Abstract:
A saw system in one embodiment includes a base including a rail system, a table positionable on the rail system and including a work piece support surface defining a support plane, and a roller system attached to the table and configured to engage the rail system when the table is positioned on the rail system, the roller system including a helical actuator assembly configured such that rotational movement of an actuator rod from a first position to a second position causes at least one roller to move along a locking axis between a third position whereat the at least one roller is not engaged with the rail system and a fourth position whereat the at least one roller is engaged with the rail system, wherein the locking axis is substantially parallel to the support plane when the table is positioned on the rail system.

Description:
FIELD OF THE INVENTION 
     This patent relates generally to the field of devices used to cut tiles and other hard materials, including materials which require cooling while being worked. 
     BACKGROUND 
     Tile saws are widely used for cutting hard materials such as bricks and tiles. These hard materials require a cooling liquid to be applied as they are being cut since high temperature working of the material may result in cracking. Accordingly, tile saw systems typically include a power head assembly, a table, a base for supporting the table and a water tray located under the base. The system is configured to apply a stream of water to a blade held within the power head assembly. The water flows over the work piece and is collected in the water tray. The water is thus used to cool the blade and the work piece. Additionally, debris formed by cutting the work piece is entrapped in the water. 
     In some tile saw systems, the table upon which a work piece is supported is movable with respect to the power head assembly. This allows for increased control over the cut since the work piece can be secured to the table at a desired orientation. In such moving table systems, a rail structure may be provided on the base. The rail structure is engaged by rollers attached to the table. By applying force to the table, the rollers roll along the rail system allowing the work piece to be brought into contact with the blade in the power head assembly. 
     While rail and roller system can be very effective in increasing the accuracy of cuts, the rail and roller system are generally exposed to water spray which carries debris that is generated by the cutting operation. As a result, the rails and rollers become coated with debris which interferes with smooth operation of the rail and roller system. This interference necessitates increased use of force by the operator and erratic movement of the table. Consequently, cuts become more difficult to control and accuracy of the cuts is reduced. Additionally, operation of the rail and roller system coated with interfering debris causes increased wear of the rail and roller system further adding to the imprecision of cuts. 
     In order to alleviate the effects of debris build-up on rail and roller systems, the systems must be cleaned. Cleaning of the systems is problematic in some systems, however, because of the location of the rail and roller system underneath the table as well as the tight clearances in the rail and roller system. 
     What is needed is a rail and roller system which can be used to guide movement of a table with a work piece positioned thereon. What is further needed is a system which allows a user to easily and thoroughly remove debris from the rail and roller system. 
     SUMMARY 
     In accordance with one embodiment of the disclosure, a saw system includes a base including a rail system, a table positionable on the rail system and including a work piece support surface defining a support plane, and a roller system attached to the table and configured to engage the rail system when the table is positioned on the rail system, the roller system including a helical actuator assembly configured such that rotational movement of an actuator rod from a first position to a second position causes at least one roller to move along a locking axis between a third position whereat the at least one roller is not engaged with the rail system and a fourth position whereat the at least one roller is engaged with the rail system, wherein the locking axis is substantially parallel to the support plane when the table is positioned on the rail system. 
     In another embodiment, a saw system includes a base including a rail system, a table removably positioned on the rail system and including a work piece support surface defining a support plane, at least one roller attached to the table and configured such that when the table is positioned on the rail system, the at least one roller is movable along an axis parallel to the support plane between a first position spaced apart from the rail system and a second position whereat the at least one roller is engaged with the rail system, and a transfer mechanism configured to force movement of the at least one roller between the first position and the second position in response to rotation of an actuator rod between a third position and a fourth position. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  depicts a perspective view of a tile saw system in accordance with principles of the present invention; 
         FIG. 2  depicts a partial perspective bottom view of the system of  FIG. 1  showing a roller system that can be used to releasably connect a table to a rail system; 
         FIG. 3  depicts an inverted exploded perspective view of the roller system of  FIG. 2 ; 
         FIG. 4  depicts an inverted perspective view of the roller system of  FIG. 2 ; 
         FIG. 5  depicts a partial perspective bottom view of a locking mechanism that inhibits inadvertent release of the roller system of  FIG. 2  using a strike plate and a resilient latch; 
         FIG. 6  depicts a partial perspective view of the latch of the locking mechanism of  FIG. 5 ; 
         FIG. 7  depicts a partial top plan view of a locking mechanism that inhibits inadvertent release of the roller system of  FIG. 2  using a leaf spring attached to a pin, wherein a latch pivotably connected to a handle selectively compresses the leaf spring to allow rotation of the handle; 
         FIG. 8  depicts a partial perspective top view of a locking mechanism that inhibits inadvertent release of the roller system of  FIG. 2  using a bar inserted into a slot in the handle; 
         FIG. 9  depicts a partial front cross sectional view of the locking mechanism of  FIG. 8 ; 
         FIG. 10  depicts a partial top perspective view of a locking mechanism that inhibits inadvertent release of the roller system of  FIG. 2  using a pivoting latch and a ledge on a strike plate; 
         FIG. 11  depicts a partial top perspective view of the locking mechanism of  FIG. 10  with the handle removed; 
         FIG. 12  depicts a partial top perspective view of a locking mechanism that inhibits inadvertent release of the roller system of  FIG. 2  using a rotating latch that extends through a handle and a keyed bore in a strike plate; 
         FIG. 13  depicts a partial plan view of the strike plate of  FIG. 12  with the latch rotated such that the lock block is not aligned with the keyed bore of the strike plate; 
         FIG. 14  depicts a partial top perspective view of the locking mechanism of  FIG. 12  with the latch rotated to align the lock block with the keyed bore in the strike plate; and 
         FIG. 15  depicts a partial plan view of the strike plate of  FIG. 12  with the latch rotated such that the lock block is aligned with the keyed bore of the strike plate. 
     
    
    
     DESCRIPTION 
     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 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. 
       FIG. 1  depicts a saw system  100 . The saw system  100  includes a base  102 , a support structure  104 , and a table assembly  106 . A power tool (not shown) is supported by the support structure  104  at a location above the base  102 . The base  102  includes a tray portion  108  that may be configured to collect water. The tray portion  108  may include one or more connections (not shown) for supplying water to the saw system  100  and for providing drainage of the tray portion  108 . 
     The saw system  100  further includes a rail system  110  which in this embodiment includes two rails  112  and  114  fixedly attached to the base  102  and extending along the entire length of the base  102 . The rails  112  and  114  are substantially mirror images of each other and are described more fully with reference to rail  112  which is shown more clearly in  FIG. 2 . 
     The rail  112  includes a substantially “U” shaped base  120  with a number of mounting holes  122  extending through a bottom portion  124  of the base  120  at locations above the tray portion  108 . A guide rod  126  is fixedly attached to an inner wall  128  of the base  120 . A stiffening member  130  extending from the inner wall  128  to the bottom portion  124  provides the inner wall  128  with increased rigidity. The guide rod  126  and stiffening member  130  extend along substantially the entire length of the inner wall  128 . 
     Returning to  FIG. 1 , the table assembly  106  includes a table  140 . The table  140  has a generally planar work piece support surface  142  which defines a support plane. Various trenches  144  provided in the support surface  142  allow work pieces (not shown) to be supported at various angles, typically with the assistance of an angled block (not shown) or the like. The table  140  is attached to the rail system  110  by a pair of stationary rollers  146 / 148  and a pair of movable rollers  150 / 152  (see  FIG. 2 ). The rollers  146 / 148 / 150 / 152  are part of a roller system  154  that is shown in further detail in  FIG. 3 . 
     The roller system  154  includes a handle  156  connected to an actuator rod  158 . The actuator rod  158  includes a shank portion  160  and a shaft portion  162 . A helical slot  164  extends from a distal end  166  of the shaft portion  162  toward the shank portion  160 . The slot  164  extends from the outer surface  168  of the shaft portion  162  to an inner wall  170  which defines a bore  172 . A bore  174 , which in this embodiment opens to the slot  164 , is located near the distal end  166  and extends from the outer surface  168  to the inner wall  170 . 
     The shaft portion  162  is sized to extend through a hole  176  in a support flange  180 . The slot  164  is sized to receive a tab  182  which extends from the support flange  180  into the hole  176 . The bore  172  of the actuator rod  158  is sized to receive a proximal end portion  184  of an actuator rod follower  186 . The actuator rod follower  186  includes a bore  188  sized to receive a pin  190 . A neck  192  connects the proximal end portion  184  to a reduced diameter portion  194 . 
     The reduced diameter portion  194  is sized to fit within a sleeve bearing  196  which in turn is sized to be received within a bore  198  of a roller support plate  200 . The neck portion  192  is not sized to fit within the bore  198 . The roller support plate  200  includes two roller receptacles  202 / 204  on a lower surface  206 . The roller receptacles  202 / 204  are configured to rotatably secure the movable rollers  150 / 152  to the roller support plate  200 . The upper surface  208  includes two articulation areas  210 / 212  at the outer edges of the upper surface  208 . 
     The two articulation areas  210 / 212  align with two articulation areas  214 / 216  on a roller support base  218 . The roller support base  218  is positioned on a flange  220  which is attached to the table  140  (see  FIG. 2 ). A pair of clamp bearings  222  clamps the roller support plate  200  to the roller support base  218  with the articulation areas  210 / 212  in contact with the articulation areas  214 / 216 , respectively. The clamp bearings  222  include bearing lips  224  which bear against the lower surface  206  of the roller support plate  200 . Stop portions  226  of the clamp bearings  222  limit movement of the roller support plate in a direction toward the support flange  180 . 
     The roller system  154  is assembled by inserting the reduced diameter portion  194  of the actuator rod follower  186  within the sleeve bearing  196  (see  FIG. 3 ). The reduced diameter portion  194  and the sleeve bearing  196  are then inserted into the bore  198  in the roller support plate  200 . The reduced diameter portion  194  is sized such that as the neck  192  comes into abutment with the roller support plate  200 , a portion of the reduced diameter portion  194  extends outwardly of the bore and a snap ring  228  can be used to preclude movement of the neck  192  away from the roller support plate  200 . 
     Next, the roller support plate  200  and the actuator rod follower  186  are positioned on the roller support base  218  which is attached to the flange  220  which is, in turn, attached to the table  140 . In this configuration, the articulation areas  210  and  212  are positioned on the articulation areas  214  and  216 , respectively. The support plate  200  is then clamped onto the roller support base  218  using the clamp bearings  222  which maintain the articulation areas  210  and  212  in contact with the articulation areas  214  and  216  while allowing for movement between the articulation areas  210 / 212  and the articulation areas  214 / 216 . 
     Once the support plate  200  is clamped onto the roller support base  218 , the proximal end  184  of the actuator rod follower  186  is aligned with the opening  176  in the support flange  180 . The helical slot  164  of the actuator rod  158  is then aligned with the tab  182  and the shaft portion  162  is inserted through the opening  176  in the support flange  180 . In some embodiments, the slot  164  may be a straight slot at the distal end of the shaft portion  162 . 
     As the shaft portion  162  is extended through the opening in the support flange  180 , the bore  172  will be aligned with the proximal end portion  184  of the actuator rod follower  186 . The proximal end portion  184  is then received into the bore  172  and the axial and radial position of the actuator rod follower  186  is adjusted so that the bore  174  in the actuator rod  158  is aligned with the bore  188  in the actuator rod follower  186 . The pin  190  is then inserted through the bore  174  into the bore  188  to axially and rotationally secure the actuator rod  158  and the actuator rod follower  186 . 
     Assembly of the roller system  154  is completed by attaching the handle  156  to the shank portion  160  of the actuator rod  158  and by inserting the rollers  150  and  152  into the roller receptacles  204 / 206 . The resulting configuration is depicted in  FIG. 4 . 
     When the roller assembly  154  is assembled, as shown in  FIG. 4 , the rollers  150  and  152  are rotatably held within the roller support plate  200 . The actuator rod follower  186  is also rotatable with respect to the roller support plate  200 , but axially fixed within the bore  198  by the neck  192  and the snap ring  228  (see  FIG. 3 ). The actuator rod follower  186  is also axially fixed with respect to the actuator rod  158  by the pin  190  while the tab  182  is positioned within the slot  164  of the actuator rod  158 . 
     The roller system  154  allows the table  140  to be easily removed and reattached to the rail system  110 . By way of example, the table may initially be in the configuration depicted in  FIG. 2 . In  FIG. 2 , the movable rollers  150  and  152  are engaged with the guide rod  126  on the rail  112  while the stationary rollers  146 / 148  are engaged with a similar guide rod (not clearly shown) on the rail  114 . This allows the table  140  to be moved by a user along the rails  112 / 114  to cut a work piece (not shown) positioned on the work piece support surface  142  since the rollers  146 / 148 / 150  and  152  are rotatably engaged with the guide rods of the rails  112 / 114 . 
     When it is desired to remove the table  140 , a user rotates the handle  156  from the position shown in  FIG. 1  in a counterclockwise direction as indicated by the arrow  240  in  FIG. 1 . As can be seen in  FIGS. 3 and 4 , the tab  182  is engaged with the slot  164 . Accordingly, as the handle  156  is rotated in the direction of the arrow  240  (note that the orientation of the roller system as depicted in  FIGS. 3 and 4  is inverted with respect to the orientation in  FIG. 1 ), the wall of the slot  164  contacts the tab  182  and the actuator rod  158  is forced to move in the direction of the arrow  242  (see  FIG. 4 ) along the locking axis  230 . The slot  164  and the tab  182  thus form a transfer mechanism which transfers rotational force into axial movement. 
     Axial movement of the actuator rod  158  along the locking axis  230 , which is substantially parallel to the support plane defined by the work piece support surface  142  (not shown in  FIG. 4 ), causes axial movement of the actuator rod follower  186  along the locking axis  230 . Because the roller support plate  200  is axially fixed with respect to the actuator rod follower  186  while being in articulating contact with the articulation areas  214 / 216 , axial movement of the actuator rod follower  186  along the locking axis  230  causes the roller support plate  200  to move axially along the locking axis  230 . 
     Linear movement of the actuator rod  158  thus results in movement of the roller support plate  200  along the locking axis  230 . Accordingly, the movable rollers  150 / 152  are forced to move linearly along the locking axis  230  away from the guide rod  126 . The slot  164  is configured such that as the handle  156  is rotated 180 degrees from the position depicted in  FIG. 1 , the movable rollers  150 / 152  move from a fully engaged location to a location spaced apart from the guide rod  126  whereat the side of the table  140  adjacent to the handle  156  can be rotated upwardly without the movable rollers  150 / 152  contacting the guide rod  126 . Once the movable rollers  150 / 152  are clear of the guide rod  126 , the table  140  may be pulled away from the rail  114 , thereby disengaging the stationary rollers  146 / 148  and removing the table  140  from the rail system  110 . 
     When the table  140  is to be replaced, the above described sequence is substantially reversed, resulting in the engagement of the rollers  146 / 148 / 150 / 152  with the guide rods of the associated rails  112 / 114 . 
     In order to prevent inadvertent disengagement of the movable rollers  150 / 152  from the guide rod  126 , one or more locking mechanisms are incorporated into the saw system  100 . By way of example,  FIGS. 5 and 6  depict a locking mechanism  250  that includes a strike plate  252  attached to the table  140  and a resilient flange  254  extending from the handle  156 . The resilient flange  254  includes a protuberance  256  which is sized to fit within a notch  258  in the strike plate  252 . When the protuberance  256  is located within the notch  258 , rotation of the handle  156  is impeded. Only when a force sufficient to resiliently deform the flange  254  is applied to the resilient flange  254  can the handle  156  be rotated so as to disengage the movable rollers  150 / 152  as described above. By applying about the same force in the opposite direction, the flange  254  can be resiliently deformed to allow the protuberance  256  to be rotated into a position adjacent the notch  258 , thereby re-latching the handle  156 . 
       FIG. 7  depicts a locking mechanism  270  which is incorporated into some embodiments of the saw system  100 . The locking mechanism  270  includes a lever arm  272  that is pivotably attached to the handle  156  by a pivot  274 . The lever arm  272  is fixedly attached to a leaf spring  276  which is in turn fixedly attached to a pin  278 . The leaf spring  276  biases the pin  278  to a location underneath the table  140 , thereby inhibiting rotation of the handle  156 . The handle may be rotated by pivoting the lever arm  272  about the pivot  274  thereby compressing the leaf spring  276  toward the handle  156 . As the leaf spring  276  is compressed, the pin  278  is moved away from the table  140 . Once the pin  278  is clear of the table  140 , the handle  156  may be rotated. To lock the handle  156 , the above described process is reversed. 
       FIGS. 8 and 9  depict a locking mechanism  290  that includes a slot  292  in the handle  156  and a bar  294  mounted to the table  140  by a pivot  296 . A plate  298  is movably located on the edge of the table. If the handle  156  begins to rotate while the bar  294  is in the position depicted in  FIG. 9 , the side of the slot  292  will contact the bar  294  and bind. Accordingly, inadvertent movement of the handle  156  is inhibited. When the handle  156  is to be rotated, a user simply moves the plate  298 , the absence of which is illustrated in  FIG. 9 , and pivots the bar  294  about the pivot  296  in a clockwise direction (with reference to  FIG. 9 ) and then the handle  156  may be rotated to disengage the rollers  150 / 152 . 
       FIGS. 10 and 11  depict a locking mechanism  300  that includes a strike plate  302  fixedly attached to the table  140  and a latch  304  that is pivotably attached to the actuator rod  158 . The latch  304  includes a lip  308  that rests upon a ledge  310  of the strike plate  302 . In the configuration of  FIG. 10 , rotation of the handle  156  simply forces the lip  308  against the ledge  310 , thereby restricting rotation of the handle  156 . By pivoting the latch  304  away from the latch  302 , the lip  308  is moved to a location outwardly of the ledge  310 . The handle  156 , actuator rod  158 , and latch  304  may then be rotated to disengage the rollers  150 / 152 . 
       FIGS. 12-14  depict a locking mechanism  320  that includes a strike plate  322  and a latch  324 . The strike plate  322  is fixedly supported by the table  140  and includes a keyed bore  326  with a circular portion  328  and a rectangular extension  330  extending sideways from the circular portion  328  (see  FIG. 13 ). The latch  324  includes a handle portion  332  which is positioned within a cut-out  334  of the handle  156  and a shank  336  that in the configuration of  FIGS. 12 and 13  extends through the handle  156  and the circular portion  328  of the strike plate  322 . A lock block  338  extends from the distal end of the shank  336 . 
     In the configuration of  FIGS. 12 and 13 , the lock block  338  is not aligned with the rectangular extension  330  of the keyed bore  326 . Accordingly, the shank  336  cannot be removed from the strike plate  322 . Consequently, the shank  336  precludes rotation of the handle  156 . By rotating the handle portion  332  to the orientation of  FIG. 14 , the lock block  338  is rotated into alignment with the rectangular extension  330  as depicted in  FIG. 15 . Accordingly, the latch  324  can be pulled away from the table  140  such that the shank  336  no longer extends through the strike plate  322 . The handle  156  can then be rotated without interference between the latch  324  and the strike plate  322 . 
     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.