  can define a passage  254   a . The passage  254   a  can be sized to enable the blade  200  to pass therethrough, and can generally have a depth configured such that a majority of the blade  200  is disposed within the passage  254   a.    
     With reference to  FIGS. 24 and 26 , the sight guide  208  can be coupled to the first side  260  of the crash plate  252  ( FIG. 24 ). In this regard, the sight guide  208  can be coupled to the first side  260  such that the sight guide  208  can extend substantially an entire length of the first side  260  of the crash plate  252 . The sight guide  208  can be comprised of any suitable material, such as a metal, metal alloy or polymer, that can be coated with a color, which contrasts with the field case  21 , such as red, to enable the user to easily view the sight guide  208 . The sight guide  208  can be coupled to the crash plate  252  via any suitable technique, such as molding, adhesives, mechanical fasteners, etc. For example, the sight guide  208  can comprise a polymeric material that can be adhesively coupled to the crash plate  252 , or the sight guide  208  can comprise a polymeric coating, such as paint, that can be applied to the first side  260  of the crash plate  252 . The sight guide  208  can assist the user in predicting the cutting plane of the blade  200 , without reducing or altering the blade  200 . In use, the user can align the sight guide  208  with a line or scribe on the work-piece and maintain this alignment throughout the cutting operation, which can assist the user in producing accurate cuts. 
     With reference to  FIGS. 27-29 , the lighting system  18  can illuminate the work-piece, generally in an area adjacent to and encompassing the desired cutting area or cutting path through the work-piece. The lighting system  18  can be housed within the component box  106  of the control system  104  on the front section  20  of the housing  12 . The lighting system  18  can include a light source  300  ( FIG. 29 ), a printed circuit board (PCB)  302  ( FIG. 29 ), a baffle  304  ( FIGS. 28 and 29 ), a housing  306  ( FIGS. 28 and 29 ) and a switch  308  ( FIG. 27 ). 
     With reference to  FIGS. 27 and 29 , the light source  300  can comprise any suitable light emitting device, such a light emitting diode (LED), organic light emitting diode (OLED), etc. If a LED is employed as the light source  300 , the LED can comprise a one-half watt LED. The light source  300  can emit light rays R onto the work-piece to aid the user in the cutting operation. The light source  300  can be coupled to the PCB  302 . 
     With reference to  FIG. 29 , the PCB  302  can be in communication with and responsive to the controller  104 , via a connector  302   a , to receive power or current from the lighting power supply  110 . The PCB  302  can include suitable circuitry to power the light source  300  with the power received from the lighting power supply  110 . Upon receipt of the current from the controller  104 , the PCB  302  can activate the light source  300  to illuminate the work-piece. 
     With reference to  FIGS. 28 and 29 , the baffle  304  can be positioned over the light source  300  and the PCB  302 . The baffle  304  can be generally annular, and can be sized to surround the light source  300  and the PCB  302  such that the PCB  302  is hidden from the view of the user. The baffle  304  can be composed of any suitable heat resistant material, such as a metal, metal alloy or polymer. The baffle  304  can include a bore  304   a , a shade  304   b  and keys  304   c . The bore  304   a  can be sized to enable the light source  300  and the PCB  302  to be retained within the baffle  304 . The shade  304   b  can be generally V-shaped, and can cover at least a portion of the light source  300 . The shade  304   b  can prevent the light rays from the light source  300  from shining in the user&#39;s eyes. The keys  304   c  can ensure that the baffle  304  is properly inserted within the housing  306 , and that the baffle  304  does not rotate relative to the housing  306 . 
     The housing  306  can couple the lighting system  18  to the component box  106 . The housing  306  can be composed of any suitable material, such as a metal, metal alloy or polymer, and can generally comprise a translucent polymer. The housing  306  can include a bore  306   a  and at least one coupling feature  306   b . The bore  306   a  can be configured to receive the baffle  304 , and can include mating keys  312 . The mating keys  312  can engage the keys  304   c  of the baffle  304 , which can ensure that the baffle  304  is properly orientated and remains properly orientated within the housing  306 . The coupling feature  306   b  can couple the housing  306  to the component box  106 . For example, the coupling feature  306   b  can comprise a bore for receipt of a mechanical fastener, such as a screw, bolt, etc. to couple the housing  306  to the component box  106 , as shown in  FIG. 15 . 
     With reference to  FIGS. 15 and 27 , the switch  308  can also be coupled to the component box  106 , and can be in communication with the controller  108 . The switch  308  can be coupled to the component box  106  such that the switch  308  can be easily manipulated by the user. In this regard, the switch  308  can enable the user to activate or deactivate the light source  300 . Thus, based on the user input received, the switch  308  can transmit a signal to the controller  108 , which can then transmit or cease transmitting power to the PCB  302 , effectively activating or deactivating the light source  300 . 
     In order to assemble the lighting system  18 , the light source  300  can be coupled to the PCB  302 , and that assembly can be inserted into the baffle  304 . Then, the baffle  304  can be inserted into the housing  306 , which can then be coupled to the component box  106 . The user can then manipulate the switch  308  to activate or deactivate the light source  300 . Thus, the lighting system  18  can be easily assembled and coupled to the portable band saw  10  to enable a user to selectively illuminate the work-piece, while not projecting light rays into the user&#39;s eyes. 
     The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the invention, and all such modifications are intended to be included within the scope of the invention.