Patent ID: 12214527

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

DETAILED DESCRIPTION

FIG.1illustrates a cart10for supporting a power tool, such as a cut-off saw15. The cart10is capable of conveying the saw15over surfaces during operation and for transport. The cart10is able to transport the saw15in a transport direction, along the x-axis shown inFIG.1, in either a forward or backwards direction.

With reference toFIG.2, the saw15includes a housing75, a support arm80coupled to and extending from the housing75, a cutting wheel85carried by the support arm80, and a guard90covering a portion of the circumference of the cutting wheel85. The cutting wheel85can be a blade, an abrasive disk, or any other rotatable element capable of removing material from a workpiece. In the illustrated embodiment, the cutting wheel85has a diameter greater than 9 inches and is preferably 14 inches in diameter. In other embodiments, the cutting wheel85can be between about 10 inches and about 16 inches in diameter.

The saw15includes a rear handle105that extends from the rear of the housing75in a direction generally opposite the support arm80. A trigger110for operating the saw15and a lockout shuttle115that prevents the user from pulling the trigger110unless it is first depressed are both located on the rear handle105. The saw15also includes a front handle120that wraps around an upper portion of the housing75and that in conjunction with the rear handle105, provides grip areas to facilitate two-handed operation of the saw15.

The saw15includes an on-board battery pack135that provides power to an electric motor (not shown). The battery pack135is removably coupled to a battery receptacle140, which is located on the upper portion of the housing75. As such, the front handle120at least partially surrounds the battery receptacle140and the battery pack135, when the battery pack135is attached to the receptacle140. The battery pack135is a power tool battery pack and includes a battery housing145and a plurality of rechargeable battery cells (not shown) disposed within the battery housing145. The battery cells are lithium-based battery cells but can alternatively have any other suitable chemistry. In the illustrated embodiment, the battery pack135has a nominal output voltage of about 80V. In other embodiments, the battery pack135can have a different nominal voltage, such as, for example, 36V, 40V, 72V, between 36V and about 80V, or greater than 40V. In an alternative embodiment, the battery receptacle140may be incorporated on the cart10, instead of the saw15, to provide electrical power to the motor of the saw15.

With continued reference toFIG.2, the saw15further includes a fluid distribution system150. The fluid distribution system150includes a connector155attachable to a fluid supply line170(FIG.11), a control valve160supported upon the front handle120, and a distributor165supported upon the guard90. The supply line170provides fluid, such as water, to the fluid distribution system150from an external source. In the illustrated embodiment, the external source is a water tank175(FIG.1) carried onboard the cart10. The water tank175includes a connector180(FIG.11), which may include an integrated shutoff valve, to which the supply line170is connected. A first line (not shown) extends from the connector155to the control valve160, and a second line (not shown) extends from the control valve160to the distributor165. In the illustrated embodiment, the distributor165includes a pair of spray nozzles185disposed on opposite sides of the guard90connected by a supply line190. The spray nozzles185are operable to discharge fluid onto each side of the cutting wheel85for cooling, lubrication, and dust abatement.

With reference toFIGS.1and1A, the cart10includes a frame25to which the saw15is attachable, a handle30upwardly extending from the frame25that is graspable by a user for maneuvering the cart10, a front wheel35, and a rear wheel assembly40having two rear wheels540,545. The frame25includes a material discharge guard (e.g., mud flap45(FIG.3)) that blocks material cut by the saw15from contacting a user of the cart10and a loop48(FIG.6) that is used as a lifting point or hoist loop. The loop48is coupled to an upper portion of the frame25and allows a device, such as a crane or the like, to hook onto the cart10for easy transportation of the cart10. The loop48is capable of supporting up to quadruple the weight of the cart10. In some embodiments, the loop48may be a separate component from the frame25that is attached thereto (e.g., by welding, etc.). In other embodiments, the loop48may be integrally formed with the frame25. The cart10further includes first and second latches50(FIG.1),55(FIG.5) that are used to retain the water tank175on a bracket58(FIG.3) coupled to the frame25. The first and second latches50,55are on opposite sides of the water tank175when positioned for use. The first and second latches50,55are over-center latches that apply a clamping force to hooks60on the water tank175to pull the water tank175downward and secure it in place. The bracket58is removably coupled to the frame25so the frame25can support alternative brackets1100that support alternative water tanks1110(FIG.23).

With reference toFIG.1A, the cart10includes a mounting assembly200to secure the saw15to the frame25. The mounting assembly200includes a front mount205on a lower portion of the frame25and a rear mount210on an upper portion of the frame25. As shown inFIGS.1A, the front mount205defines a channel220in which a lower portion of the front handle120of the saw15is receivable. The channel220is open along its top and lateral sides to facilitate insertion of the handle120from the top of the channel220(i.e., in a direction parallel the y-axis shown inFIG.1) or from the side of the channel220(i.e., in a direction parallel to the z-axis).

With reference toFIG.3, the rear mount210includes a housing235and a cover240that is pivotably coupled to the housing235about an axis (not shown). The housing235includes parallel bores250a,250bthrough which a threaded rod225and a guide rod230, respectively, protrude for supporting the housing235on the frame25. The guide rod230is cantilevered from the frame25and includes a smooth cylindrical outer periphery along which the bore250ais slidable. The threaded rod225is also cantilevered from the frame25, and includes external threads that are engaged with a bushing251that is welded in the frame25. Further description of the operation of the threaded rod225appears below. When the cover240is closed, the housing235and cover240define a cavity255(FIG.4) in which the rear handle105of the saw15is positioned. When the cover240is pivoted away from the housing235toward an open position, the rear handle105is removable from the cavity255.

With reference toFIG.4, the cover240includes a boss260on its interior that presses the lockout shuttle115of the saw15when the cover240is moved to the closed position, which allows the trigger110to be pulled to operate the saw15. In some embodiments, the cover240and/or the housing235may include a resilient member (e.g., a compression or torsion spring) that biases the cover240away from the housing235to keep the cavity open for ease of tool attachment. The rear mount210further includes two latches265that secures the cover240in the closed position. In the illustrated embodiment, the latches265are configured as an over-center latches265to apply a clamping force between the cover240and the housing235to thereby maintain the lockout shuttle115in an override position.

To position the saw15on the cart10, a user holds the rear and front handles105,120of the saw15and aligns the rear handle105with the rear mount210and the front handle120with the front mount205. The user then lowers the front handle120along the y-axis into the channel220. Simultaneously, with the cover240in its open position, the rear handle105is moved transversely along the z-axis and positioned into the portion of the cavity255defined by the housing235. The cover240is then pivoted to the closed position and the latches265adjusted to its locking configuration, thereby securing the saw15on the cart10. In some embodiments, the cover240includes internal features (e.g., integral guides, etc.) that bias the handle105of the saw15into supports268of the housing235. In other words, the cover240includes internal features that naturally guide the handle105into the cavity255as the cover240is being closed to secure the handle105in the rear mount210. The motion of pivoting the cover240to the closed position engages the lockout shuttle115with the boss260, moving the lockout shuttle115to the override position where the trigger110may be pulled to activate the saw15.

With reference toFIGS.5, the cart10further includes a depth adjustment assembly270for varying the plunge depth of the cutting wheel85into a support surface20of the cart10. The depth adjustment assembly270includes a wheel arm275, an adjustment lever280, and a link285interconnecting the wheel arm275and the adjustment lever280. The wheel arm275includes a first end290and a second end295(FIG.1) opposite the first end290. The front wheel35is rotatably coupled to the first end290of the wheel arm275, whereas the second end295is pivotably coupled to a lower portion of the frame25about an axis A2, which is also the rotational axis of the rear wheels540,545(FIGS.1and1A). As such, the position of the front wheel35relative to the frame25is adjustable along an arc302having an origin intersected by the axis A2.

As shown inFIG.6, the adjustment lever280also includes a housing315attached to an upper portion of the frame25and an arcuate plate345, which has teeth360on its outer periphery, affixed to the housing315. Accordingly, the orientation of the housing315and the plate345is fixed relative to the frame25. The adjustment lever280is pivotably coupled to the frame25about an axis A3that is parallel with axis A2. The adjustment lever280includes a D-shaped handle305enclosing a pair of support brackets335interconnected with pins340,343. The arcuate plate345is positioned between the support brackets335. One of the pins340extends through an arcuate slot365in the plate345, the radius of which has an origin intersected by the axis A3. Lower ends355of the respective support brackets335extend from a lower opening330in the housing315. The support brackets335also extend from an upper opening328in the housing315having an arc length corresponding to the arc length of the portion of the plate345having the teeth360.

With reference toFIG.7, the adjustment lever280includes an actuator (i.e., pull handle350) having an upper end370that protrudes from an internal opening325in the D-shaped handle305and an opposite, lower end375that engages the gear teeth360on the arcuate plate345. The adjustment lever280also includes a resilient member (e.g., a compression spring) that biases the pull handle350toward a position in which the lower end375is engaged with the gear teeth360. When a user pulls the upper end370of the pull handle350, the lower end375is lifted out of engagement with the gear teeth360, allowing the D-shaped handle305to pivot about the axis A3relative to the housing315. Although not shown, the housing315may include depth adjustment markings thereon for the user to reference when adjusting the position of the D-shaped handle305.

With reference back toFIG.5, the link285includes a first end380that is pivotably coupled to the lower ends355(FIG.7) of the respective support brackets335and a second end385that is pivotably coupled to the wheel arm275via a pin390positioned between the first and second ends290,295of the wheel arm275. In an alternative embodiment, the adjustment lever280of the depth adjustment assembly270may be replaced by a hand crank, which may be rotatable about an axis to impart displacement to the link285, thus causing pivoting movement of the wheel arm275in the manner described above.

The depth adjustment assembly270adjusts the vertical position of the frame25relative to the front wheel35. In other words, the depth adjustment assembly270adjusts the vertical position of the cutting wheel85, when the saw15is attached to the cart10, relative to the support surface20of the cart10to vary the plunge depth of the cutting wheel85into the support surface20. To adjust the plunge depth of the cutting wheel85, a user pulls the upper end370of the pull handle350, which lifts the lower end375out of engagement with the gear teeth360on the arcuate plate345, allowing the adjustment lever280to rotate about the axis A3(FIG.7). As the adjustment lever280rotates, the wheel arm275is pivoted about the axis A2by the link285, changing the position of the frame25relative to the wheel arm275, and thus the position of the cutting wheel85relative to the support surface20. If the adjustment lever280is rotated forward, as indicated by arrow395(FIG.5), the frame25is pivoted downwards relative to the wheel arm275, dropping the cutting wheel85further into the support surface20(and increasing the plunge depth of the cutting wheel85). Alternatively, if the adjustment lever280is rotated backwards as indicated by arrow400(FIG.5), the frame25is pivoted upwards relative to the wheel arm275, raising the cutting wheel85away from the support surface20(and decreasing the plunge depth of the cutting wheel85).

With reference toFIG.11, a distance Y between the saw guard90and the outer periphery of the cutting wheel85is indicative of the maximum plunge depth of the cutting wheel85into the support surface20. In one embodiment of the cart10, the distance Y is within a range of about 4 inches to about 7 inches, depending upon the diameter of the cutting wheel85that is used. Now with reference toFIG.5, the wheel arm275is pivotable about the axis A2relative to the frame25between two extreme positions. The first extreme position of the wheel arm275(shown in solid lines) is when the cutting wheel85is at its minimum plunge depth into the support surface20, and the second extreme position of the wheel arm275(shown in broken lines) is when the cutting wheel85is beyond its maximum plunge depth into the support surface20. Therefore, a vertical distance X between the first end290of the wheel arm275in the first extreme position and the first end290of the wheel arm275in the second extreme position will always be greater than the maximum plunge depth of the cutting wheel85, indicated by distance Y. As such, the wheel arm275can always be adjusted a greater amount than the maximum plunge depth of the cutting wheel85. This allows the cart10to be operated with multiple sizes of cutting wheels85.

With reference toFIG.1, the cart10includes a remote throttle system405for activating and deactivating the saw15when it is supported on the frame25. With reference toFIG.8, the throttle system405includes a throttle lever410pivotably coupled to the handle30and a throttle cable415having a first end430that is selectively coupled to the handle30and a second end435(FIG.4) proximate the trigger110of the saw15. The remote throttle system405also includes an interlock system420operable in a first mode in which pivoting movement of the throttle lever410is incapable of tensioning the throttle cable415for pulling the trigger110, and a second mode in which pivoting movement of the throttle lever410tensions the throttle cable415for pulling the trigger110.

The interlock system420includes a housing440coupled to the handle30and an actuator (e.g., a button445) that is biased by a spring450to protrude from a top side of the housing440. Within the housing440, the interlock system420includes a first arcuate bracket455that is coupled for co-rotation with the throttle lever410and a second arcuate bracket460that is coupled to the first end430of the throttle cable415. The first arcuate bracket455includes a slot475on its outer periphery in which a pin465is receivable. The second arcuate bracket460includes the pin465pivotably coupled thereto by extension arms468. The extension arms468and the movable pin465are biased upward towards the button445by a resilient member (e.g., a torsion spring470). The button445is movable between a first position, in which the spring450biases the button445away from the pin465, and a second position, in which the button445is depressed against the bias of the spring450to push the pin465(against the bias of the torsion spring470) into the slot475. In the first position of the button445, the pin465is not received in the slot475, thereby permitting the first arcuate bracket455to pivot independently of the second arcuate bracket460. As a result, pivoting movement of the throttle lever410is incapable of tensioning the throttle cable415for pulling the trigger110. In the second position of the button445, the pin465is received within the slot475to thereby rotationally unitize the first and second arcuate brackets455,460to pivot in unison with the throttle lever410when it is depressed. As a result, pivoting movement of the throttle lever410tensions the throttle cable415for pulling the trigger110.

With reference toFIG.4, the remote throttle system405also includes an actuator arm480pivotably coupled to the housing235of the rear mount210. The second end435of the throttle cable415is coupled to the actuator arm480. The actuator arm480is pivotable and includes a finger490positioned beneath the trigger110of the cut off saw15, when positioned on the cut off saw cart10. In some embodiments, the remote throttle system405includes a first spring494seated on the throttle cable415between the actuator arm480and the housing235and a second spring495between the actuator arm480and the second end435of the throttle cable415. The first and second springs494,495allow the second end435of the throttle cable415to continue moving after the finger490has squeezed the trigger110to its maximum depressed position. This ensures that the throttle lever410, when pivoted to its maximum depressed position against the handle30, pulls the trigger110to its maximum depressed position coinciding with the maximum rotational speed of the cutting wheel85(in an embodiment of the saw15where the trigger110is configured as a variable-speed trigger). In some embodiments, the throttle cable415is routed through the handle30and/or the frame25of the cart10. In such embodiments, the throttle cable415exits the housing440into the handle30of the cart10, and is then routed from the handle30into a lower portion of the frame25. The second end of the throttle cable415exits the frame25adjacent the housing235for connection to the actuator arm480. All entry and exit openings in the frame25may include a grommet to prevent chaffing the jacket of the throttle cable415. Routing the throttle cable415through the frame25and handle30conceals and protects it.

To activate the saw15, a user depresses the button445to the second position, which depresses the pin465against the bias of the torsion spring470into the slot475to rotationally unitize the first and second arcuate brackets455,460. A user then pivots the throttle lever410towards the handle30, pivoting the arcuate brackets455,460and tensioning the throttle cable415. As a user progressively pulls the throttle lever410towards the handle30, the throttle cable415progressively pulls the actuator arm480towards the trigger110of the saw15. Because the lockout shuttle115is continuously depressed by the boss260on the cover240of the rear mount210, the finger490squeezes the trigger110to activate the motor, thereby varying the rotational speed of the cutting wheel85on the saw15. Once a user releases the throttle lever410, it pivots away from the handle30. The torsion spring470removes the pin465from the slot475, and the spring450displaces the button445away from the pin465. In order to re-activate the cutting wheel85, a user must again depress the button445before pulling the throttle lever410towards the handle30.

With reference toFIG.3, the cart10includes a track control system505that adjusts the skew angle of the cutting wheel85relative to the support surface20. The track control system505includes the threaded rod225and the guide rod230, discussed above. As discussed above, the threaded rod225is received within the bore250aand the threaded bushing251welded in the frame25, whereas the guide rod230is slidably received within the bore250b. The threaded rod225includes a rotatable knob510. When the knob510and the threaded rod225are rotated in a counter-clockwise direction, the rear mount210(and thus the rear handle105of the saw15) are moved towards the frame25, which in turn moves the cutting wheel85away from the wheel arm275. Alternatively, when the knob510and the threaded rod225are rotated in a clockwise direction, the rear mount210(and thus the rear handle105of the saw15) are moved away from the frame25, which in turn moves the cutting wheel85towards the wheel arm275. In this manner, the skew angle of the cutting wheel85relative to the x-axis (FIG.1) can be adjusted. Additionally, when the cover240is closed, the threaded rod225and guide rod230are arranged in the cavity255. When the cover240is open, a user has access to the knob510to adjust the skew of the saw. In some embodiments, the cover240includes indicia indicating to a user which way to rotate the knob510in order to adjust the skew angle of the saw15.

With reference toFIG.9, the cart10further includes a battery pack mount515coupled to the frame25to which a spare removable battery pack525, which is interchangeable with the removable battery pack135on the saw15, is attachable for storage. The battery pack mount includes a C-shaped bracket520coupled to the frame25and defines a channel530. The removable battery pack525includes a rail535that has an increased thickness portion538. The rail535is positioned in the channel530of the C-shaped bracket520to mount the removable battery pack525to the cart10. The rail535is friction fit inside the channel530of the C-shaped bracket520at a point where the rail535progresses to the increased thickness portion538. The battery rail535may extend the full length of the removable battery pack525or only a portion of the removable battery pack525. Now referencingFIG.10, the battery pack mount515further includes a platform539that supports the bottom of the battery pack525. The battery pack mount515may be coupled to other locations on the frame25other than where it is illustrated. In some embodiments, the battery pack mount515includes a latch for securing the removable battery pack525. In further embodiments, the battery pack mount515includes terminals for on board charging of the removable battery pack525. In another embodiment, the battery pack mount515stores multiple battery packs.

With reference toFIG.12, the cart includes an adjustable handle assembly565. The handle assembly565includes the handle30that is graspable by a user pushing the cart10and a joint575for securing the handle30in a desired rotational position relative to the frame25. The joint575includes a first clamshell580with teeth585fixed to the handle30, and a second half clamshell590with teeth585fixed to the frame25. When the teeth585of the first and second clamshells580,590are meshed, the handle30is rotationally locked.

With reference toFIG.13, the handle assembly565also includes a bolt shank595extending through the handle30and the first clamshell580, a knob600on one end of the shank595, and an opposite threaded end605threaded to a threaded bore610in the second half-clamshell590. Although not illustrated, a compression spring may be positioned between the clamshells580,590to push them apart. In the illustrated embodiment, the joint575is positioned on a side of the adjustment lever280that is further away from the frame25. In other embodiments, the joint575may be positioned on a side of the adjustment lever280that is closer to the frame25as shownFIG.15.

To adjust the height of the handle assembly565, a user can rotate the knob600to loosen the bolt shank595from the threaded bore610of the second half-clamshell590drawing the first half-clamshell580away from the second half-clamshell590. Once the teeth585of the respective clamshells580,590are disengaged, the handle30can be rotated relative to the first half-clamshell580and bolt shank595to a desired height. Once the desired height is reached, a user can rotate the knob600in the opposite direction to tighten the connection between the shank595and the threaded bore610, which re-engages the teeth585of the respective clamshells580,590, again locking the rotational position (and therefore the height) of the handle30relative to the frame25.

With reference toFIG.10, the cart10includes a tracking device614. The tracking device614shares location information, last used date and time, and other metrics with a user. The tracking device614may communicate with a user via a Bluetooth enabled device such as a smart phone with an application for the tracking device614. The tracking device614may be coupled to the frame25of the cart10, the saw15, or other components of the cart10. The tracking device614may be coupled to the cart10using an adhesive, fasteners, tie wraps, or the like. In the illustrated embodiment, the tracking device614is mounted on the frame25of the cart10adjacent the battery pack mount515. In some embodiments, the cart10includes other storage spaces to mount the tracking device to the cart10where the tracking device will not interfere with any moving components on the cart10or otherwise be subject to impacts or undesired contact during normal use of the cart10.

FIG.14illustrates a rear wheel assembly640for the cut off saw cart10according to another embodiment of the invention. The rear wheel assembly640includes a left wheel642, a right wheel645, a solid axle650connecting the left and right wheels642,645and an adjustment knob655. The axle650is supported by a tube660on the cart10that extends through the second end295of the wheel arm275and is coaxial with the axis A2. The axle650remains stationary within the tube660while the left and right wheels640,645rotate around the axle650. The adjustment knob655includes a threaded screw (not shown) that may be loosened in and out of contact with the axle650. To adjust the lateral position of the axle650and wheels640,645, a user can rotate the adjustment knob655to loosen the threaded screw, allowing the axle650to slide linearly along the axis A2within the tube660. Once a desired position has been reached, a user can rotate the adjustment knob655to tighten the threaded screw and secure the axle650in place. This permits either of the wheels640,645to be moved further inboard if it is desired to push the cart10with the attached saw15in close proximity to a wall.

FIG.16illustrates a depth adjustment assembly710on the cart10according to another embodiment of the invention. The depth adjustment assembly710includes a mounting plate715that supports the saw15, a foot treadle720, and a ratchet gear725. The mounting plate715is coupled to the frame25of the cart10about a pivot shaft730. The mounting plate715, and thus the saw15, is pivotable relative to the frame25about the pivot shaft730. The ratchet gear725is coupled to the mounting plate715on one side of the frame25and to the foot treadle720on the other side of the frame25. As shown inFIGS.23and24, a user may place their foot on the treadle720and rotate it backwards and forwards to rotate the mounting plate715to adjust the cutting depth of the saw15between a non-cutting position (FIG.17) and a max cutting position (FIG.18).

FIG.19illustrates a depth adjustment assembly810according to another embodiment of the invention. The depth adjustment assembly810is similar to the depth adjustment assembly710but includes a hand crank815instead of a foot treadle720. The hand crank815is coupled to the mounting plate715through a gear assembly825. As a user rotates the hand crank815, the gear assembly825is driven which pivots the mounting plate715about the pivot shaft730adjusting the cutting depth of the saw15. In some embodiments, as shown inFIG.20, an actuator830(e.g., a jack, pump, or the like) is coupled to the mounting plate715. A user may then control the actuator830to pivot the mounting plate715about the pivot shaft730.

FIG.21illustrates a depth adjustment assembly910on the cart10according to another embodiment of the invention. The depth adjustment assembly910includes a foot pedal915that when engaged releases a lock on the axle of the wheels540,545allowing a push handle920to be pivoted forward to plunge the saw15into the support surface20. When the foot pedal915is fully engaged, it rests on the support surface20.

FIG.22illustrates a depth adjustment assembly1010on the cart10according to another embodiment of the invention. The depth adjustment assembly1010is similar to the depth adjustment assembly270but includes a hand lever1015instead of a D-shaped handle305. The hand lever1015includes a depth adjustment lock1020, an actuator1025, and a pin1030seated between depth adjustment teeth1035for locking the hand lever1015. To adjust the cutting depth of the saw15, a user grasps the depth hand lever1015and squeezes the actuator1025of the depth adjustment lock1020. Squeezing the actuator1025lifts the pin1030out of engagement with the depth adjustment teeth1035, allowing the hand lever1015to pivot toward a new position coinciding with a different cutting depth of the cutting wheel85. Pivoting the hand lever1015translates the link285, which then raises/lowers the wheel arm275. Raising the wheel arm275lowers the cut off saw15, thus increasing the cutting depth of the cutting wheel85, whereas lowering the wheel arm275raises the cut off saw15, thus reducing the cutting depth of the cutting wheel85.

Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the invention as described.

Various features of the invention are set forth in the following claims.