Abstract:
A portable machine, for example a saw, has a light construction using composite materials such as fiber reinforced resins and a closed cell foam. The saw may have a housing formed from multiple skins of the composite materials in which in the closed cell foam. Metallic inserts may be used to bond to either or both of the foam and the composite skin to accept working components. A saw is also described which uses gears sharing the same support element.

Description:
BACKGROUND OF THE INVENTIONS  
         [0001]    1. Field of the Invention  
           [0002]    This relates to movable machinery, including hand-held, portable, self propelled and similar machinery, and including saws, drills for example coring drills, cutting and grinding machinery and other machinery for treating concrete, paving, masonry and the like.  
           [0003]    2. Related Art  
           [0004]    Machinery design for movable machinery takes into account the function of the machinery, strength and reliability, cost of materials and similar considerations. Machine design sometimes results in machines that are difficult to maneuver and heavy. Depending on the application, machinery such as saws are made primarily of metal parts and sometimes plastic housings, switches or controls to lower the weight of the product.  
           [0005]    While it should be understood that the present inventions may apply to a wide variety of different types of movable machinery, the present discussion and examples will be directed to wall saws, such as those used to cut lines or openings in walls, such as those made by Dimas and sold under model number 360-1500H or 360-2100S, the instruction manuals for which are incorporated herein by reference. Elements of model No. 360-2100S are also described in U.S. Pat No. 5,588,418, also incorporated herein by reference.  
           [0006]    One example of a wall saw is shown in FIGS.  1 - 2 , in which are shown a concrete wall  100  (FIG. 1) a track  102  mounted to the wall through clamps  104  and having a gear track  106  along which the saw  108  travels. A typical saw includes a carriage  110 , a bearing housing and assembly  112 , a gearbox  114 , saw blade  116  and a blade guard  118  (FIGS. 1 and 2).  
           [0007]    Considering the saw and track in more detail with respect FIG. 2, the bracket  104  includes leveling screws  120  and track  102  is mounted to the brackets  104  through cap screws  122 . The saw is mounted and retained on the track through retention rollers  124  positioned at least at respective ends of four legs extending downwardly from the carriage  110  alongside the track. Only one retention roller  124  is shown in FIG. 2. A plurality of guide rollers  126  are supported by the carriage  110  and guide the carriage along the track. A manual travel control  128  is accessible from the top of the saw. The travel control  128  is turned with a suitable wrench so as to move a gear (not shown) under the carriage along the track rack  106  through a series of intermediate gears.  
           [0008]    The bearing housing and assembly  112  include an outer housing  130  and suitable gears, drive shaft and bearings. The assembly  112  receives drive input from a hydraulic drive motor (not shown) mounted to the housing opposite the gearbox  114  and drives the saw blade through the gearbox  114 . The assembly  112  also includes gears for positioning the blade relative to the work piece, such as the concrete wall  100 .  
           [0009]    A blade depth control  132  is also accessible from the top of the saw. It is turned with a suitable wrench so as to move the gear (not shown) in the bearing assembly  112  which then pivots the gearbox about the drive shaft, which in turn adjusts the position of the saw blade relative to the work piece.  
           [0010]    The gearbox  114  transmits drive power to the saw blade mounted to a blade drive shaft through inner and outer blade flanges  134 . The blade flanges  134  also include internal structures for passing fluid along the sides of the saw blade. A blade guard coupler  136  mounts a blade guard support  138  to a blade guard support bracket for supporting the blade guard.  
         SUMMARY OF THE INVENTIONS  
         [0011]    Methods and apparatus are described for producing a portable machine, for example a wall saw, having a light construction. Methods and apparatus are also described for producing a portable machine having light components and having strength sufficient to operate as a portable machine, for example in a wall saw. Methods and apparatus are discussed for producing components of a portable machine that can form a final assembly wherein at least one or part of one of the components is formed as a composite material, at least one component of which is plastic, for example a thermosetting resin. Methods and apparatus are also disclosed that can produce a portable machine that is more versatile and easier to use.  
           [0012]    In one example of methods and apparatus disclosed herein, a portable machine, in one example a wall saw, is formed with at least one housing formed from a composite material. In one example, the composite material includes fibers, for example carbon fibers, glass fibers, Kevlar or other reinforcing material, the composite material may include a thermosetting resin, and the material may include both a reinforcing fiber and a thermosetting resin. In an example of a component made with a composite material, a carriage for a wall saw is formed with composite material skins. In another example of a component made with a composite material, a bearing housing for a wall saw is formed with composite material skins, and in another example a travel gear housing is formed from a composite material. In a further example, a gearbox is formed from a composite material, and in another example a gearbox is formed from a combination of composite material and metal to form the gearbox housing and support for the gears and bearings. In a preferred form, the skin thickness ranges from about 0.030 inch to about 0.060 inch, with areas having greater strength having a greater thickness. In another preferred form, the skin is formed from about six layers of fiber, and may also be formed from four layers, five layers, seven layers or eight layers.  
           [0013]    In a further example of methods and apparatus disclosed herein, a portable machine, for example a wall saw, includes least one component formed with a housing formed from multiple skins of composite material. The skins include edge portions which preferably overlap each other. In a further preferred form, the overlapping edge portions adhere to each other. In a still further preferred form, the overlapping edge portions adhere to each other through an adhesive, for example an epoxy adhesive. In a preferred form, the adhesive thickness is about 0.005 inch and may be somewhat higher up to about 0.010 inch or somewhat lower.  
           [0014]    In another example of methods and apparatus disclosed herein, a portable machine, for example a wall saw, is formed with at least one component assembled from a composite skin and a foam core or body to form a housing for components or to form a support structure, for example a carriage. In one form, the foam core is formed of a closed cell foam. In another example, the composite skin and the foam are bonded, adhered or fixed together. Preferably, the composite skin and the foam are bonded with an adhesive, for example an epoxy adhesive. In another form, the foam core is formed from multiple pieces of foam, adjacent ones of which are adhered or bonded or fixed to each other, for example by an adhesive. In another example, more than one component is assembled from a composite skin and foam core or body. In still another example, all of the housing&#39;s enclosing or supporting moving components such as gears, shafts and the like are formed from a composite skin and foam core or body. In a further example, where he composite skin and foam are to be bonded together, the composite skin can be formed with an attached etching paper, which can later be peeled or pulled off to give a rough surface for receiving the adhesive for bonding the composite with the foam. In another example, where a closed cell foam is used within a composite skin in a component for a portable machine, the closed cell foam is preferably at least 60 percent closed cell and preferably in a range from 80 percent to 98 percent, and more preferably about 96 percent. Where closed cell foam&#39;s are used, the closed cell foam is preferably a high-density foam.  
           [0015]    In an additional example of methods and apparatus disclosed herein, a portable machine, for example a wall saw, is formed with at least one component assembled from a composite skin and inserts wherein the inserts are configured to receive other components. In several examples, the other components can be fasteners, component housing&#39;s, bearing supports, motor supports, component mounts, and the like. The inserts are preferably bonded, adhered or otherwise fixed to portions of the composite skin. In a further example, at least one component of a portable machine, for example a wall saw, is formed with a housing having at least one component as a composite skin, a foam core or body and inserts, and at least two and preferably each of the composite skin, foam core and inserts are bonded or adhered to adjacent ones of the other. For example, a portion of the composite skin and an adjacent insert can be bonded together, a foam core and an adjacent insert can be bonded together or a composite skin and an adjacent foam core can be bonded together. Where a given insert is adjacent both a composite skin and a portion of foam, the insert is preferably bonded to each. In those examples using either a composite skin and a foam, a composite skin and inserts, or a foam and inserts, or any combination thereof, the equipment, procedures and materials used by Composite Tek of Boulder, Colo., or a similar company are preferably used. Possible techniques and configurations for components described herein can be found in their Composites Design Guide, Revision 2, incorporated herein by reference.  
           [0016]    In one example of methods and apparatus disclosed herein, a portable machine, for example a wall saw, is formed with at least one component having a housing formed from a composite skin coated with a UV absorbing material. For example, a carriage, bearing housing, motor mount, and/or gearbox have housing&#39;s formed from composite materials coated with a UV absorbing material. In one example, the composite material may be coated with a PPG high-grade UV protecting clear coat automotive paint.  
           [0017]    In another example of methods and apparatus disclosed herein, a portable machine, for example a wall saw, includes several transmission components, such as gears, supported on a common support, such as a common shaft. For example, idler gears may be supported on common or coaxial shafts. In the example of a wall saw, a gear for driving the saw blade may be supported on the same axis, and may be coaxial with, the gear used to keep the blade guard level relative to the work surface such as a concrete wall. In another example, the saw blade may have a blade shaft drive gearing ratio of 3.512:1, and the blade guard leveling gears may have a ratio of 1:−1.  
           [0018]    A further example of methods and apparatus disclosed herein include a portable machine, for example a wall saw, having two drive gears, wherein a given drive gear is used to engage a track rack with the saw oriented in one direction and the other drive gear is used to engage the track rack with the saw oriented in another direction. This allows, for example, a track having an offset rack to be used with the saw going in either direction without having to reorient the track.  
           [0019]    In an example of methods and apparatus disclosed herein, a portable machine, for example a wall saw, is formed with at least one component having a housing formed from at least one of than preferably both a composite and a foam with metal inserts bonded to one or both of the composite and the foam. Preferably, the inserts are formed from AL4-6V titanium or from 2024-T351 aluminum that is hard anodized. These materials are lightweight, minimize galvanic action between the metal and carbon fiber and have high material yield properties. The gears may be formed from stainless steel, such as 416 stainless or 86L20 alloy, and the shafts may be stainless as well, but they may be lighter if formed from heat-treated aluminum or from titanium.  
           [0020]    These and other aspects of the present inventions can be considered in more detail in conjunction with the drawings, a brief description of which follow, and the detailed description. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0021]    [0021]FIG. 1 is a schematic of an isometric view of a wall saw representing one example of a movable machine that can incorporate one or more of the present inventions.  
         [0022]    [0022]FIG. 2 is a front left side isometric view of a conventional wall saw on a track.  
         [0023]    [0023]FIG. 3 is a right side and rear isometric view of one example of a wall saw incorporating several aspects of the present inventions.  
         [0024]    [0024]FIG. 4 is a left side and rear isometric view of the saw of FIG. 3.  
         [0025]    [0025]FIG. 5 is a right side and rear isometric view of the saw of FIG. 3 showing the working components of the saw and the housing components in phantom.  
         [0026]    [0026]FIG. 6 is a right side and front isometric view of the saw of FIG. 3 showing the working components of the saw and the housing components in phantom.  
         [0027]    [0027]FIG. 7 is a left side and front isometric view of the saw of FIG. 3 showing the working components of the saw and housing components in phantom.  
         [0028]    [0028]FIG. 8 is an enlarged view of FIG. 6.  
         [0029]    [0029]FIG. 9 is an enlarged view of FIG. 7.  
         [0030]    [0030]FIG. 10 is a rear elevation view of the working components of the saw of FIG. 3 with the housing components in phantom.  
         [0031]    [0031]FIG. 11 is a top plan view of the working components of the saw of FIG. 3 with housing components and phantom.  
         [0032]    [0032]FIG. 12 is an upper right front isometric view of FIG. 6.  
         [0033]    [0033]FIG. 13 is and upper left front isometric view of the travel drive assembly and the blade height drive assembly of the saw of FIG. 3.  
         [0034]    [0034]FIG. 14 is an upper right front isometric view of the travel drive assembly and the blade height drive assembly of the saw of FIG. 3.  
         [0035]    [0035]FIG. 15 is a bottom plan view of the travel drive assembly and the blade height drive assembly of the saw of FIG. 3.  
         [0036]    [0036]FIG. 16 is a lower left isometric view of the travel drive assembly and the blade height drive assembly of the saw of FIG. 3.  
         [0037]    [0037]FIG. 17 is a right side isometric view of the gearbox and blade guard support of the saw of FIG. 3.  
         [0038]    [0038]FIG. 18 is a right front isometric view of the working components of the gearbox with the gearbox housing in phantom for the saw of FIG. 3.  
         [0039]    [0039]FIG. 19 is a right rear isometric view of the drive shafts and gear trains for driving the saw blade and positioning the blade height for the saw of FIG. 3.  
         [0040]    [0040]FIG. 20 is a lower right side isometric view of the drive shafts and gear trains of FIG. 19.  
         [0041]    [0041]FIG. 21 is a front left side isometric view of the drive shafts and gear trains of FIG. 19.  
         [0042]    [0042]FIG. 22 is a right front isometric view of the shafts and gear trains of the gearbox of the saw of FIG. 3.  
         [0043]    [0043]FIG. 23 is a lower right front isometric view of the drive shafts and gear trains for driving the saw blade and positioning the blade height for the saw of FIG. 3.  
         [0044]    [0044]FIG. 24 is a lower right isometric view of the saw blade and blade guard gear trains and blade drive shaft positioned in a schematic of the gearbox housing.  
         [0045]    [0045]FIG. 25 is an enlarged view of the lower portion of the assembly shown in FIG. 24.  
         [0046]    [0046]FIG. 26 is an enlarged view and partial section of the saw drive shaft and blade flanges.  
         [0047]    [0047]FIG. 27 is a transverse cross-section and isometric view of the saw blade drive shaft.  
         [0048]    [0048]FIG. 28 is an isometric and partial sectional view of one of the saw blade drive gears and the blade height position gears supported on a common shaft.  
         [0049]    [0049]FIG. 29A is an upper right isometric view of the housing&#39;s of the saw of FIG. 3.  
         [0050]    [0050]FIG. 29B is an inverted front plan view of the housings of FIG. 29A.  
         [0051]    [0051]FIG. 29C is a left side elevation view of the housings of FIG. 29A.  
         [0052]    [0052]FIG. 29D is a bottom plan view of the housings of FIG. 29A.  
         [0053]    [0053]FIG. 30A is a right front isometric view of a carriage for use with the saw of FIG. 3.  
         [0054]    [0054]FIG. 30B is an upper left isometric view of the carriage of FIG. 30A.  
         [0055]    [0055]FIG. 30C is a lower left isometric view of the carriage of FIG. 30A.  
         [0056]    [0056]FIG. 30D is a lower right isometric view of the carriage of FIG. 30A.  
         [0057]    [0057]FIG. 30E is a bottom plan view of the carriage of FIG. 30A.  
         [0058]    [0058]FIG. 30F is a vertical transverse cross-section of the carriage of FIG. 30E taken along line A-A.  
         [0059]    [0059]FIG. 30G is a vertical transverse cross-section of the carriage of FIG. 30E taken along line B-B.  
         [0060]    [0060]FIG. 30H is an inverted front view of the carriage of FIG. 30A.  
         [0061]    [0061]FIG. 30I is an inverted left side view of the carriage of FIG. 30A.  
         [0062]    [0062]FIG. 31 is a top plan view and partial cutaway of the carriage of FIG. 30A.  
         [0063]    [0063]FIG. 32 is an upper right front isometric and vertical longitudinal cross-section of the carriage of FIG. 30A.  
         [0064]    [0064]FIG. 33 is an enlarged view of a vertical transverse section of the carriage housing of FIG. 30A taken behind the section for FIG. 30F.  
         [0065]    [0065]FIG. 34 is a lower left rear isometric view of the section of FIG. 33.  
         [0066]    [0066]FIG. 35 is an upper right isometric and partial cutaway view of the section of FIG. 33.  
         [0067]    [0067]FIG. 36 is an upper left isometric view and partial cutaway of the section of FIG. 33.  
         [0068]    [0068]FIG. 37 is an upper right isometric view of a foam assembly for use with the carriage of FIG. 30A.  
         [0069]    [0069]FIG. 38 is a lower right rear isometric view of the foam assembly of FIG. 37.  
         [0070]    [0070]FIG. 39 is an upper right front isometric view of inserts for the carriage of FIG. 29A with the carriage of FIG. 30A shown in phantom.  
         [0071]    [0071]FIG. 40 is a bottom right front isometric view of the inserts of FIG. 39.  
         [0072]    [0072]FIG. 41 is a bottom left rear isometric view of the inserts of FIG. 39.  
         [0073]    [0073]FIG. 42A is an upper right rear isometric view of a bearing housing for the saw of FIG. 3.  
         [0074]    [0074]FIG. 42B is an upper right front isometric view of the bearing housing of FIG. 42A.  
         [0075]    [0075]FIG. 42C is a bottom and left side isometric view of the housing of FIG. 42A.  
         [0076]    [0076]FIG. 42D is a bottom man right side isometric view of the housing of FIG. 42A.  
         [0077]    [0077]FIG. 42E is a top plan view of the housing of FIG. 42A.  
         [0078]    [0078]FIG. 42F is a front sideways view of the housing of FIG. 42A.  
         [0079]    [0079]FIG. 42G is a left side elevation view of the housing of FIG. 42E.  
         [0080]    [0080]FIG. 42H is a vertical transverse section of the housing of FIG. 42E taken along line A-A.  
         [0081]    [0081]FIG. 42I is a vertical longitudinal cross-section of the housing of FIG. 42E taken along line B-B.  
         [0082]    [0082]FIG. 43A is a bottom left front isometric view of foam and metal inserts for the bearing housing of FIG. 42A.  
         [0083]    [0083]FIG. 43B is a bottom left rear isometric view of the inserts of FIG. 43A.  
         [0084]    [0084]FIG. 43C is a bottom left isometric view of the inserts of FIG. 43A.  
         [0085]    [0085]FIG. 43D is a bottom right rear isometric view of the inserts of FIG. 43A.  
         [0086]    [0086]FIG. 43E is a bottom plan view of the inserts of FIG. 43A.  
         [0087]    [0087]FIG. 43F is a front sideways view of the inserts of FIG. 43A.  
         [0088]    [0088]FIG. 43G is a left side view of the inserts of FIG. 43E.  
         [0089]    [0089]FIG. 43H is a vertical transverse section of the inserts of FIG. 43E taken along line A-A.  
         [0090]    [0090]FIG. 43I is a vertical longitudinal cross-section of the inserts of FIG. 43E taken along line B-B.  
         [0091]    [0091]FIG. 44 is a vertical transverse section.  
         [0092]    [0092]FIG. 45 is a right rear isometric view of a vertical transverse section of the bearing housing of FIG. 42A.  
         [0093]    [0093]FIG. 46 is a right rear or isometric view of a vertical transverse section of the bearing housing of FIG. 42A.  
         [0094]    [0094]FIG. 47 is a bottom right isometric view of a horizontal longitudinal section of the bearing housing of FIG. 42A.  
         [0095]    [0095]FIG. 48 is a bottom right isometric view of a horizontal longitudinal section of the bearing housing of FIG. 42A.  
         [0096]    [0096]FIG. 49A is a left rear isometric view of a travel housing for the saw of FIG. 3.  
         [0097]    [0097]FIG. 49B is a bottom right rear isometric view of the travel housing of FIG. 49A.  
         [0098]    [0098]FIG. 49C is a front elevation view of the housing of FIG. 49A.  
         [0099]    [0099]FIG. 49D is a left side elevation view of the housing of FIG. 49A.  
         [0100]    [0100]FIG. 49E is a vertical transverse section of the housing of FIG. 49D taken along line A-A.  
         [0101]    [0101]FIG. 49F is a top plan view of the housing of FIG. 49A.  
         [0102]    [0102]FIG. 49G is a vertical longitudinal section of the housing of FIG. 49F taken long line B-B.  
         [0103]    [0103]FIG. 50 is a bottom right isometric view of the gearbox for the saw of FIG. 3.  
         [0104]    [0104]FIG. 51 is a left front isometric view of the gearbox of FIG. 50.  
         [0105]    [0105]FIG. 52 is an exploded view of one embodiment of components of a gearbox housing for the gearbox of FIG. 50.  
         [0106]    [0106]FIG. 53 is an exploded view of housing components for the gearbox of FIG. 50. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0107]    The following specification taken in conjunction with the drawings sets forth the preferred embodiments of the present inventions in such a manner that any person skilled in the art can make and use the inventions. The embodiments of the inventions disclosed herein are the best modes contemplated by the inventor for carrying out the inventions in a commercial environment, although it should be understood that various modifications can be accomplished within the parameters of the present inventions.  
         [0108]    A movable or portable machine is described which is lighter than conventional counterparts, and which can be made more reliable. Methods and apparatus are also described for making an improved movable or portable machine, for example a portable machine for working on work piece, in the disclosed example a wall saw. While the disclosed example is directed to a wall saw, the inventions can be applied to other portable machines, including hand-held machines and power tools, portable machines and power tools, self propelled machines and power tools, as well as other movable machines for operating on surfaces and work pieces. The inventions can be applied to machines used to work on concrete, pavement and other masonry forms or products, of which a wall saw and core drill are several examples. The wall saw described herein is an example of a device well-suited to application of the present inventions.  
         [0109]    A wall saw such as may be used with the track  102  of FIG. 1 may include a carriage  140 , a bearing assembly  142 , a travel assembly  144 , a gearbox assembly  146  and blade flanges  150  for supporting a saw blade (not shown) and a blade guard support  152  for supporting a blade guard (not shown) (FIGS.  3 - 9 ). The blade guard support  152  may be a conventional structure, as may be the blade flanges  150 . The carriage includes lower roller assemblies  154 , which may be conventional roller assemblies or Nylatron roller assemblies, or combinations of the two. Preferably, at least one set of roller assemblies are eccentric rollers for permitting adjustment of the carriage position on the track. The carriage  140  also preferably includes a set of corresponding upper roller assemblies  156 , which are preferably conventional roller assemblies. One or more side roller assemblies  158  may also be included. Each of the rollers are supported in the carriage  140  by respective inserts, described more fully below. The carriage also includes a right side wall  160  (FIG. 3) and a left side wall  162  (FIG. 4), a handle  164  and a platform  166  extending generally horizontally between the right side wall and left side wall (FIG. 30A) for supporting the bearing assembly  142  and the travel assembly  144 , also as described more fully herein.  
         [0110]    The bearing assembly  142  is mounted and fixed to the carriage  140  through appropriate fasteners engaging respective inserts  167  (FIGS. 5, 8). The bearing assembly  142  has a conventional hydraulic motor assembly  168  mounted to a bearing housing mounting plate  170  (FIGS. 5, 6,  8  and  10 ). The hydraulic motor drives the saw blade through the saw blade drive train described more fully below. The mounting plate  170  is fastened to and supported by a hydraulic motor mount insert  172  supported and bonded or adhered to the inside of the right skin of the bearing housing. The insert is preferably titanium AL46V, as titanium is intended to support a heavier load than the hard anodized aluminum 2024 T351. The bearing housing also includes suitable bearings and seals about the main shaft through the bearing housing for supporting the main shaft in the housing. A second insert  174  in the bearing housing opposite the insert  172  is bonded or otherwise adhered to the inside of the left bearing housing skin for supporting a gearbox mount  176 , which is supported on the main shaft by appropriate bearings and sealed by appropriate seals. The bearing housing also supports on the main shaft a gearbox rotation worm mating gear  177  (FIGS.  8 - 16 ). The worm mating gear  177  is driven by the gearbox rotation drive assembly for changing blade position or blade depth.  
         [0111]    The travel assembly  144  includes a manual travel control  178  and a hydraulic travel control motor  180  (FIGS. 6 and 8) drive the travel gear train. A manual blade level control  182  and a hydraulic gearbox rotation motor  184  (FIGS. 5 and 11) control the level of the blade guard through rotation of the gearbox assembly. Both of the travel controls and blade level controls are mounted in and supported by the travel assembly  144 , which in turn is supported by the carriage  140 . The travel assembly  144  is mounted to the carriage  140  through appropriate fasteners engaging inserts in the carriage.  
         [0112]    The travel assembly  144  includes access covers  186  and  188  (FIG. 8) supporting respective  189 , which in turn support a driven worm gear  190  (FIGS. 9, 11,  12 - 16 ) controlled by worm gear  192 . As shown in FIGS.  13 - 16 , the worm gear is controlled by the manual travel control  178  and by the hydraulic travel control motor  180 . The travel control motor  180  includes a drive gear  194  engaging an idler gear  196 , which intern engages gear  198  on the shaft of worm gear  192 . Rotation of the worm gear shaft moves the driven worm gear  190 , which in turn rotates both of the worm driven gears  200  and  202 . The worm driven gears  200  and  202  engage the drive pinion gears  204  and  206 , respectively. The shafts supporting the worm driven gears  200  and  202  and the drive pinion gears  204  and  206  are also preferably formed from titanium. The drive pinion gears  204  and  206  are supported by respective bearings, as can be seen in FIGS. 8 and 12.  
         [0113]    The gearbox rotation motor includes a gear  208  which drives idler gear  210 , which in turn engages gear  212  on the shaft  214  of the gearbox rotation manual control  182 . Rotation of shaft to 14 turns worm gear  216 , which in turn drives the worm mating gear  177  for moving the gearbox.  
         [0114]    Aluminum inserts are placed in the travel housing for receiving and supporting the hydraulic motors, the manual drive shafts and/or the gear assemblies, if desired. A first insert  218  shown in phantom in FIG. 11 supports the gearbox rotation motor  184  and a second insert  220  supports the travel gear assembly. These aluminum inserts are preferably bonded or adhered within the travel housing in the same manner as the other inserts, as described more fully below.  
         [0115]    The gearbox includes a splined input shaft  230  engaging a complementary surface on the main drive shaft in the bearing housing  142  from the hydraulic drive motor. The shaft  230  extends into the gearbox as described more fully below. The gearbox housing includes a metal insert  232  (FIGS. 17 and 53) bonded into the gearbox housing  234  for mounting the gearbox to a corresponding mounting surface  235  (FIGS. 20 and 21) in the bearing housing so that when the worm mating gear  177  turns the gearbox turns at the same time. A follower one inch pitch diameter pinion gear  236  (FIGS. 17, 19,  22  and  24 - 25 ) runs on a stationary 5.2 inch pitch diameter ring gear  238  fixed within the bearing housing to the support  176  (FIGS. 6, 8,  11  and  12 ). The follower gear  236  is mounted on a shaft  240  supported on bearings, which in turn are supported by the gearbox. On the opposite end of the shaft  240 , a one inch pitch diameter gear  242  drives a first 2.2 inch pitch diameter gear  244 , which in turn drives an identical second 2.2 inch pitch diameter gear  246 . The second gear  246  drives a third 2.2 inch pitch diameter gear  248 , which in turn drives a 5.2 inch pitch diameter ring gear  250 , resulting in a gear ratio from the bearing housing to the blade guard support of 1:−1. Therefore, as the gearbox rotates through action of the worm follower gear  177 , the blade guard stays level with the work surface. Each gear is supported on a respective shaft supported by a pair of bearings.  
         [0116]    The main drive shaft  252  passes through a bearing which supports an external shaft  254  (FIG. 19), which in turn supports the worm follower gear  177  so that the main drive shaft  252  can rotate independently of the worm follower gear  177 . The main drive shaft  252  engages the splined shaft  230 , which includes a 1.5 inch pitch diameter gear  256  and a bearing  258  for supporting the splined shaft. The gear  256  drives a 2.7 inch pitch diameter idler gear  260 , which in turn drives a second 2.7 inch pitch diameter idler gear  262 , which then drives the 4.7 inch pitch diameter output gear  264 . The resulting gear ratio is 3.512:1, which produces a relatively high torque given the geometry constraints of the gearbox, the gear sizes and weights, and the like. The gear  264  is fixed to and drives the blade output shaft  266  supported by first and second bearings  268  and  270 . Each gear is supported on a respective shaft supported by a pair of bearings.  
         [0117]    The blade output shaft  266  is preferably substantially hollow over a significant length of the shaft. The shaft includes a first bore  272  having a relatively large diameter greater than approximately half the overall diameter of the shaft, about which the gear  264  is mounted. The bore  272  extends approximately half the length of the shaft. The other half is substantially solid except for bore  274  for receiving the blade mounting bolt  276  (FIG. 4) for mounting the inner blade flange  278  and the outer blade flange  280  to the output shaft  266 . A blade flange seal  282  extends outwardly to the inner blade flange  278  for sealing with the blade flange. The blade flange seal  282  is supported by a blade guard mounting bracket  284 , which also supports a blade guard coupler  286 . A first bearing  288  and a second bearing  290  extend between the blade output shaft and the bracket  284 . The ring gear  250  is mounted to the bracket  284  so that ring gear  250  and gear  264  are supported on a common shaft. The first and second bearings  288  and  290  each extend on the outer side of respective fluid seals  292  and  294 . Fluid passes between the seals and around the output shaft and through a number of openings axially along the output shaft to the space  296  between the inner and outer blade flanges. The blade shaft may be formed from  416  stainless steel or from titanium, as with the other titanium parts described herein.  
         [0118]    Gears  236 ,  242  and  260  are supported on a common shaft and gears  248  and  262  are also supported on a common shaft. These gears and shafts include four bearings, such as shown in FIGS.  24 - 27  and also  28 . As shown in FIG. 28, gear  236  is supported on shaft  240  which also supports gear to  42 . The shaft is supported in the gearbox by respective bearings  300  and  302 , and the shaft  240  also supports bearing  304  which intern supports a coaxial shaft  306 . The coaxial shaft  306  is supported in the gearbox by first and second gears  308  and  310 , respectively, and the coaxial shaft supports gear  260 . A similar arrangement is used for gears  248  and  262 .  
         [0119]    The gears are preferably formed from 86L20 alloy or the equivalent and heat treated. The alloy is preferably heat treated to a case depth of 0.020 to 0.035, surface hardness of approximately 58 R/C and core hardness of between 35 and 45 R/C. The part is sub-zero cooled to within a range of minus 100 degrees Farenheit to minus 150 degrees Farenheit for a period of two hours starting within 20 minutes of the quench from the high temperature. The other metal parts may be formed from aluminum, 2024 T351 hard anodized, but they may also be made from other materials, including titanium AL46V. The inserts and other metal components supporting the greatest loads are preferably formed from titanium, while the other inserts are preferably formed from the hardened aluminum.  
         [0120]    At least one of the housings (FIGS.  29 A- 29 D), and preferably several, and more preferably each of the housings are formed from composite materials. Additionally, the same housings are preferably formed with a plurality of inserts that can be used to support, mount or otherwise serve as an interface for metal or other components of the machine. The carriage housing  350 , bearing housing  352  and transfer housing  354  are preferably formed with composite skins of carbon fiber and thermoplastic resins such as epoxy resin. The housing skins may then be coated with a UV absorbing paint. In a further preferred form of the inventions, any housing which includes a composite material skin also includes a foam core or body for adding strength to the housing. In one example, the foam is a closed cell foam, and may be as much as 96 to 98 percent closed cell, but could be as low as 60 percent.  
         [0121]    Considering one example of the carriage housing  350  in more detail, the carriage housing is preferably formed from three milled closed cell foam sections, including a right side section  356 , a left side section  358  and a center section  360 , each of which are preferably milled precisely to fit within the skins of the housing, leaving an approximately 0.005 inch space for adhesive, preferably on all surfaces between the foam and the skin. The left and right side foam sections preferably extend to the bottom surface of the top carriage skin and the center section preferably meets the sides of the right and left side sections, as shown in FIGS. 30F and 33. As the drawings of FIGS.  3 - 53  are Solid Works drawings, a number of the lines intermediate and surfaces are drawing transition lines rather than end surfaces of the material. However, it should be understood that any given foam section can be configured to be assembled from two or more individual sections. However, it is preferred that the number of individual sections forming the core is minimized. Any joining foam surfaces between one foam section and another is preferably sealed with a suitable adhesive, preferably about 0.005 inch thick and possibly up to about 0.010 inch thick. For example, adhesive  362  is applied between the joining surfaces between the left side section  358  and the center section  360  and between the center section  360  and the right side section  356  (FIG. 33). Additionally, if a given foam section is formed as multiple sections, they are preferably joined together with a suitable layer of adhesive.  
         [0122]    The carriage preferably includes a plurality of metal inserts for receiving moving components and/or fasteners or other components that do not bond or adhere well to the foam or the skin, but adhere better to the metal inserts. The inserts are preferably titanium AL46V or hard anodized 2024 T351 aluminum. As shown in FIGS.  39 - 41 , the carriage inserts include roller inserts  364  and  366 , roller inserts  368  and roller inserts  370 . The carriage inserts also include heli-coil or re-thread inserts  372  for receiving aluminum fasteners. The inserts  372  are preferably substantially identical in geometry. The carriage also includes cap screw inserts  374 , preferably having identical geometry&#39;s, and a third cap screw  374  having a flange for providing greater strength and support. The carriage may also include roller supports  376  having a flange  378  and a hemi-cylindrical wall  380  for providing added support and strength. Wherever any of the inserts are adjacent a foam surface or a skin surface, a suitable layer of adhesive is preferably applied in between the bond the inserts to any adjacent surface. As shown in FIGS.  37 - 38 , the openings for receiving the cap screw inserts and the heli-coil inserts have foam surfaces to which the adhesive is applied at the same time as the insert. Similar comments applied to other inserts for the various housings. Likewise, any inserts surfaces adjacent a skin surface also have an adhesive layer applied to bond between the insert surface and the skin surface. Therefore, for example, the wall  380  of the insert  376  is adhered to the adjacent foam surface for support and strength. Likewise for the other surfaces of the inserts adjacent foam, and for the surfaces adjacent skin. The inserts can take a number of forms, preferably increasing the surface area of contact and also increasing the shear strength. For the fastener inserts, for example, the inserts may be formed with flanges extending over the skin surface opposite the direction from which the fastener is received. Alternatively, the ends of the insert may be flush with the foam surfaces and the adjacent skin extend over the ends of the insert to the opening of the insert. In this configuration, the sides of the insert are bonded to the foam and the ends of the insert are bonded to the overlying skin surfaces.  
         [0123]    As shown in FIGS. 30E and 31, the sides of the carriage are preferably curved inward in a vertical plane centered along a vertical axis at approximately the center  382  of the length of the carriage. The sides of the carriage are also preferably curved in a horizontal plane centered along a horizontal transverse axis, as can be seen in FIG. 30I. The curvature, including the combined curvature, provides increased strength and structural support for the carriage.  
         [0124]    The skins of the carriage, as well as the skins of the other housing components, are preferably formed from a carbon fiber composite with the epoxy resin, the skins having the characteristics set forth in the table below. The skins are preferably formed to maximize strength, durability and structural integrity. In one example, the left skin  384  is preferably formed to have a U-shaped cross-section at many of the vertical or transverse locations along the skin (see FIG. 33) so as to allow overlapping or lap joints  386  with adjacent skins, such as the center skin  388 . A 0.005 inch gap designed into the skins is filled with a suitable adhesive to bond the lap joints or other joints. In the example shown in FIGS.  33 - 36 , the lap joints are substantially continuous about each laterally-extending walls of the skins forming the lap joint, except for those locations where openings are formed for receiving inserts or other components, such as opening  390 . To the extend that a given surface on the carriage or other housing is not straight, such as at the base  392  (FIG. 34) for receiving the travel housing, the overlapping surfaces of the left and center skins follow the contour, thereby enhancing the integrity of the structure. Similar comments apply with respect to the right skin  394  and the lap joints  396  and  398  with the center skin  388 .  
         [0125]    Considering the carriage housing, as assembled, the joined materials and surfaces will often include a first skin  400  adjacent a second skin  402  and between which adhesive layer  404  is applied. The second skin  402  is adjacent a portion of foam core material and an adhesive layer is placed between the two. Additionally, an adhesive layer is placed between the outer skin wall  406  and the adjacent foam wall  408 , and adhesive layer is placed between the opposite skin wall  410  and the adjacent foam surface  412 . An adhesive layer is also placed at  362  between adjacent foam portions. The top surface  414  of the foam section also includes an adhesive layer between the it and the adjacent surface  416  of the center skin  388 , and adhesive layer is placed in the lap joint  386  between the center skin and the top horizontal surface of the left skin. Consequently, adhesive layer surrounds the foam core portion and also extends between the lap joints to provide strength and structural integrity. Similar structures exist with other combinations of foam, skin and lap joints to form a housing for supporting machine components.  
         [0126]    The bearing housing  352  (FIGS.  42 A- 48 ) preferably includes machine closed cell foam cores  420 , a right skin  422 , a left skin  424  and a top skin  426 , bonded and joined in ways similar to those described with respect to the carriage housing. The bearing housing also includes a main insert  428  for receiving and supporting a hydraulic motor. The housing also includes a hydraulic motor mount insert  430  for supporting the main hydraulic motor  168 . The housing also includes a blade guard level ring gear insert  432  for supporting ring gear  238 . A composite cylindrical tube  434 , about 0.030 inch in wall thickness, extends from the left skin  424  to the outside surface of the right skin  422 , to help support insert  432  and the hydraulic motor mount insert  430 , as well as to help support the hydraulic motor. The tube  434  may be notch or cut to accommodate various surfaces to which it is adjacent. The tube is also bonded with a suitable layer of adhesive to adjacent surfaces. The bearing housing also includes a bottom skin  436 . The skins, foam and inserts are preferably formed, configured and assembled into manner similar to that described above with respect to the carriage housing.  
         [0127]    Additionally inserts may include cap screw inserts  438  for mounting the bearing housing to the carriage. Heli-coil inserts  440  may also be set in the bottom foam  420  through the bottom skin  436 , also for mounting the bearing housing to the carriage.  
         [0128]    The travel housing  354  preferably includes a travel gear insert  442  (FIGS. 49D and 49G) and transfer housing foam  444  around the insert  442 . The foam includes a fastener insert  446  for receiving a fastener through the cap screw insert  448  (FIG. 42B) in the bearing housing. A travel motor mount  450  is also set into foam and secured with adhesive. Right skin  452  and left skin  454  are bonded to the foam and inserts in a manner similar to that described above with respect to the carriage housing.  
         [0129]    The gear box  146  includes the housing assembly  234  having in the present example and inner section  460 , an intermediate section  462  and an outer section  464 . The housing supports the saw blade drive gears and bearings and seals as well as the blade guard level gear train, bearings and seals. In one example, the sections  460 , 462  and  464  are formed from composite skin covered foam sections such as inner foam section  466 , intermediate foam section  468 , and outer foam section  470  for supporting metal inserts for fasteners and metal inserts for bearing assemblies, seals and the like (FIG. 52). The fasteners  472  and  474  engage respective inserts  476  and  478  and  480  to assemble and hold the three sections together. The inserts and the foam are bonded together with a suitable adhesive layer in a manner similar to that described above with respect to the carriage housing.  
         [0130]    Each section may be formed as a composite assembly in ways similar to those described above with respect to the other housing assemblies. The inner section  460  is formed from the foam core  466  (FIG. 52) and covered with a composite skin. In one example, the skin on the inner section  460  is a double composite skin, and in another example, the skin on the inner section  460  is approximately twice the thickness of the 0.060 inch skins. As with the previous housings, the foam core is milled or cut to the desired shape for receiving the metal inserts, such as mounting bracket  232 , and the bearing supports  482 ,  484  and  486  for receiving corresponding bearing assemblies. The inserts are bonded into the inner section  460  with a suitable adhesive layer.  
         [0131]    The intermediate section  462  may also be formed from a composite skin over a milled foam core for receiving respective metal inserts  488 ,  490 ,  492  and  494 . The inserts receive respective bearing assemblies, seals or other structures. The composite skin and the foam are adhesively bonded, and the inserts are adhesively bonded to the intermediate section. The outer section  464  is formed in a similar manner by taking a milled foam core and bonding the inserts  476  into respective openings and covering the assembly with a composite skin.  
         [0132]    In an alternative construction, the intermediate section can be formed by milling a lightweight metal such as the aluminum referred to herein to have the desired surface shape and configuration for receiving the corresponding bearing assemblies, seals and other components.  
         [0133]    The inner, intermediate and outer sections can then be assembled with the corresponding gear trains, bearings, seals and other components for the final gear box assembly.  
                                                                                                                                                                                                                               Fabric                                    Description   3K-135-8HS                    366 +/− 14   GRAMS/SQUARE           Fiber areal weight       METER                Yarns per inch   24 × 23                yarn size   3000   FILAMENTS           weave style   8   Harness satin            Fiber   Material   carbon           Number of filaments   3000           Tensile Strength (ksi)   512           Tensile Modulus (ksi)   33.4           Elongation %   1.5           Yield g/1000 m   198           Density g/cubic meter   1.76       Resin   material   epoxy           density (g/cc)   1.2290           Tg (from G″ DMA Curve, F.)   270.00           Tensile Modulus (ksi)   440.00           Tensile Strength (ksi)   10.70           Elongation at Break (%)   4.00           Tg after 24-Hr water boil F   169.00           Water Absorption %   3.90       Adhesive   Material   epoxy                lap shear strength R.T.   4700.00   psi           lap shear strength 250   3000.00   psi           Tensile Properties @ R.T.   6000.00   psi           Tensile Properties @ 225   3000.00   psi                Tensile Elongation @ R.T.   3.10%           Tensile Elongation @ 225   3.70%                Compressive Properties @ RT   10000.00   psi           Compressive Properties @ 225   3700.00   psi           Compressive Modulus @ R.T.   300000.00   psi           Compressive Modulus @ 225   200000.00   psi            Foam   Material   Closed cell polyurethane foam           Temperature range   −320 to +275                CTE   3.5 × 10-5   in/in/F                Closed cell content     96%           Thermal Conductivity (BTU/HR-ft2 -F/in)   0.302           Poisson&#39;s Ratio   0.3           Hardness, Shore D 4 lbs/ft3   5.4           Hardness, Shore D 40 lbs/ft4   73           Tumbling Friability @ 4 lbs/ft3     22%           Tumbling Friability @ 40 lbs/ft3   0.16%                Water Absorption   .028   lbs/ft2           Dielectric constant   1.4 @ 20   lbs/ft3           Compressive Strength parallel   712   psi           Compressive Strength perpendicular   578   psi           Compressive Strength parallel 250 deg F.   281   psi           Compressive Strength perpendicular 250 Deg.   190   psi           F.           Compressive Modulus Parallel R.T.   22203   psi           Compressive Modulus Perpendicular R.T.   14875   psi           Compressive Modulus Parallel 250 deg. F.   11853   Psi           Compressive Modulus Perpendicular 250   8060   Psi           Deg. F           Shear Strength RT   420   Psi           Shear Modulus RT   6400   Psi           Tensile Strength RT   570   Psi           Tensile Modulus RT   20785   Psi           Flexural Strength RT   864   Psi           Flexural Modulus RT   28220   Psi           Density   0.0056   lb/in 3                    
 
         [0134]    Having thus described several exemplary implementations of the invention, it will be apparent that various alterations and modifications can be made without departing from the inventions or the concepts discussed herein. Such operations and modifications, though not expressly described above, are nonetheless intended and implied to be within the spirit and scope of the inventions. Accordingly, the foregoing description is intended to be illustrative only.