Dust collection assembly for a power tool

This patent application claims priority to prior-filed, co-pending U.S. Provisional Patent Application Ser. Nos. 60/562,592, filed Apr. 15, 2004, and 60/608,851, filed Sep. 10, 2004, the entire contents of both of which are hereby incorporated by reference.

The present application is related to U.S. Patent Application entitled “Miter Adjustment Assembly for a Saw”, filed Apr. 15, 2005 (11/107,384); U.S. Patent Application entitled “Bevel Adjustment Assembly for a Saw”, filed Apr. 15, 2005 (11/107,314); U.S. Patent Application entitled “Table and Base Assembly for a Power Tool”, filed Apr. 15, 2005 (11/108,156); and U.S. Patent Application entitled “Power Tool Having an Elastomeric Material”, filed Apr. 15, 2005 (11/108,170), the entire contents of all of which are hereby incorporated by reference.

This invention relates generally to power tools and, more particularly, to saws, such as miter saws, chop saws, etc.

A conventional saw, such as a miter saw, may generally include a saw unit supported by a table for movement between a raised or non-cutting position and a lowered or cutting position. The table, in turn, may be movably coupled to a base about a substantially vertical axis or a miter axis to adjust a miter angle of the saw unit. To adjust the miter angle of the saw unit, a user may unlock the table from the base, rotate the table relative to the base until the desired miter angle is achieved, and lock the table to the base. The saw unit may also be movably coupled to the table about a substantially horizontal axis or a bevel axis to adjust a bevel angle of the saw unit. To adjust the bevel angle of the saw unit, the user may unlock the saw unit from the table, rotate the saw unit relative to the table until the desired bevel angle is achieved, and lock the saw unit to the table. Some miter saws also include structure to allow sliding movement of the saw unit along the bevel axis.

In some aspects and in some constructions, the invention provides a sliding saw, such as a sliding compound miter saw, generally including a base operable to support a work piece, at least one tube slidably coupled to the table below a work piece support surface of the saw, and a saw unit coupled to the at least one tube for movement with the tube relative to the base.

In some aspects and in some constructions, the invention provides a saw, such as a miter saw, generally including a base operable to support a work piece, and a saw unit coupled to the base for movement relative to the base, and a carry strap coupled to the saw to facilitate transportation of the saw.

In some aspects and in some constructions, the invention provides a saw, such as a miter saw, generally including a base operable to support a work piece, and a saw unit coupled to the base for movement relative to the base, and the saw unit may include a permanent magnet motor operable to drive a saw blade.

In some aspects and in some constructions, the invention provides a saw, such as a miter saw, generally including a base operable to support a work piece, and a saw unit coupled to the base for movement relative to the base, and the saw unit may include a fixed upper blade guard covering an upper portion of a saw blade and a movable lower blade guard covering a lower portion of the saw blade. A relief may be defined in the fixed upper blade guard to allow an increased cutting capacity of a work piece, and the saw unit may also include a supplemental blade guard for selectively covering the portion of the saw blade exposed by the relief in the fixed upper blade guard.

In some aspects and in some constructions, the invention provides a saw, such as a miter saw, generally including a base operable to support a work piece, a saw unit coupled to the base for movement relative to the base, and an on-board dust collection assembly for capturing dust generated during cutting of a work piece by the saw unit. In some aspects and in some constructions, the dust collection assembly may include a vacuum fan positioned in an electric motor of the saw unit to assist with dust collection.

In some aspects and in some constructions, the invention provides a saw, such as a miter saw, generally including a base operable to support a work piece, a saw unit coupled to the base for movement relative to the base, and at least one fence movably coupled to the base. In some aspects and in some constructions, the at least one fence may include quick-release structure to allow an operator to adjust the position of the fence with respect to the base using only one hand.

In some aspects and in some constructions, the invention provides a saw, such as a miter saw, generally including a base, a table coupled to the base for movement relative to the base, and a saw unit coupled to the table for movement relative to the table, and the table may include fine-adjustment structure allowing the table to be adjusted relative to the base in small angular increments.

In some aspects and in some constructions, the invention provides a saw, such as a miter saw, generally including a base operable to support a work piece, a saw unit coupled to the base for movement relative to the base about a generally horizontal bevel angle, and a bevel angle adjustment mechanism operable to adjust the bevel angle of the saw unit relative to the base. The bevel angle adjustment mechanism may include an actuator positioned on or in proximity to a surface of the saw which is engageable by the operator to adjust the bevel angle. The surface may include a handle, such as the main operator's handle of the saw unit, so that the operator may engage the actuator while engaging the surface to adjust the bevel angle.

In some aspects and in some constructions, the invention provides a saw, such as a miter saw, generally including a base, a table coupled to the base for movement relative to the base, a saw unit coupled to the table for movement relative to the table, and one or more digital readouts to display, among other things, the miter angle and/or the bevel angle of the saw.

In some aspects and in some constructions, the invention provides a saw, such as a miter saw, generally including a base operable to support a work piece, a saw unit coupled to the base for movement relative to the base, and a variable intensity laser line for indicating a cutting line for the saw unit. In some aspects and in some constructions, the intensity of the laser line may be adjusted to adapt to a work environment of low light and/or to a work environment of bright light.

In some aspects and in some constructions, the invention provides a saw, such as a miter saw, generally including a base operable to support a work piece, a saw unit coupled to the base for movement relative to the base, and one or more lights coupled to the saw unit to illuminate the workpiece. In some aspects and in some constructions, a light switch separate from the main power switch of the saw unit may be coupled to the saw unit to independently operate the one or more lights and the saw unit.

In some aspects and in some constructions, the invention provides a saw, such as a miter saw, generally including a base, a table coupled to the base for movement relative to the base, a saw unit coupled to the table for movement relative to the table, and a bevel stop assembly operable to define one or more bevel angles of the saw unit relative to the table.

In some aspects and in some constructions, a saw may generally include a miter adjustment assembly including a coarse adjustment assembly and a fine adjustment assembly.

In some aspects and in some constructions, a saw may generally include a bevel adjustment assembly including a brake mechanism and a bevel detent assembly.

In some aspects and in some constructions, a saw may generally include a dust collection assembly including a dust chute defining a dust both around the bevel arm.

In some aspects and in some constructions, a saw may generally include a table having a top wall with a peripheral rim and a side wall depending from the top wall, and a base defining an opening in which the side wall is received and a ledge above which the rim is positioned.

In some aspects and in some constructions, a saw may generally include elastomeric material covering a portion of the base, such as a bottom surface, a lateral surface, a grip surface, etc.

Independent features and independent aspects of the invention will become apparent to those skilled in the art upon review of the following detailed description, drawings and claims.

In the drawings, wherein like reference numerals indicate like parts:

FIGS. 1A-1L are views of a saw, such as a sliding compound miter saw.

FIGS. 2A-2L are views of another construction of a saw, such as a compound miter saw.

FIGS. 3A-3C are views of yet another construction of a saw, such as a sliding compound miter saw.

FIGS. 4A-4B are views of a further construction of a saw, such as a compound miter saw.

FIGS. 5A-5M are views of alternate constructions of a saw, such as a miter saw.

FIGS. 6A-6B are perspective views of a portion of a saw.

FIGS. 7-10 are perspective views of a portion of a saw, such as a sliding miter saw, and illustrating a base and table assembly.

FIGS. 11A-11B are schematic views of another construction of a portion of a saw and illustrating a table assembly.

FIGS. 12A-12B are perspective views of yet another construction of a portion of a saw and illustrating a table assembly.

FIGS. 13A-13D are views of alternate constructions of a portion of a saw and illustrating a fence assembly.

FIGS. 14A-14E are views of another construction of a fence assembly.

FIGS. 15A-15B are partial cross-sectional views of a portion of a saw and illustrating a drive assembly and a guard assembly.

FIGS. 16A-16C are views of a portion of a saw and illustrating a drive assembly.

FIGS. 17A-17E are views of alternate constructions of a portion of a saw and illustrating a drive assembly and a dust collection assembly.

FIG. 18 is a schematic diagram illustrating an electrical circuit and an electric motor of a saw.

FIG. 19 is a side view of a portion of a saw and illustrating a drive assembly and a speed control assembly.

FIGS. 20A-20D are perspective views of a portion of a saw and illustrating a drive assembly and a wiring arrangement.

FIGS. 21A-21B are cross-sectional views of a portion of a saw and illustrating a motor assembly mounted within a slide tube.

FIGS. 22A-22F are views of a portion of a saw and illustrating a dust collection assembly.

FIGS. 23A-23E are views of a portion of a saw and illustrating a dust chute and arm assembly.

FIGS. 24A-24C are views of a portion of a saw and illustrating a blade guard support gusset.

FIGS. 25A-25G are views of a portion of a saw and illustrating a dust chute assembly.

FIGS. 26A-26E are views of an alternate construction of a dust chute assembly.

FIGS. 27A-27J are views of a portion of a saw and illustrating a dust chute assembly and a light assembly.

FIGS. 28A-28B are schematic views of a portion of a saw and illustrating a multi-piece dust chute assembly.

FIG. 29 is a schematic view of a portion of a saw and illustrating another construction of a dust collection assembly.

FIG. 30 is a schematic view illustrating operation of a portion of the dust collection assembly of FIG. 17C .

FIGS. 31A-31J are views of a portion of a saw, such as a compound miter saw, and illustrating a miter angle fine adjustment assembly.

FIGS. 32A-E are views of an alternate construction of a bushing shown in FIG. 31D .

FIGS. 33A-33F are views illustrating operation of the fine adjustment assembly shown in FIGS. 31A-31J .

FIG. 34 is a side view similar to that in FIG. 33C and illustrating another construction of a fine adjustment assembly.

FIGS. 35A-C are views of yet another construction of a fine adjustment assembly including a sine-clutch assembly.

FIGS. 36A-36D are views of a portion of a saw, such as a sliding miter saw, and illustrating a miter angle fine adjustment assembly.

FIGS. 37A-37B are views of a further construction of a fine adjustment assembly.

FIGS. 38A-38B are views of a portion of an alternate construction of a portion of a fine adjustment assembly and illustrating a harmonic drive assembly.

FIGS. 39A-39E are views of alternate constructions of portions of a fine adjustment assembly.

FIGS. 40A-40G are views of another construction of a fine adjustment assembly.

FIGS. 41A-41G are views of yet another construction of a fine adjustment assembly.

FIGS. 42A-42C are views of a further construction of a fine adjustment assembly.

FIGS. 43A-43C are views of another construction of a fine adjustment assembly.

FIGS. 44A-44D are views of an alternate construction of a portion of a fine adjustment assembly shown in FIGS. 43A-43C .

FIG. 45 is a schematic view of yet another construction of a fine adjustment assembly.

FIG. 46 is a schematic view of the fine adjustment assembly shown in FIG. 45 .

FIGS. 47A-47B are schematic views of an alternate construction of a portion of the fine adjustment assembly shown in FIG. 45 .

FIGS. 48A-48G are schematic views of alternate constructions of a portion of a fine adjustment assembly.

FIGS. 49A-49C are views of a further construction of a fine adjustment assembly.

FIG. 50 is a top view of another construction of a fine adjustment assembly.

FIGS. 51A-51D are views of yet another construction of a fine adjustment assembly.

FIGS. 52A-52D are views of a further construction of a fine adjustment assembly.

FIGS. 53A-53B are views of another construction of a fine adjustment assembly.

FIGS. 54A-54B are views of yet another construction of a fine adjustment assembly.

FIGS. 55A-55B are views of a further construction of a fine adjustment assembly.

FIGS. 56A-56M are views of alternate constructions of portions of a saw, such as a fine adjustment assembly, adjustment controls, locking assemblies, handles and/or a digital display indicating the miter angle of the miter saw.

FIGS. 57A-57N are views of portions of a saw, such as base and table assembly and/or and another construction of a fine adjustment assembly.

FIGS. 58A-58C are views of portions of a saw, such as a base and table assembly, yet another construction of a fine adjustment assembly and a detent override assembly and illustrating operation of the fine adjustment assembly and the detent override assembly.

FIGS. 59A-59J are views of portions of a saw, such as a base and table assembly, a further construction of a fine adjustment assembly, and/or a locking assembly, such as a wedge locking assembly.

FIG. 60 is a front perspective view of a portion of a saw, such as another construction of a fine adjustment assembly and a supplemental miter angle locking assembly.

FIG. 61 is a schematic view illustrating another construction of a miter angle locking assembly.

FIG. 62 is a schematic view illustrating yet another construction of a miter angle locking assembly.

FIG. 63A-63B are views of a further construction of a miter angle locking assembly.

FIGS. 64A-64C are views of a portion of a saw, such as a miter angle scale and a user-adjustable detent assembly.

FIGS. 65A-65E are views of alternate constructions of a miter angle scale and a plurality of integrally-formed detents.

FIGS. 66A-66B are views of an adjustable miter angle stop assembly.

FIGS. 67A-67C are views of a portion of a saw, such as a compound miter saw, a sliding compound miter saw, etc., and illustrating portions of a bevel angle adjustment assembly and a bevel detent assembly.

FIGS. 68A-68B are views of another construction of a bevel angle adjustment assembly and a bevel detent assembly.

FIG. 69 is an exploded view of yet another construction of a bevel angle adjustment assembly and a bevel detent assembly.

FIG. 70 is a perspective view of an alternate construction of a detent pin.

FIGS. 71A-71C are views of portions of a further construction of a bevel angle adjustment assembly.

FIGS. 72A-72B are perspective views of a portion of a saw and illustrating operation of a bevel angle adjustment assembly.

FIGS. 73A-73D are views of portions of a bevel angle adjustment assembly and a bevel angle locking assembly, such as a pull brake assembly.

FIG. 74 is a schematic view of an alternate construction of a pull brake assembly.

FIGS. 75A-75C are views of another construction of a bevel angle adjustment assembly and a bevel angle locking assembly.

FIGS. 76A-76G are views of alternate constructions of an angular adjustment assembly and a locking assembly, such as a bevel angle adjustment assembly and a bevel angle locking assembly.

FIGS. 77A-77B are schematic views of a portion of a saw and illustrating power transmission through the slide tube.

FIGS. 78A-78G are views of a portion of a saw, such as a bevel stop assembly.

FIGS. 79A-79G are views another construction of a bevel stop assembly.

FIGS. 80A-80G are views of yet another construction of a bevel stop assembly.

FIGS. 81A-81B are exploded perspective views of alternative constructions of a portion of a saw, such as a D-handle assembly, a bevel adjustment actuator assembly and an upper blade guard.

FIGS. 82A-82E are views of a D-handle assembly and an alternate construction of a bevel adjustment actuator assembly.

FIGS. 83A-83B are exploded perspective views of alternative constructions of a portion of a saw, such as a pistol grip handle assembly, a bevel adjustment actuator assembly, and an upper blade guard.

FIGS. 84A-84B are views of a saw, such as a sliding compound miter saw, and illustrating an angular display arrangement.

FIGS. 85A-85K are schematic views of saw, such as a compound miter saw, and illustrating a transducer arrangement and an angular display arrangement.

FIGS. 86A-86D are views of portions of a saw and illustrating a transducer arrangement.

FIG. 87 is a schematic view illustrating a sensor, such as a microswitch, sensing engagement of a detent during angular adjustment of the saw unit.

FIGS. 88A-88C are schematic views illustrating alternate sensors, such as switch elements, to sense the position of a detent.

FIGS. 89A-89F are views of portions of a saw and illustrating an angular sensing arrangement, such as a capacitive sensor, a digital caliper, etc., and/or an angular display arrangement.

FIGS. 90A-90B are schematic views of a portion of a saw and illustrating another construction of an angular sensing arrangement.

FIG. 91 is a schematic view of a portion of a saw and illustrating yet another construction of an angular sensing arrangement.

FIG. 92 is a schematic view of a portion of a saw and illustrating a further construction of an angular sensing arrangement.

FIGS. 93A-93C are views of a portion of a saw and illustrating an angular sensing arrangement, an angular display arrangement and a wiring arrangement.

FIGS. 94A-94E are views of a portion of a saw, such as a sliding miter saw, and illustrating an angular display arrangement and a cover assembly.

FIG. 95 is an exploded perspective view of a saw, such as a miter saw, and illustrating an angular display arrangement and a cover assembly.

FIGS. 96A-96G are views of portions of a saw and illustrating a light assembly.

FIG. 97 is a schematic side view of a saw, such as a sliding miter saw and illustrating another construction of a light assembly.

FIG. 98 is a schematic side view of a saw, such as a sliding miter saw and illustrating yet another construction of a light assembly.

FIG. 99 is a schematic side view of a saw, such as a sliding miter saw and illustrating a further construction of a light assembly.

FIGS. 100A-100D are views of a portion of a saw, such as a sliding miter saw, and illustrating a laser assembly.

FIGS. 101A-101D are views of a portion of a saw, such as a sliding miter saw, and illustrating another construction of a laser assembly.

FIGS. 102A-102F are views of a portion of a saw, such as a sliding miter saw, and illustrating yet another laser assembly, such as an add-on laser module.

FIG. 103 is a schematic view of another construction of an add-on laser module.

FIGS. 104A-104B are schematic views of yet another construction of an add-on laser module.

FIGS. 105A-105C are schematic views of a saw, such as a sliding miter saw, and illustrating a further construction of a laser assembly, such as a laser targeting a polished faceted nut.

FIGS. 106A-106C are schematic views of a saw, such as a sliding miter saw, and illustrating a further construction of a laser assembly, such as a laser positioned in an arbor of the saw unit.

FIGS. 107A-107F are schematic views of a portion of an illumination assembly, such a variable intensity laser assembly, and an actuator assembly

FIGS. 108A-108C are views of a saw and illustrating a transport assembly, such as a carry strap assembly.

FIGS. 109A-109C are views of another construction of a carry strap assembly.

FIGS. 110A-110G are views of alternate constructions of a transport assembly

Before any features and at least one embodiment 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 arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

The use of “including”, “having”, and “comprising” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The use of letters to identify elements of a method or process is simply for identification and is not meant to indicate that the elements should be performed in a particular order.

Constructions of a power tool or saw 10 , such as a chop saw, a miter saw, a sliding saw, a compound miter saw, etc., embodying one or more independent aspects of the invention are illustrated in the figures.

General

Constructions of a saw 10 , such as a chop saw, a miter saw, a sliding saw, a compound miter saw, a sliding compound miter saw, etc., embodying independent aspects of the invention are illustrated in FIGS. 1A-1H , 2 A- 2 M, 3 A- 3 B, 4 A- 4 B and 5 A- 5 M.

Generally, as discussed below in more detail, the saw 10 may include a base and table assembly T including a base T 14 and a table T 18 for supporting a work piece WP. The saw 10 may include a drive assembly D operable to drive a saw blade SB to cut a work piece WP supported on the base and table assembly T. The drive assembly D may include a saw unit D 14 (including the saw blade SB), a motor D 18 and a drive train D 22 operable to drive the saw blade SB.

In some independent aspects and in some constructions, the saw 10 may include a fence assembly F supported by and cooperating with the base and table assembly T to support the work piece WP. In some independent aspects and in some constructions, the saw 10 may include a dust collection assembly C for collecting debris, dust, etc. generated by the saw blade SB cutting the work piece WP.

In some independent aspects and in some constructions, the saw 10 may include a miter angle adjustment assembly M providing for adjustment of the angle of the saw blade SB relative to the work piece WP about a generally vertical axis T 30 . In some independent aspects and in some constructions, the saw 10 may include a bevel angle adjustment assembly B providing for adjustment of the angle of the saw blade SB relative to the work piece WP about a generally horizontal axis B 18 . In some independent aspects and in some constructions, the saw 10 may include a digital display arrangement or digital readout arrangement R for displaying information to a user (e.g., a relative position of a portion of the saw 10 , such as the miter angle, the bevel angle, etc., information relating to the operation of the saw, such as motor speed, battery capacity, battery charging status, etc., historical information relating to the saw, such as number of cuts performed, warranty information, etc.).

In some independent aspects and in some constructions, the saw 10 may include a handle assembly H engageable by a user to adjust a relative position of at least a portion of the saw 10 (e.g., to move the saw unit D 14 and the saw blade SB between the raised, non-cutting position and the lowered, cutting position, to adjust the miter angle, to adjust the bevel angle, to transport the saw 10 , etc.). In some independent aspects and in some constructions, the saw 10 may include an elastomeric material E provided on surfaces of the saw 10 (e.g., carrying surfaces, gripping surfaces, support surfaces, protruding surfaces, etc.)

In some independent aspects and in some constructions, the saw 10 may include an illumination assembly L for illuminating an object (e.g., the work piece WP, the surface of the base and table assembly T, etc.), for indicating a cut-line, etc. In some independent aspects and in some constructions, a transport assembly TR is provided to assist the user in transporting to the saw 10 to, from and around a job site.

Base and Table Assembly T

In addition to FIGS. 1-5 , FIGS. 6-12 illustrate constructions of a base and table assembly T. In the illustrated constructions, the base and table assembly T includes a base T 14 supported on a work surface WS, such as a work bench, saw stand, etc., and a turntable or table T 18 supported by the base T 14 . The table T 18 includes a table surface T 22 , and the base T 14 includes support surfaces T 26 which are generally planar with the surface T 22 . The surfaces T 22 and T 26 cooperate to support a work piece WP.

In the illustrated constructions, the saw 10 is a miter saw, and the table T 18 is coupled to the base T 14 for pivoting movement about a generally vertical miter axis T 30 . As shown in FIGS. 1-5 , the drive assembly D and saw blade SB are coupled to the table T 18 for pivoting movement with the table T 18 relative to the base T 14 to allow the saw blade SB to perform various angled miter cuts on a work piece WP supported on the table T 18 and/or on the base T 14 .

A connecting assembly T 34 is provided to pivotally connect the table T 18 and the base T 14 . The connecting assembly T 34 generally defines the miter axis T 30 . A bearing assembly (not shown) is provided between the table T 18 and the base T 14 .

The saw unit D 14 and the saw blade SB are coupled to the table T 18 for movement relative to the table T 18 between a raised, non-cutting position (see FIG. 5A ) and a lowered, cutting position (see FIG. 1A ). In some constructions, the saw unit D 14 and the saw blade SB may also be coupled to the table T 18 for pivoting movement about a bevel axis B 18 to allow the saw blade SB to perform bevel cuts on a work piece WP supported on the table T 18 and/or the base T 14 .

The base T 14 defines an opening T 42 for receiving the table T 18 . Ledges or ridges T 46 are provided adjacent to and below the associated support surfaces T 26 . The table T 18 includes a top wall T 50 and a side wall T 54 depending from the top wall T 50 . In some constructions, the side wall T 54 is spaced inwardly from the periphery of the top wall T 50 to provide an annular rim T 58 . The side wall T 54 is positioned in the opening T 42 and may extend the full depth of the opening T 42 . The rim T 58 is positionable above the ridges T 46 which may provide support to the rim T 58 .

Vertical ridges T 62 may be provided on the side wall T 54 , and contoured recesses (not shown) may be provided on the bottom surface of the rim T 58 to provide a grip surface for a user's fingers (e.g., for carrying the saw, for holding a work piece WP, etc.).

With continued reference to FIGS. 1 , 3 and 5 , and with additional reference to FIGS. 7-12 , the illustrated saw 10 may be a sliding saw, and, in such constructions, the saw unit D 14 is coupled to the table T 18 for generally linear sliding movement by a sliding support assembly T 66 . In the illustrated construction, the sliding support assembly T 66 generally includes support or slide tubes T 70 supported for sliding movement relative to the table T 18 along an axis generally parallel to the bevel axis B 18 and for pivoting movement with the table T 18 relative to the base T 14 . The saw unit D 14 is supported by the slide tubes T 70 for movement with the slide tubes T 70 relative to the table T 18 .

In the illustrated construction of the saw 10 , the slide tubes T 70 are located below and in a common horizontal plane oriented substantially parallel with the plane of the surface T 22 of the table T 18 . The side wall T 54 of the table T 18 defines an open circumferential space T 74 to the rear and a forward tongue portion T 78 . The space T 74 and the tongue portion T 78 accommodate sliding movement of the slide tubes T 70 between a forward position (shown in FIG. 1 ), in which the slide tubes T 70 at least partially extend into the tongue portion T 78 , and a rearward position (shown in FIG. 3 ), in which the slide tubes T 70 project to a greater extent through the space T 74 . In some constructions, such as that shown in FIGS. 7-10 , the space T 74 may be relatively large (e.g., extending about 180 degrees). In other constructions, such as that shown in FIGS. 12A-12B , the space T 74 is relatively narrow.

The slide tubes T 70 are slidably supported in the table T 18 by linear bearing assemblies T 82 . In the illustrated construction, the sliding support assembly T 66 also includes a sub-table T 86 which cooperates with the table T 18 as a “clamshell” to hold the bearing assemblies T 82 and which can be pivotally mounted to the base T 14 . The sub-table T 86 may include a side wall T 90 extending upwardly from the base T 14 and at least partially closing a relatively large space T 74 (as shown in FIGS. 7-10 ) to cooperate with the table T 18 to substantially enclose components within the base and table assembly T (e.g., the bearing assemblies T 38 , T 82 , etc.).

In some constructions, such as that shown in FIGS. 7-10 , the sub-table T 86 may provide an open cup shape with channels T 92 for the bearing assemblies T 82 and/or slide tubes T 70 . In other constructions, such as that shown in FIGS. 12A-12B , the sub-table T 86 may provide a relatively tight fit sandwiching the bearing assemblies T 82 and/or slide tubes T 70 to the table T 18 .

As shown in FIGS. 12A-12B , the bearing assemblies T 82 may be at least partially located outside of the side wall T 54 of the table T 18 , and the connecting assembly T 34 defining the miter axis T 30 may be located inside of the side wall T 54 of the table T 18 and the sub-table T 86 .

In some constructions, such as that shown in FIGS. 11A-11B , radial support ribs T 98 may be provided between the inner side wall T 54 and the top wall T 50 . Also, a relatively short peripheral wall T 102 may depend from the periphery of the top wall T 50 . In some constructions, the support ribs T 98 extend between the peripheral side wall T 102 and the inner side wall T 50 to provide support to the rim T 58 .

As shown in FIG. 12A , the tongue portion T 78 may have a wider portion T 106 accommodating movement of the slide tubes T 70 and a narrower, stepped-down or necked-down portion T 110 accommodating components of the miter adjustment assembly M. A slide locking assembly T 114 may be provided to releasably lock the slide tubes in a position relative to the table T 18 .

In other constructions (not shown), the side wall T 54 may be slanted or non-vertical. In yet other constructions (not shown), a side wall may extend upwardly from the base T 14 to close a portion of the opening T 42 .

In further constructions (not shown), a shorter side wall may extend upwardly from the base T 14 , and a relatively short side wall may depend from the table T 18 . A gap or slot may be provided between the side walls to accommodate pivoting movement of the slide tubes T 70 . In such constructions, a flexible material, such as a brush, a curtain, etc. may be provided in the gap/slot between the side walls of the table T 18 and the base T 14 . The slide tubes T 70 would be able to pivot with the table T 18 through the flexible material, and the flexible material would limit entry of debris into the gap or slot.

In other constructions (not shown), no side wall may be provided between the table T 18 and the base T 14 .

In other constructions, the sliding support assembly T 66 may include slide tubes (not shown) configured and/or oriented in other ways. For example, the support tubes may be mounted above the plane of the surface T 22 (e.g., i) support tubes mounted in a vertical orientation relative to the plane of the surface T 22 , ii) support tubes mounted in a horizontal orientation relative to the plane of the surface T 22 , iii) support tubes mounted in an oblique orientation relative to the plane of the surface T 22 , etc.).

FIG. 5D illustrates a sliding miter saw 10 including an above-the-table sliding support assembly T 66 . In the illustrated construction, the assembly T 66 includes support tubes T 60 connected to the saw unit D 14 and slidably supported by an arm, such as a bevel arm B 14 . FIG. 21A illustrates another construction of a miter saw including an above-the-table sliding support assembly T 66 .

In other constructions (not shown), the sliding miter saw 10 may include support tubes that are fixed to a base and table assembly T and a saw unit D 14 that is slidably movable along the support tubes. In some constructions, the support tubes may project toward the front of the base and table assembly T (i.e., the tubes are supported at the rear of the base and table assembly T) and slide into the saw unit D 14 (e.g., i) support tubes mounted in a vertical orientation relative to the plane of the surface T 22 , ii) support tubes mounted in a horizontal orientation relative to the plane of the surface T 22 , iii) support tubes mounted in an oblique orientation relative to the plane of the surface T 22 , etc.).

In some constructions (not shown), the support tubes may project toward the rear of the base and table assembly T (i.e., the tubes are supported at the front of the base and table assembly T) and slide into the saw unit D 14 (e.g., i) support tubes mounted in a vertical orientation relative to the plane of the surface T 22 , ii) support tubes mounted in a horizontal orientation relative to the plane of the surface T 22 , iii) support tubes mounted in an oblique orientation relative to the plane of the surface T 22 , etc.).

As shown in FIG. 5E-5F , the saw 10 may include movable work support assemblies. Lateral movable work support assemblies T 118 may be movably supported by the base T 14 and may telescope laterally out of the base T 14 to extend the lateral length of the base T 14 and support a relatively long work piece WP. The movable work support assemblies T 118 may be movably supported by the base T 14 or may be movable relative to but not removable from the base T 14 .

The base T 14 and/or the movable work support assemblies T 118 may include a locking arrangement T 122 to lock the movable work support assemblies T 118 in a position relative to the base T 14 . The locking assembly T 122 may include a quick-locking assembly, such as, for example, a cam-locking assembly, to the secure the position of the movable work support assemblies T 118 relative to the base T 14 .

Other movable work support assemblies T 126 to adjust the lateral width of the base T 14 to support a relatively wide work piece WP. The movable work support assemblies T 126 may be movably supported relative to the movable work support assemblies T 118 and/or relative to the base T 14 . The movable work support assemblies T 126 may be removable from the movable work support assemblies T 118 and/or from the base T 14 or may be movable relative to but not removable from the movable work support assemblies T 118 and/or from the base T 14 . A locking arrangement T 130 , such as, for example, a cam-locking assembly, may be provided between the movable work support assemblies T 126 and the movable work support assemblies T 118 and/or the base T 14 to the secure the position of the movable work support assemblies T 126 relative to the movable work support assemblies T 118 and/or the base T 14 .

In some constructions, such as those illustrated in FIGS. 1-5 , the saw 10 may include one or more extensions T 134 to impede rearward tipping of the saw 10 relative to the work surface WS. The extension(s) T 134 may also provide auxiliary gripping or carrying surface(s) or handle(s) for the saw 10 . Such extension(s) T 134 may be contoured to provide a gripping surface and/or may include grippable elastomeric material E.

In some constructions, as shown in FIGS. 1-4 , and 5 K- 5 M, the extension(s) T 134 may be fixed relative to the base T 14 . In other constructions, as shown in FIGS. 5 A and 5 H- 5 I, such extension(s) T 134 may be movable (e.g., slidable ( FIG. 5A ), pivotable ( FIGS. 5H-5I ), etc.) relative to the base T 14 .

Elastomeric Material E

In some constructions, as shown in FIGS. 1-6 , the base T 14 may provide auxiliary carrying surfaces or handles T 138 (e.g., on the bottom of the lateral sides of the base T 14 ). As shown in FIGS. 1-4 , 5 K- 5 M and 6 , the carrying surfaces or handles T 138 may be covered with elastomeric material E, such as, for example, rubber, Santoprene, etc., to provide improved gripping and/or comfort for a user. The carrying surfaces or handles T 138 and/or the elastomeric material E may also be contoured to fit a user's hand.

As shown in FIG. 6 , the elastomeric material E may be formed as a separate grip member E 14 which is attachable to the base T 14 (e.g., to the extension(s) T 134 , to the carrying surfaces or handles T 138 , etc.). Alternatively, the elastomeric material E may be provided as an overmold (e.g., on the extension(s) T 134 , on the carrying surface(s) or handle(s) T 138 , etc.).

Generally, the saw 10 defines an outer periphery, and the base T 14 has a peripheral surface T 142 (laterally and/or vertically). The base T 14 has a bottom surface T 146 which is engageable with the work surface WS to support the saw 10 on the work surface WS. The base T 14 also has a lateral surface T 150 including corner surfaces T 154 .

As shown in FIGS. 5K-5M and 6 , elastomeric material E may cover a portion of the periphery of the saw 10 (e.g. bottom surface T 146 , the lateral surface T 150 and/or the corner surfaces T 154 , etc.). In some constructions, such as that shown in FIG. 6 , the elastomeric material E may be provided as a separate portion (e.g., a foot portion E 18 ) which is attachable to the base T 14 (e.g. bottom surface T 146 , the lateral surface T 150 and/or the corner surfaces T 154 , etc.). As shown in FIG. 5F-5G , the base T 14 may include rounded lateral edges T 150 and corners T 154 .

The elastomeric material E may inhibit damage to, provide increased friction with, etc. a work surface WS on which the saw 10 is supported. The elastomeric material E may also inhibit damage to other objects during movement of the saw 10 (e.g., inhibit damage if the saw 10 impacts a wall, etc.), improve comfort to a user during movement of the saw 10 (e.g., cover points which may engage against a user during transport), etc.

Elastomeric material E may be provided on portions of the saw 10 which may be engageable by an operator (e.g., gripping or handling surfaces, such as, for example, the handle assembly H, the angular adjusting handle(s) of the miter adjustment assembly M and/or of the bevel adjustment assembly B, auxiliary carrying surface(s) or handle(s) T 138 (and T 134 ), etc.) and on surfaces engageable with a work surface WS or other object to provide one or more of, among other things, protection (e.g., to improve comfort, to prevent damage of the work surface WS or other objects), friction between the work surface and the saw 10 , etc.

Fence Assembly F

FIG. 5K illustrates a fence assembly F including one or more fence assemblies F 14 which are releasably coupled to the base T 14 and/or the table T 18 such that a user may adjust the position of the fence assembly F 14 using only one hand. The illustrated fence assembly F 14 includes a lower portion F 18 fixed to the base T 14 and an upper portion F 22 that is adjustable relative to the base T 14 . FIGS. 1-4 illustrate similar fence assemblies F 14 .

A locking assembly, such as an over-center locking assembly F 26 , is provided between the upper portion F 22 and the lower portion F 18 . A lever F 30 is operable to actuate the locking assembly F 26 . The lever F 30 is recessed from the work piece-contacting surface F 34 of the fence assembly F 14 so to not interfere with the work piece WP. As such, to adjust the fence assembly F 14 , the user first pushes (or, in other constructions, pulls) the lever F 30 to unlock the upper portion F 22 from the fixed lower portion F 18 . The user then may adjust the position of the upper portion F 22 relative to the lower portion F 18 with the same hand utilized to manipulate the lever F 30 . When the final position of the upper portion F 22 is achieved, the user may lock the upper portion F 22 to the lower portion F 18 again by returning the lever F 30 to its original or home position (shown in FIG. 5K ).

In other constructions (not shown), the lever F 30 and/or the locking assembly F 26 may be biased to the locking position.

In other constructions (not shown), the lower portion F 22 may be movable relative to the base T 14 . In such constructions, a locking assembly (not shown but similar to the locking assembly F 26 ) may be provided between the lower portion F 22 and the base T 14 to releasably lock the position of the lower portion F 22 relative to the base T 14 .

FIG. 13A illustrates another construction of an adjustable fence assembly F 34 . The fence assembly F 34 includes an upper portion F 38 movable relative to a lower portion F 42 . The fence assembly F 34 also includes an actuator or handle F 46 that is manipulatable by the user to lock the upper portion F 38 relative to the lower portion F 42 . The handle F 46 is coupled to a wedge F 50 and a fulcrum F 54 to selectively lock the upper portion F 38 to the lower portion F 42 . The procedure for adjusting the fence assembly F 34 is substantially similar to that of the fence assembly F 14 of FIG. 5K , such that an operator may adjust the position of the upper portion F 38 with one hand.

FIG. 13B illustrates yet another construction of an adjustable fence assembly F 58 . The fence assembly F 58 also includes an upper portion F 62 movable relative to a lower portion F 66 . A lever portion F 70 includes a surface F 74 substantially co-planar with the work piece-supporting surface F 78 of the upper portion F 62 . The lever portion F 70 is operable to actuate a cam structure F 82 to lock the upper portion F 62 to the lower portion F 66 . The procedure for adjusting the fence assembly F 58 is substantially similar to that of the fence assembly F 14 of FIG. 5K , such that a user may adjust the position of the upper portion F 62 with one hand.

FIG. 13C illustrates a further construction of an adjustable fence assembly F 86 . The fence assembly F 86 includes a lower portion F 90 , which may be adjustable relative to the base T 14 in a similar manner to any one of the upper portions of the fence assemblies F 14 , F 34 or F 58 shown FIG. 5K or 13 A- 13 B. The fence assembly F 86 also includes an upper portion F 94 that may be pivotable relative to the lower portion F 90 . More particularly, the upper portion F 94 may pivot about a central pivot F 98 about 180 degrees. Alternatively, the upper portion F 94 may be removed from the lower portion F 90 by removing the upper portion F 94 from the central pivot F 98 .

FIG. 13D illustrates a tilting fence assembly F 102 . A tilting portion F 106 may be tilted to adjust a position of a work supporting surface F 110 of the tilting portion F 106 relative to the base T 14 .

FIGS. 14A-14D illustrate a fence assembly F 114 including a movable fence portion F 118 . The fence assembly F 114 may include a fixed fence portion F 122 cooperating with the movable fence portion F 118 to provide a support surface F 126 for a work piece WP. A locking assembly F 130 is provided to lock the movable fence portion F 118 in a position relative to the fixed fence assembly F 122 , if one is provided, and relative to the base T 14 . The locking assembly F 130 includes an actuator or fence handle F 134 which operates a cam F 138 to cause a clamp bracket F 142 to move into and out of clamping engagement with the fixed portion (e.g., a fixed fence portion F 122 , the base T 14 , etc.).

A spring clip F 146 is provided to selectively retain the movable fence portion F 118 . The spring clip F 146 includes a blocking portion F 150 selectively preventing the movable fence portion F 118 from disengaging (e.g., from the fixed fence portion F 122 , from the base T 14 , etc.). A user may manipulate a release portion F 154 of the spring clip F 146 to allow the movable fence portion F 118 to be removed (e.g., from the fixed fence portion F 122 , from the base T 14 , etc.).

In other constructions (not shown), the lower “fixed” fence portion F 122 may also be movably supported relative to the base T 14 . In such constructions, a locking assembly (not shown) is provided between the movable fixed fence portion and the base. Such a locking assembly may include a thumb screw or a locking assembly similar to that shown in Figs. FIGS. 14A-14E .

FIGS. 5A-5E , 5 G- 5 H and 5 M illustrate arrangements of movable and/or removable fence assemblies F 14 . In FIGS. 5E-5F , additional movable fence portions (not shown) may be slidably received in the movable work support assemblies T 118 . The movable fence portion may slidable into and out of the movable work support assemblies T 118 . FIG. 5D illustrates a fence assembly F 14 including a movable vertical crown stop F 158 .

FIG. 5I illustrates at least one fence assembly F 14 including a movable fence portion F 162 . A locking assembly F 166 including a lever F 170 is provided between the movable fence portion F 162 and a fixed fence portion F 174 . In other constructions (not shown), the locking assembly may be provided between the movable fence portion F 162 and the base T 14 , and a fixed fence portion (such as fixed fence portion F 174 ) may not be provided.

FIG. 5J illustrates a fence assembly F 14 including an adjustable crown stop F 178 . A locking assembly F 182 , such as a thumb screw locking assembly, is operable to hold the stop F 178 in a position relative to the fence assembly F 14 . In other constructions (not shown), another locking assembly, such as an over-center lever, may be provided. The stop F 1178 can be moved out of the way when not in use (e.g., by being flipped to the rear).

Drive Assembly D

FIGS. 15A-15B illustrates a drive assembly D for a saw 10 . The drive assembly D generally includes a saw unit D 14 (including a saw blade SB), a motor D 18 and a drive train D 22 operable to drive the saw blade SB. A housing assembly D 26 houses the motor D 18 and the drive train D 22 . At least a portion of the drive assembly D (such as the saw unit D 14 ) is supported for movement between the raised, non-cutting position and the lowered, cutting position about an axis D 28 .

As shown in FIGS. 1-4 , an arm D 28 extends from the housing assembly D 26 . A handle H is supported on the arm D 28 .

The housing assembly D 26 includes a fixed upper blade guard D 30 having a portion D 34 removed to provide increased vertical cutting capacity compared to conventional miter saws. With reference to FIG. 15A , the portion D 34 of the upper blade guard D 30 between the blade axis BA and the fence assembly F is relieved to increase the vertical cut capacity of the saw 10 . The upper blade guard D 30 may or may not still cover the teeth on the rear portion of the saw blade SB, as in the saw 10 shown in FIGS. 1-4 . As a result, an auxiliary blade guard (not shown) may be provided to cover the exposed teeth of the rear portion of the saw blade SB. Such an auxiliary blade guard may be fixed, flexible, or movable to allow selective exposure of the rear portion and/or teeth of the saw blade SB.

FIGS. 16A-16B illustrate a drive assembly D incorporating a drive train D 22 coupling the motor D 18 and the saw blade SB that allows the motor D 18 to be remotely positioned relative to the blade arbor D 38 such that the motor D 18 substantially does not interfere with the fence assembly F, base and table assembly T, or work piece WP when the saw unit D 14 is positioned for a bevel cut. In some constructions of the saw 10 , the motor D 18 may include a permanent magnetic motor, while in other constructions of the saw 10 , the motor D 18 may include a standard or universal motor, a switched reluctance (SR) motor, etc.

The motor D 18 includes a motor shaft D 42 defining a motor axis D 46 that is substantially parallel to the saw blade SB and substantially perpendicular to the blade arbor D 38 . Also, as viewed from the side, the motor axis D 46 defines an oblique angle with respect the table T 18 or the work piece support surface T 22 such that the motor housing D 26 is tilted away from a user. By tilting the motor housing D 26 away from the user, the exhaust of a motor fan D 50 may be directed away from the user, and an auxiliary dust collection fan C 130 may be coupled to the motor shaft D 42 .

As shown in FIG. 16C , the drive train D 22 includes a dual-stage drive train configuration drivably coupling the motor shaft D 42 and the blade arbor D 38 . In the illustrated construction, the first stage D 54 includes a spiral bevel gear set, and the second stage D 58 includes a helical gear set. A spiral bevel pinion D 62 is coupled to the end of the motor shaft D 42 by a coupling D 66 . An idler assembly, including a spiral bevel gear D 70 and a helical pinion D 74 , is rotatably supported on a shaft D 78 such that the spiral bevel pinion D 62 is drivably engageable with the spiral bevel gear D 70 . Further, a helical gear D 78 is coupled to the blade arbor D 38 and drivably engageable with the helical pinion D 74 of the idler assembly.

Alternative drive train configurations (not shown) may include (1) a single-stage bevel gear set, in which a spiral bevel gear is directly coupled to the blade arbor and drivably engaged by a spiral bevel pinion coupled to the motor shaft; (2) a dual-stage spiral bevel gear set, with the first stage utilizing an oblique mesh angle to permit a wide range of motor orientations, (3) a single-stage worm gear set, in which a gear is directly coupled to the blade arbor and drivably engaged by a worm gear coupled to the motor shaft, (4) a single-stage hypoid gear set, in which a hypoid gear is directly coupled to the blade arbor and drivably engaged by a hypoid pinion coupled to the motor shaft, etc.

As shown in FIGS. 16C and 19 , the drive assembly D may also include a speed control (SC) assembly D 82 . The SC assembly D 82 includes a SC pickup D 86 , such as toothed metal cog, supported for rotation with the spiral bevel pinion D 62 and a SC sensor D 90 sensing rotation of the SC pickup D 86 . The SC sensor D 90 communicates with a controller D 92 (see FIG. 20A ) which is operable to control the speed of the motor D 18 . FIGS. 20A-20D illustrate a portion of a wiring arrangement D 93 for the saw 10 .

FIGS. 17A-17E illustrate a drive assembly D used with a dust collection assembly C, such as an on-board dust collection assembly. Such a dust collection assembly C is discussed in more detail below.

FIG. 18 schematically illustrates motor D 18 , such as a permanent magnet motor D 94 . The permanent magnet motor D 94 includes permanent magnets (not shown) and a wound armature (not shown) with commutator. In operation of the motor D 94 , AC line power is rectified and passed by brushes to the armature. Additional electronics may be added to modulate the input power to provide speed control for the motor D 94 . Components, such as relatively simple resistors or other electronics, may be added to control acceleration and deceleration of the motor D 94 .

The permanent magnet motor D 94 may generally allow the saw blade SB to be driven in a smooth and controlled manner for more accurate cutting. More particularly, the permanent magnet motor D 94 may generally provide “soft start” and “soft stop” of the saw blade SB and a reduced no-load speed (when compared to a universal motor), which contributes to more accurate cutting. Also, the permanent magnet motor D 94 may generally have a reduced size compared to a universal motor of the same power output, a flatter speed torque characteristic with minimal electronics, resulting in a more constant speed without expensive feedback circuits, 100% braking efficiency in bringing the saw blade SB to a complete stop, and/or increased power compared to a comparably-sized universal motor.

FIGS. 21A-21B illustrate a saw 10 , such as a sliding miter saw, including a motor D 98 mounted inside of a slide tube T 70 . The motor D 98 is connected to the output spindle D 102 via a flexible coupling D 106 , such as, for example, a U-joint, a flexible shaft, etc.

As shown in FIG. 5M , the saw 10 includes a movable stop assembly D 102 for limiting the depth to which the saw blade SB may be moved into the work piece. In the illustrated construction, the depth stop assembly D 102 includes a thumb screw D 106 which is engageable with a surface on the saw arm to set a limit for pivoting movement of the saw head D 14 relative to the bevel arm B 14 and relative to the table T 14 . In other constructions (not shown), the stop assembly D 102 may include one or more quickly-adjustable stops for a given depth positions (e.g., one-eighth inch, one-quarter inch, three-eighths inch, one-half inch, etc.).

Dust Collection Assembly C

FIGS. 17D-17E , 22 - 24 and 27 - 28 illustrate constructions of at least portions of a dust collection assembly C, such as a dust chute assembly C 14 , for a saw 10 . As shown in FIGS. 22A-22F , the dust chute assembly C 14 may include a dust chute C 18 extending through the bevel arm B 14 . A chip deflector C 22 is provided to direct debris into the chute inlet port C 26 , which is generally tall and wide to capture a high percentage of dust and debris. The chip deflector C 22 moves with the saw unit D 14 relative to the dust chute C 18 as the saw unit D 14 is moved between the raised, non-cutting position and the lowered, cutting position.

The chip deflector C 22 may be mounted below the motor housing D 26 ahead of the upper blade guard D 30 . The chip deflector C 22 may scissor in and out of the top of the dust chute C 18 as the saw unit D 14 is raised and lowered. The chip deflector C 22 may serve as a blade guard to replace that portion of the fixed upper guard D 30 which would otherwise be in place. The chip deflector C 22 also automatically adjusts the inlet height of the dust chute C 18 as the saw unit D 14 is raised and lowered.

A curved, inside surface of the chip deflector C 22 may redirect dust and debris coming off the saw blade SB, thereby bending the dust and debris stream downward to the chute exhaust port C 30 . In a similar fashion, this surface may redirect air coming off the tips of the saw blade SB, creating flow across the top, inner surface of the chip deflector C 22 and the dust chute C 18 to assist in moving dust toward the chute exhaust port C 30 .

In other constructions (not shown), the chip deflector C 22 may be mounted to allow some pivoting movement relative to the motor housing D 26 and upper guard D 30 to optimize the direction of deflection of debris as the saw unit D 14 and upper guard D 30 are moved between the raised, non-cutting position and the lowered, cutting position.

As shown in FIGS. 22D-22F , the chute exhaust port C 30 is generally large and smooth to facilitate efficient flow of material through the dust chute C 18 . In some constructions, the chute exhaust port C 30 may provide a downwardly angled outlet to minimize the amount of dust that might otherwise spray around the room when the chute exhaust port C 30 is open (e.g., when a debris collector (a bag, a hose, etc.) is not attached) and to improve the effectiveness of directing the dust to some type of outboard storage container (e.g., a box, bucket, or large bag).

A rear dust chute deflector C 34 may be positioned on the chute exhaust port C 30 . The deflector C 34 may provide the downwardly angled outlet. The deflector C 34 may connect to the chute exhaust port C 30 by simply accepting the chute exhaust port C 30 (in a manner similar to the connection of vacuum pipe sections in many typical wet/dry vacuums). In other constructions (not shown), another connecting assembly may be provided to releasably connect the deflector C 34 to the dust chute C 18 .

FIGS. 24A-24B illustrate a blade guard support gusset C 36 formed on a portion of the motor housing D 26 . FIGS. 27A-27J illustrate a dust collection assembly which is similar to the dust collection assembly C 14 .

As shown in FIGS. 23A-23E , in another construction, the dust chute assembly C 38 includes a dust chute C 42 which does not go through the bevel arm B 14 . Instead, the dust chute C 42 goes around the bevel arm B 14 . Because the bevel arm B 14 does not include the dust chute (such as the dust chute D 14 ) extending therethrough, such a construction provides a bevel arm B 14 which may be easier to manufacture, sturdier, etc., require less material, etc. FIGS. 1-4 illustrate a similar dust chute assembly C 38 .

As shown in FIG. 23D , the dust chute C 42 defines openings C 46 for receiving a portion of the bevel arm B 14 . When assembled, as shown in FIGS. 23A-23B , the dust chute C 42 defines a path C 50 on each side of the bevel arm B 14 from the chute inlet port C 54 to the chute exhaust port C 58 .

FIGS. 25A-25G illustrate a dust chute assembly C 62 for a saw 10 , such as a sliding compound miter saw, which includes a dust chute C 66 which extends around, rather than through, the bevel arm B 14 . The dust chute C 66 is formed of dust chute portions C 70 and C 74 . The portions C 70 and C 74 are secured on opposite sides of the bevel arm B 14 and cooperate to provide the dust chute C 66 .

Each portion C 70 and C 74 provides a portion of the chute inlet port C 78 and of the chute exhaust port C 82 . Each portion C 70 and C 74 cooperates with the outer surface of the bevel arm B 14 to define a path C 86 around the bevel arm B 14 .

A rib C 90 is formed on each portion C 70 and C 74 and extends into the associated path C 86 to direct flow through the dust chute C 66 . Each rib C 90 defines a recessed portion C 94 to provide a close fit with the outer surface of the bevel arm B 14 .

A fastening assembly (partially shown) including fastener receiving opening portions C 98 secures and seals the dust chute C 66 around the bevel arm B 14 . In some constructions, additional sealing members (not shown), such as flexible gaskets, may be provided at the interface between the portions C 70 and C 74 to provide a relatively air tight dust chute C 66 so that debris can only flow out through the chute exhaust port C 82 .

A rear dust chute deflector C 102 is connectable at the chute exhaust port C 82 of the dust chute C 66 . A connecting assembly C 106 is provided to removably connect the deflector C 102 to the dust chute C 66 . In the illustrated construction, the deflector C 102 defines an opening C 110 which receives a portion of the dust chute C 66 (e.g., the rearmost fastener receiving opening portions C 98 ). A lower ledge C 114 formed on the deflector C 102 may be received by a portion of the dust chute C 66 (e.g., a slot).

To attach the deflector C 102 , the opening C 110 receives the portion of the dust chute C 66 (e.g., the rearmost fastener receiving opening portions C 98 ). The deflector C 102 is then pivoted such that the ledge C 14 engages the slot to prevent the rearmost fastener receiving opening portions C 98 from disengaging the opening C 110 .

A debris collector (not shown), such as a bag, a hose, a debris “sock”, etc., may be connectable to the outlet C 118 of the deflector C 102 . The outlet C 118 may be have a standard configuration and/or may be formed with a portion of a connecting assembly to releasably secure a standard debris collector to the outlet C 118 .

FIGS. 26A-26E illustrate a dust chute assembly C 122 for a saw 10 , such as a compound miter saw, which includes a dust chute C 66 which extends around, rather than through, the bevel arm B 14 . The dust chute assembly C 122 is similar to the dust chute assembly C 62 .

FIGS. 17 and 28 - 30 illustrate constructions of a dust collection assembly C, such as an on-board dust collection assembly.

As shown in FIGS. 17A-17B , the dust collection assembly C 126 includes a vacuum fan C 130 which may be sealed and/or isolated from the fan D 50 of the motor D 18 but which may be fixed to the end of and drive by the motor shaft D 42 . Rotation of the motor shaft D 42 rotates the vacuum fan C 130 , which generates an airflow through a vacuum duct C 134 toward the vacuum fan C 130 .

Such an airflow may create a low pressure in a particle separator C 138 , which, in turn, creates a low pressure in a dust chute C 142 positioned proximate the saw blade SB. The low pressure in the dust chute C 142 helps to draw dust and debris generated by cutting a work piece WP into the particle separator C 138 .

The particle separator C 138 may be a sealed canister which separates dust particles and chips before the airflow enters the vacuum duct C 134 and reaches the vacuum fan C 130 . The particle separator C 138 may be detachable from the saw 10 to allow a user to dispose the dust and debris accumulated in the particle separator C 138 .

A filter (not shown) may be used to achieve dust and debris separation in the particle separator C 138 . Alternatively, cyclonic action (similar to that used in some commercial and consumer vacuum cleaners) may be used. As shown in FIG. 17B , if the particle separator C 138 does not utilize the filter, a porous dust bag C 146 may be attached to the exhaust port C 150 of the vacuum fan C 130 .

A dust sock (not shown) may be coupled to the exhaust port C 150 . In contrast to the dust bag C 146 , the dust sock is fairly long (perhaps several feet in length) and can be left open at the downstream end. By leaving the sock open, little or no back pressure is created, and the dust and debris material can be deposited directly and “gently” into an open container or onto the floor. The dust stream energy is dissipated as it moves through the sock, thereby slowing it to a “dribble” before exiting. Alternatively, the sock could have a zipper at the output end so that dust is trapped within. Given the length of the dust sock, and with a relatively porous material, back pressure may be decreased.

FIG. 17C illustrates another construction of a dust collection assembly C 150 . A single or a multi-stage fan system C 154 (shown) may generate an airflow into a Coanda device C 158 . As shown in FIGS. 17C and 30 , the airflow generated by the fan system C 154 is forced into a nozzle C 162 through a narrow opening or groove at a high velocity, creating a low pressure zone in the nozzle C 162 . The high velocity air exiting the groove follows the inside curvature of the nozzle C 162 , resulting in a low pressure zone which “pulls” ambient air into the nozzle inlet C 164 . A dust chute C 166 is positioned proximate the saw blade SB to guide dust and debris into the inlet C 164 of the Coanda device C 158 . The low pressure zone in the nozzle C 162 of the Coanda device C 158 helps to draw the dust and debris generated by the saw blade SB through the dust chute C 166 and into the dust receptacle C 170 . The air flow exiting the Coanda device C 158 has the energy of the two combined air streams.

In yet other constructions of the dust collection assembly (not shown), the dust collection assembly C may include a blower scroll enclosing a dust collection fan. In such constructions, the blower scroll may be an integral component of the saw 10 , and the dust collection fan may be driven by the motor shaft D 42 as the motor D 118 drives the saw blade SB. Also, the blower scroll and dust collection fan may be an assembly retrofitted to existing saws.

During operation of the saw 10 , the dust collection fan may generate a vacuum behind the saw blade SB to draw dust away from the work area and into a bag or other container for later disposal. Also, the dust collection fan may be mounted on the motor shaft D 42 using overrunning bearings, such that the fan may continue to rotate after the motor shaft D 42 and the saw blade SB stop rotating.

FIG. 29 illustrates yet another construction of a dust collection assembly C 174 . Dust and debris generated by cutting a work piece WP may be electrically charged and a dust chute C 178 and/or a dust receptacle C 182 may have an opposite charge to attract the charged dust or debris into the dust chute C 178 and/or the dust receptacle C 182 . Such an arrangement may be used separate from or in addition to other constructions of dust collection assemblies C.

FIG. 5A illustrates another construction of a dust collection assembly C 186 including a squirrel-cage fan C 190 which draws debris into the dust chute C 194 positioned adjacent the saw blade SB and which moves the debris into a sawdust collection bag C 198 mounted behind the fan C 190 . In the illustrated construction, the dust chute C 194 extends through the bevel arm B 14 . The dust chute C 194 includes a rear portion (not shown) which directs debris downwardly into the collection bag C 194 .

FIG. 5I illustrates another construction of a dust collection assembly C 202 including a dust collector C 206 which is removably positioned on the rear of the bevel arm B 14 . The bevel arm B 14 and the dust collector C 206 include interengaging portions which selectively hold the dust collector C 206 on the bevel arm B 14 . In the illustrated construction, the dust collector C 206 is moved onto the bevel arm B 14 and then slid downwardly so that the interengaging portions engage to hold the dust collector C 206 on the bevel arm B 14 . An additional locking arrangement may be provided to further hold the dust collector C 206 in place. As shown in FIG. 5J , the rearward portion of the dust chute C 210 may be configured to be connectable to a standard hose from a vacuum, such as a wet/dry vacuum. As shown in FIG. 5M , a detachable dust collector C 214 may be removably fixed to the bevel arm B 14 , for example, by a bracket engaging the saw arm.

Miter Adjustment Assembly M

As discussed above, in the constructions illustrated in the figures, the saw 10 is a miter saw, and the table T 18 is coupled to the base T 14 for pivoting movement about a generally vertical miter axis T 30 . As shown in FIGS. 1-5 , the drive assembly D and saw blade SB are coupled to the table T 18 for pivoting movement with the table T 18 relative to the base T 14 to allow the saw blade SB to perform various angled miter cuts on a work piece WP supported on the table T 18 and/or on the base T 14 . The saw 10 may include a miter angle adjustment assembly M providing for adjustment of the angle of the saw blade SB relative to the work piece WP about the generally vertical miter axis T 30 .

When using a miter saw, a user sometimes needs to adjust their cut slightly from a known or unknown starting angle (e.g., an angle corresponding to a miter detent position, the angle used for earlier cuts on associated work pieces, etc.). With conventional miter saws, the operator must slightly move (e.g., gently tap the side of the table) the table in small angular increments. This may not be an accurate or repeatable method for making a slight angular change. Furthermore, several motions are usually involved in locking and unlocking the table to the base to prevent movement of the table once the angle is set. Therefore, extra effort may be required by an operator who needs to make an angle adjustment at or near a detent in a conventional miter saw.

Accordingly, in many constructions illustrated in the figures, the miter adjustment assembly M includes a coarse adjustment assembly M 14 , for making relatively large angular adjustments of the miter angle, and a fine adjustment assembly M 18 , for making accurate and/or repeatable incremental adjustments of the miter angle. The miter angle may be indicated on a miter scale M 20 .

FIGS. 31A-31J illustrate a construction of a miter adjustment assembly M including a coarse adjustment assembly M 14 and a fine adjustment assembly M 18 .

As shown in FIG. 31A-31D , the coarse adjustment assembly M 14 includes a miter locking assembly M 22 and a miter detent assembly M 26 . In the illustrated construction, the miter locking assembly M 22 enables the user to lock the table T 18 in substantially any available miter angle position relative to the base T 14 . The miter locking assembly M 22 generally includes inter-engaging locking surfaces between the table T 18 and the base T 14 . In the illustrated construction, one locking surface is provided by a lock wall M 30 on the base T 14 , and the other locking surface is provided by a lock bracket M 34 supported by the table T 18 .

A locking actuator assembly M 38 selectively causes locking of the lock bracket M 34 to the lock wall M 30 . In the illustrated construction, the assembly M 38 includes a threaded lock bolt M 42 and a lock knob M 46 for threadedly adjusting the lock bolt 42 . The lock bolt M 42 has an aggressive double lead thread, and the lock bracket M 34 also acts to shield the lock wall M 30 so that the lock bolt M 42 does not “walk” on the lock wall M 30 as it is tightened, which may normally affect the accuracy of the miter angle position.

In operation, from a locked position, the user operates the assembly M 38 to reduce the force between the lock bracket M 34 to the lock wall M 30 to allow the table T 18 to move relative to the base T 14 . The user adjusts the position of the table T 18 , for example, by pushing the miter handle M 46 at least partially provided by the tongue T 78 to the left or right to the desired miter angle position. The user then operates the assembly M 38 to increase the force between the lock bracket M 34 to the lock wall M 30 to lock the table T 18 in a miter angle position relative to the base T 14 . Again, in the illustrated construction, the selected miter angle position may be substantially any available miter angle position.

It should be understood that, in other constructions, other locking members may be provided between the table T 18 and the base T 14 . Also, a different locking actuator assembly M 38 having a different locking motion or action (e.g., pivoting, non-rotating linear movement, etc.) may be provided.

The miter detent assembly M 26 provides the user with an arrangement to position the table T 18 in one or more selected miter angle positions relative to the base T 14 (e.g., 0 degrees; left 15 degrees, 22.5 degrees, 30 degrees and 45 degrees; right 15 degrees, 22.5 degrees, 30 degrees, 45 degrees, and 60 degrees; etc.). The assembly M 26 generally includes a detent projection M 50 which is selectively engageable in one or more detent notches or recesses M 54 each of which correspond to a selected miter angle position. In the illustrated construction, the recesses M 54 are provided by the base T 14 (e.g., formed on the miter scale M 20 ), and the projection M 50 is supported by the table T 18 .

The assembly M 26 includes a detent actuator assembly M 58 for moving the projection M 50 between a detent engaged position, in which the projection M 50 engages a recess M 54 , and an out-of-detent or detent disengaged position, in which the projection M 50 is not engaged with a recess M 54 . In the illustrated construction, the assembly M 58 includes a lever M 62 connected to the projection M 50 and a handle M 66 engageable by the user.

A biasing member, such as a spring M 70 , biases the projection M 50 toward the detent engaged position. In the illustrated construction, the spring M 70 engages the lever M 62 to bias the lever M 62 to a position corresponding to the detent engaged position.

To operate the detent assembly M 26 , the user unlocks the miter locking assembly M 22 . The user then lifts the handle M 66 to lift the projection M 50 out of the recess M 54 . The user adjusts the position of the table T 18 , for example, by pushing the miter handle M 46 at least partially provided by the tongue T 78 to the left or right to the desired miter angle position. If the user continues to engage the handle M 66 , thereby overcoming the biasing force of the spring M 70 , the projection M 50 will not engage subsequent recesses M 54 as it passes. If the user releases the handle M 66 , the biasing force of the spring M 70 will cause the projection M 50 to engage the next recess M 54 it passes. At the desired miter angle position (either with the projection M 50 engaged with a recess M 54 or not), the user then locks the assembly M 22 .

In the illustrated construction, the miter detent assembly M 22 operates to hold the table T 18 in the selected miter angle position unless the detent actuator assembly M 58 is operated by the user to disengage the detent projection M 50 from the detent recess M 54 .

In other constructions, the detent assembly M 22 may provide a fairly weak detent engagement which may be overcome by the user, for example, by pushing on the tongue T 78 to adjust the miter angle position. Such a weak detent engagement may be provided by a weak biasing force applied to the projection M 50 , by angled, ramp surfaces between the projection M 50 and the recesses M 54 , etc.

As discussed below, the saw 10 includes a switch R 42 , such as a detent calibration switch, which is used by the digital readout arrangement R to calibrate the sensing of the position of the detent recesses M 54 . In the illustrated construction, an adjustment assembly, such as a detent calibration switch adjusting screw M 71 , is provided to adjust the position and/or actuation of the switch R 42 .

As shown in FIGS. 31A-31D , the fine adjustment assembly M 18 generally includes inter-engaging members which are relatively movable to cause small incremental movement of the table T 18 relative to the base T 14 . In the illustrated construction, the assembly M 18 includes an assembly of a rolling or rotating member, such as a pinion M 74 , which moves along a surface, such as a rack M 78 . The rack M 78 is supported by the base T 14 behind the miter scale M 20 and has an arcuate shape. The pinion M 74 is supported by the table T 18 , and rotating engagement of the pinion M 74 and the rack M 78 causes small incremental movement of the table T 18 relative to the base T 14 and fine adjustment of the miter angle position.

The assembly M 18 also includes an fine adjustment actuator assembly M 82 for causing rotating movement of the pinion M 74 along the rack M 78 . In the illustrated construction, the assembly M 18 includes a fine adjust drive assembly M 86 . The assembly M 86 is operable between a fine adjust mode, in which the assembly M 86 is configured to provide driving engagement to the pinion M 74 , and a disengaged mode, in which the assembly M 86 is not configured to drive the pinion M 74 .

In the illustrated construction, the assembly M 86 includes a drive gear M 90 and a driven gear M 94 . A gear reduction assembly M 98 , including gears M 102 and M 106 , is provided between the gears M 90 and M 94 .

A tube assembly M 110 supports the pinion M 74 and the gears M 90 , M 94 , M 102 and, M 106 . In the illustrated construction, a tube assembly M 118 supports the pinion M 74 and the gears M 90 and M 94 , and a gear reduction tube M 122 supports the gears M 102 and M 106 . The tube assembly M 118 includes a pinion tube M 114 supporting the pinion M 74 , a drive gear tube M 126 supporting the drive gear M 90 and a driven gear tube M 130 supporting the driven gear M 94 . In the illustrated construction, the tube M 126 is rotatable relative to the tube M 130 , which is rotatably keyed to the tube M 114 by inter-engaging flat surfaces M 132 .

To provide selective engagement of the assembly M 86 , the driving engagement between the pinion M 74 and the rack M 78 is disengageable. Also, the tube assembly M 118 is movable relative to the rack M 78 to selectively engage the pinion M 74 and the rack M 78 . In the illustrated construction, the tube assembly M 118 and the supported pinion M 74 are slidable relative to the rack M 78 . The pinion M 74 is movable between a driving position, in which the pinion M 74 and the rack M 78 are engaged, and a disengaged position, in which the pinion M 74 is slid out of engagement with the rack M 78 .

Also, the tube assembly M 118 is movable relative to the tube M 122 to selectively engage the gear M 90 and the gear M 102 . In the illustrated construction, the tube M 126 and the gear M 90 are slidable relative to the axially-fixed tube M 122 and the axially-fixed gear M 102 . The gear M 90 is movable between a driving position, in which the gears M 90 and M 102 are engaged, and a disengaged position, in which the gear M 90 is slid out of engagement with the gear M 102 .

In the illustrated construction, the tube M 130 and the gear M 94 are slidable with, while being relatively rotatable to, the tube M 126 and the gear M 90 . To retain the tubes M 126 and M 130 as the assembly M 118 and slidable with the tube M 114 , tube retention clips M 134 engage at the interface between tubes M 126 and M 130 and between tubes M 130 and M 114 . The tubes M 126 , M 130 and M 114 are axially slidable relative to the table locking bolt M 42 which extends through the tubes M 126 , M 130 and M 114 .

The fine adjustment actuator assembly M 82 also includes an actuator portion or knob M 138 which is engageable by the user to engage the fine adjust drive assembly M 86 and to operate the fine adjust drive assembly M 86 to finely adjust the miter angle position. The knob M 138 is moved axially to selectively engage the assembly M 86 and then is rotated to operate the assembly M 86 .

A biasing member, such as a spring M 142 , biases the assembly M 86 to the disengaged mode. In the illustrated construction, the spring M 142 biases the knob M 138 axially away from the table T 18 so that the gear M 90 is biased out of engagement with the gear M 102 .

In the illustrated construction, the fine adjustment drive assembly M 86 also includes a detent override assembly M 146 to disengage the projection M 50 from and hold the projection M 50 out of engagement with the recess(es) M 54 . The assembly M 146 includes a ramp M 150 and an annular notch M 152 both of which are engageable with a portion M 154 of the lever M 62 .

As the knob M 138 is moved inwardly to engage the fine adjust drive assembly M 86 , the portion M 154 of the lever M 62 moves upwardly along the ramp M 150 , lifting the projection M 50 from engagement with the recess(es) M 54 . When the portion M 154 engages the notch M 152 , the portion M 154 is prevented from moving downwardly to allow engagement of the projection M 50 with a recess M 54 . The user may rotate the knob M 138 to operate the assembly M 86 to finely-adjust the miter angle position.

Engagement of the portion M 154 in the notch M 152 also maintains the assembly M 86 in the fine adjust mode. Slight rearward pressure on the knob M 138 disengages the portion M 154 from the notch M 152 allowing the assembly M 86 to move outwardly to the disengaged position. This also allows the portion M 154 of the lever M 62 to move downwardly along the ramp M 150 , returning the projection M 50 to a recess-engageable condition.

As shown in FIGS. 31A-31J , a housing assembly M 158 is provided to retain at least a portion of the miter adjustment assembly M, such as the fine adjustment assembly M 18 , as a unit. The assembly M 158 includes a mounting block M 162 receiving and supporting the tubes M 126 , M 130 , M 114 and M 122 and thus supporting the connected components. The block M 162 defines recesses M 166 . A mounting cap M 170 includes snaps M 174 which are engageable in the recesses M 166 to retain the cap M 170 on the block M 162 and to retain the supported components of the assembly M 18 . The housing assembly M 158 and supported and retained components of the fine adjustment assembly may then be connected as a unit to the table T 18 .

A bushing M 178 cooperates to maintain axial alignment of the tube M 122 with the tubes M 126 , M 130 and M 114 . FIGS. 32A-32E illustrate an alternative construction of a bushing M 182 . The bushing M 182 includes a flexible side wall M 186 which allows radial movement between the tube M 122 (and the gear M 102 ) and the tube M 126 (and the gear M 90 ). This arrangement provides a clutch to selectively disengage the gears M 90 and M 102 when an applied force is too great.

FIGS. 33A-33F illustrate operation and various positions and conditions of the miter adjustment assembly M including a coarse adjustment assembly M 14 and a fine adjustment assembly M 18 . FIGS. 33A-33B and 33 E- 33 F illustrate the miter locking assembly M 22 in the locked position, and FIGS. 33C-33D illustrate the assembly M 22 in the unlocked position. FIGS. 31A-31B , 33 D and 33 F illustrate the fine adjustment assembly M 18 in the engaged position, and FIGS. 33C and 33E illustrate the assembly M 18 in the disengaged position.

FIG. 34 illustrates an alternate construction of a miter adjustment assembly M including a coarse adjustment assembly M 14 and a fine adjustment assembly M 18 . As illustrated, the miter detent assembly M 26 is in the detent engaged position, the miter locking assembly M 22 is in the unlocked position, and the fine adjustment assembly M 18 is in the disengaged position.

FIGS. 35A-35C illustrate a fine adjustment assembly M 18 including a fine adjustment sine clutch M 186 . The clutch M 186 is between the pinion M 74 and the tube M 114 , and, if a force is too great, the clutch M 186 allows relative rotation between the pinion M 74 and the tube M 114 . As such, the pinion M 74 is not required to disengage from and then re-engage the rack M 78 as the fine adjustment assembly M 18 moves between the engaged and disengaged positions. Also, the clutch M 186 may prevent stripping of the toothed gear members if the force applied is too great (e.g., because the miter locking assembly M 22 is in the locked position).

FIGS. 36-37 illustrate structure for and operation of an alternate construction of a miter adjustment assembly M for a sliding miter saw 10 including a coarse adjustment assembly M 14 and a fine adjustment assembly M 18 .

FIGS. 38A-38B illustrate an alternate construction for a portion of the fine adjustment assembly M 18 . In the illustrated construction, the assembly M 18 includes a harmonic drive assembly M 190 which replaces the gear reduction assembly provided by the gears M 90 , M 94 , M 102 and M 106 . An indicator assembly, such as an audible indicator M 194 , provides audible feedback to the user as the assembly M 190 is operated.

FIGS. 39A-39E illustrate yet another construction of a fine adjustment mechanism M 18 . A clutch mechanism M 198 may be incorporated into the gear train to allow the pinion M 74 to remain engaged with the rack M 78 during coarse or macro-adjustment of the miter angle.

The clutch mechanism M 198 may include a plug M 202 that is selectively frictionally engageable with a cup M 206 formed in one end of a pinion shaft M 210 rotatably supported by the table T 18 . The pinion shaft M 210 may also carry the pinion M 74 that is engageable with the rack M 78 . The plug M 202 is coupled to a clutch shaft M 214 that is also rotatably supported by the table T 18 . Alternatively, the plug M 202 may be coupled to the pinion shaft M 210 , and the cup M 206 may be formed in the shaft M 214 .

The plug M 202 may be biased into engagement with the cup M 206 by a biasing member (e.g., a compression spring M 218 ( FIG. 39B ). A worm gear M 222 is fixed to the clutch shaft M 214 and engageable with a worm pinion M 226 , which is coupled to a knob M 138 or other actuator. An analog indicator M 230 is provided with the knob M 138 to indicate adjustment of the miter angle position. The indicator M 230 may be similar to that used for fine adjustment of the depth of a router.

With reference to FIG. 39A , during operation of the fine adjustment assembly M 18 , rotation of the knob M 138 imparts a rotation or a torque to the shaft M 214 through the worm gear M 222 and the pinion M 226 . When the clutch mechanism M 198 is engaged (i.e., the plug M 202 engages the cup M 206 ), the shaft rotation or torque is transmitted to the pinion shaft M 214 through the clutch mechanism M 198 . Accordingly, the pinion M 74 is rotated relative to the fixed rack M 78 to cause rotation of the table T 18 relative to the base T 14 .

A first stage reduction may be provided by the worm gear M 222 and the pinion M 226 , and a second stage reduction may be provided by the pinion gear M 74 and the rack. M 78 . Alternatively, a single stage reduction may be utilized, or additional stages of gear reduction may be utilized.

To override the fine adjustment assembly M 18 to make macro adjustments, the clutch mechanism M 198 may be disengaged. More particularly, the plug M 202 may be moved out of engagement with the cup M 206 by retracting the clutch shaft M 214 against the bias of the spring M 218 . With reference to FIG. 39B , the worm gear M 222 may be keyed to the shaft M 214 such that the gear M 222 may remain fixed relative to the worm pinion M 226 and the shaft M 214 may move relative to the worm gear M 222 .

FIG. 39B also illustrates a detent override assembly M 146 in combination with the fine adjustment assembly M 18 . A lever M 234 or other actuator may be coupled to the clutch shaft M 214 to selectively disengage the clutch mechanism M 198 . As shown in FIG. 39C , a portion of the clutch shaft M 214 may be engageable with a leaf spring M 238 , which in turn biases a ball M 242 into a detent recess M 54 formed on the base T 14 . A compression spring M 246 (or another spring member either separate from or integral with the leaf spring M 238 ) is positioned between the ball M 242 and the leaf spring M 238 .

When it is desired by the operator to perform a macro adjustment of the table T 18 , the operator may grasp and pivot the lever M 234 upwardly to retract the clutch shaft M 214 from the pinion shaft M 210 , thereby disengaging the clutch mechanism M 198 . Also, the clutch shaft M 214 may disengage the leaf spring M 238 such that the biasing force on the ball M 242 is substantially decreased. The ball M 242 may then be allowed to move in and out of the detent recesses M 54 formed in the base T 14 during macro adjustment of the table T 18 .

However, when it is desired by the operator to lock the table T 18 to the base T 14 , the operator may release the lever M 234 to allow the compression spring M 246 to return the clutch shaft M 214 to a position in which the clutch mechanism M 198 is engaged. Also, the clutch shaft M 214 may re-engage the leaf spring M 238 to apply additional biasing force to the ball M 242 to remain in the detent M 54 . A supplemental miter lock, such as the miter locking assembly M 22 , may also be utilized in addition to the mechanical advantage provided by the fine adjustment assembly M 118 .

FIGS. 39D-39E illustrate another construction of the clutch mechanism M 250 that may be utilized in the fine adjustment mechanism M 18 shown in FIGS. 31A-31C . The clutch mechanism M 250 includes a tapered ring M 254 fixed to a first shaft, a ball assembly M 258 , and a hub M 262 fixed to a second shaft.

During operation of the clutch assembly M 250 , the ring M 254 axially moves in and out of engagement with the ball assembly M 258 . Due to the taper of the ring M 254 , the balls M 266 are displaced radially outwardly when the ring M 254 is moved toward the ball assembly M 258 , thus causing the balls M 266 to engage the ring M 254 and lock the first shaft to the second shaft. Further, when the ring M 254 is moved away from the ball assembly M 258 , the balls M 266 disengage the ring M 254 to allow relative movement between the first and second shafts.

FIGS. 40-41 illustrate a further construction of a fine adjustment assembly M 18 . An arcuate rack M 270 is fixed to the base T 14 , and a selectively movable pinion M 274 is connected for rotation relative to the table T 18 . The pinion M 274 is biased into engagement with the rack M 270 by one or more springs M 278 coaxial with a shaft M 282 supporting the pinion M 274 in the table T 18 .

A lever M 286 or other actuator is connected to the shaft M 282 to pivot against the table T 18 to disengage the pinion M 278 from the rack M 274 (i.e., move the pinion M 278 away from the rack M 274 ). Alternatively, a second lever or other actuator (not shown) may be connected to the shaft M 282 to pre-load the biasing member M 278 to impart an increased amount of friction between the pinion M 278 and the rack M 274 .

Fine adjustment of the table T 18 with respect to the base T 14 may be accomplished by a single-reduction gear train including a driven gear M 290 rotatably fixed to the pinion M 278 and a driving gear M 294 that is manipulatable by the operator via a knob M 138 or other actuator. Rotation of the knob M 138 imparts rotation to the driving gear M 294 , which in turn rotates the driven gear M 290 and the pinion M 278 . Rotation of the pinion M 278 , when it is engaged with the rack M 274 , causes rotation of the table T 18 relative to the base T 14 . The driving gear M 294 may be biased into engagement with the driven gear M 290 by one or more springs, such that the driving gear M 294 retracts from the rack M 274 with the pinion M 278 when the pinion M 278 is retracted by the lever M 138 .

Alternative constructions of the fine adjustment assembly M 18 may utilize a pad and friction roller in place of the rack and pinion (as shown in FIGS. 48B-48D ). Also, still other constructions of the fine adjustment assembly may utilize different gear designs and/or other gear reductions other than the hypoid drive gear. Further, the gear train may be configured or arranged differently to drive the pinion. A supplemental miter lock may also be utilized in addition to the mechanical advantage provided by the fine adjustment assembly M 18 .

FIGS. 42A-42C illustrate another construction of a fine adjustment assembly M 18 . The assembly includes a shaft M 298 rotatably supported by the table T 18 and having an end engageable with an arcuate lip M 302 , an arcuate groove, or an arcuate pad fixed to the base T 14 . A handle M 306 is coupled to the shaft such that an operator may grasp the handle and impart rotation to the shaft. A lever M 308 is also pivotably coupled to the table and positioned such that the shaft passes through a portion of the lever. The shaft includes a shoulder portion M 312 that is engageable by the lever, such that pivoting of the lever causes axial movement of the shaft. A biasing member (e.g., a compression spring M 316 ) is positioned between the lever and a portion of the table to bias the lever downward and bias the shaft toward the base, such that the end M 320 of the shaft frictionally engages the arcuate lip or groove in the base.

With reference to FIG. 42C , fine adjustment of the table with respect to the base may be accomplished by rotating the handle M 306 , which in turn rotates the shaft M 298 relative to the arcuate lip M 302 or groove. The frictional engagement between the end M 320 of the shaft and the arcuate lip M 302 or groove is sufficient to rotate the table relative to the base.

To allow macro adjustment of the table with respect to the base, the operator may rotate the lever M 308 upwardly against the bias of the biasing member M 316 to move the shaft axially away from the base. As such, the end of the shaft may disengage the arcuate lip or groove on the base. To lock the table to the base, the operator may release the lever to allow the end of the shaft to re-engage the arcuate lip or groove of the base.

Alternatively, the end of the shaft and the arcuate lip or groove may be configured with spaced upstanding projections (e.g., knurls, teeth, etc.) to provide additional surface area for engagement between the end of the shaft and the arcuate lip or groove.

FIGS. 43-44 illustrate yet another construction of a fine adjustment assembly M 18 . The fine adjustment assembly M 18 includes a rod or shaft M 298 rotatably supported by the table T 18 and having an end M 320 frictionally engageable with an arcuate lip M 302 of the base. A driven gear M 328 is fixed to an opposite end of the shaft, such that a driving gear M 324 fixed to a handle M 306 meshes with the driven gear. Rotation of the handle imparts rotation to the shaft.

A lever M 308 may also be pivotably coupled to the table and positioned such that the shaft passes through a portion of the lever. The shaft may include a shoulder M 312 that is engageable by the lever, such that pivoting of the lever may cause axial movement of the shaft. The teeth of the driving and driven gears may be straight-cut to allow the driven gear to move axially relative to the driving gear. A biasing member (e.g., a compression spring M 316 ) may be positioned between the lever and a portion of the table to bias the lever downward and bias the shaft toward the base, such that the end of the shaft frictionally engages the arcuate lip of the base.

Fine adjustment of the table with respect to the base may be accomplished by rotating the handle M 306 , which in turn rotates the shaft M 298 relative to the arcuate lip M 302 or groove. The frictional engagement between the end M 320 of the shaft and the arcuate lip M 302 or groove is sufficient to rotate the table relative to the base.

To allow macro adjustment of the table with respect to the base, the operator may rotate the lever M 308 upwardly against the bias of the biasing member M 316 to move the shaft axially away from the base. As such, the end of the shaft may disengage the arcuate lip or groove on the base. To lock the table to the base, the operator may release the lever to allow the end of the shaft to re-engage the arcuate lip of the base, such that a wedge-effect is created between the end of the shaft and the arcuate lip to lock the table to the base.

Alternatively, as shown in FIG. 44 , more than one rod or shaft may be utilized to frictionally engage more than one arcuate lips of the base. Such a design may provide additional force with which to lock the table to the base.

FIGS. 45-48 illustrate another construction of a fine adjustment assembly M 18 to allow miter angle adjustments in small increments at or near a detent recess M 54 . With reference to FIG. 45 , with the table T 18 located at an arbitrary angle to the base T 14 , the table is locked in position to the base through a mechanical advantage created by the interface between a gear M 332 and an arcuate rack M 336 . The gear may be supported by the table, and the rack may be supported by the base.

Alternatively, a roller and a pad (not shown) may be used in place of the gear and rack. A supplemental lock may also be employed in addition to the mechanical advantage between the gear and rack or the roller and pad. The pinion/rack or roller/pad combination may utilize a single-reduction gear train. For simplicity, “pinion” may include either a gear type pinion or a roller, and “rack” may include either a gear type rack or a pad.

The pinion may be biased into engagement with the rack by a biasing member (e.g., a compression spring M 340 ), resulting in the locking action through mechanical advantage or friction. The pinion may be disengaged from the rack when the operator squeezes a lever M 344 that loads the biasing member and separates the pinion and the rack. This unlocks the table from the base, which allows the operator to make angle adjustments in large increments, or macro adjustments.

When the lever is released, the biasing member causes the pinion to re-engage the rack, thereby locking the table to the base again. The miter angle of the table, however, may be still be adjusted. This may be accomplished by rotating a knob M 348 or other actuator that is coupled to the pinion to rotate the pinion. When the pinion rotates relative to the fixed rack, the table moves relative to the base.

As shown in FIGS. 47A-47B , to facilitate re-engagement of the pinion with the rack, the teeth of the pinion may be tapered so that meshing of the pinion to the rack becomes easier. When utilizing the roller and pad, this concern may be eliminated since inter-engaging teeth of the pinion and the rack are eliminated. The roller and pad utilize friction between the two parts to keep them from slipping relative to each other. Alternatively, FIGS. 48A-48G illustrate other constructions of the pinion and the rack.

In some constructions, motion of the lever may also be used to adjust detents that may be present in the miter saw. If the original detent is “stiff,” the operator may want to disengage the detent when making a macro adjustment. A linkage could be driven from the lever that weakens or eliminates the detent when a macro adjustment is made. Alternatively, the detent may be weak or non-existent. As such, the linkage may cause the detent to strengthen so that the user can feel the detents as the miter angle of the table is adjusted.

In some constructions, operation of the fine adjustment assembly M 18 may occur such that the table could be freely-rotated when the lever is actuated. Also, the table could lock to the base when the lever is released, regardless of whether or not the table is engaging a detent defining a particular angle between the table and the base.

In some constructions, fine adjustment of the table with respect to the base could be made without an additional unlocking motion (other than that caused by the lever). Fine adjustment could be made anywhere on the table (whether or not the table is engaging a detent).

In some constructions, detents could be mechanically linked to actuation of the lever such that (1) detents engage or become stronger when the lever is actuated, (2) detents disengage or become weaker when the lever is actuated, or (3) detents are unaffected when the lever is actuated.

Additional features of the fine adjustment assembly M 18 may include fine adjustment of the table with respect to the base without locking the table. Also, fine adjustment of the table with respect to the base may be made after locking the table. In addition, fine adjustment of the table with respect to the base may be made before locking the table. Further, fine adjustment of the table with respect to the base may occur over the full range of the miter angle, or an override may be utilized for large adjustments. Fine adjustment of the table with respect to the base may be made without overriding any detents indicating a known miter angle. Fine adjustment of the table with respect to the base near a detent may occur by first overriding the detent.

With reference to FIGS. 49A-49C , another construction of a fine adjustment assembly M 18 is shown incorporating a multiple-reduction gear train. A first stage reduction may occur between a worm gear and a driven gear rotatably supported by the table. A roller may be coupled to the driven gear for co-rotation with the driven gear, such that the outer surface of the roller is frictionally engageable with a pad or a groove formed in the base of the miter saw. The roller may be sized accordingly to provide a second stage reduction between the roller and the pad or groove. The combination of the first and second stage reductions in the adjustment mechanism facilitates fine miter angle adjustments in smaller increments compared to using only a single stage reduction. FIG. 50 illustrates another construction of a fine adjustment assembly M 18 .

FIGS. 51-52 illustrate a further construction of a fine adjustment assembly M 18 . The fine adjustment assembly M 18 includes a multiple-reduction gear train and a spindle-lock clutch mechanism M 350 , which may be incorporated into the gear train to allow a pinion gear to remain engaged with an arcuate rack during macro-adjustment of the miter angle.

The spindle-lock clutch mechanism may selectively transfer torque from a clutch shaft to a pinion shaft, which has the pinion gear fixed thereto. Both of the pinion shaft and the clutch shaft are rotatably supported by the table. A driven gear is fixed to an end of the clutch shaft opposite the clutch mechanism, and a driving gear rotatably supported by the table meshes with the driven gear. A dial is also rotatably supported by the table and is engageable with the driving gear to impart rotation to the driving gear. A lever may also be pivotably coupled to the table, and a biasing member (e.g., a compression spring) may bias the lever downwardly to engage the spindle-lock clutch mechanism.

Fine adjustment of the table with respect to the base may be accomplished by rotating the dial, which in turn rotates the pinion gear relative to the arcuate rack. To allow macro adjustment of the table with respect to the base, the operator may rotate the lever upwardly against the bias of the biasing member to disengage the spindle-lock clutch mechanism, thereby disengaging the clutch shaft and the pinion shaft to allow free movement of the table with respect to the base. To lock the table to the base, the operator may release the lever to allow the spindle-lock clutch mechanism to re-engage and lock the clutch shaft to the pinion shaft.

FIGS. 53A-53B illustrate another construction of a fine adjustment assembly M 18 . More particularly, the miter saw includes a fine adjustment assembly M 18 having a shaft rotatably coupled to the table. One end of the shaft is coupled to a pinion gear M 74 , which in turn, engages an arcuate rack M 78 on the base. A biasing member (e.g., a compression spring) biases an end surface of the pinion against a friction pad.

The end of the shaft coupled to the pinion includes at least one cam projecting therefrom for selectively engaging mating cam surfaces in respective grooves in the pinion gear. A dial or a knob is fixed to the opposite end of the shaft, such that initial rotation of the knob imparts rotation to the shaft, which causes the cam on the shaft to engage the cam surface in the pinion. A thumb lever may be pivotably coupled to the table to engage a shoulder on the shaft to axially displace the shaft.

Fine adjustment of the table with respect to the base may be accomplished by rotating the knob to rotate the shaft such that the cam on the shaft engages the cam surface in the pinion. This is sufficient to move the pinion axially away from the friction pad to unlock the table from the base. Further rotation (i.e., after the pinion is moved away from the friction pad) results in the pinion gear rotating relative to the fixed rack and adjusting the table relative to the base. To allow macro adjustment of the table with respect to the base, the operator may depress the thumb lever to move the shaft and the pinion away from the friction pad against the bias of the biasing member to allow free movement of the table relative to the base. Additionally, the knob may be disengaged from the shaft (via a spline fit, etc.) when the thumb lever is depressed. To lock the table to the base, the operator may release the thumb lever to allow the end surface of the pinion gear to re-engage the friction pad.

FIGS. 54A-54B illustrate yet another construction of a fine adjustment assembly M 18 . More particularly, the miter saw includes a table-in-table assembly, such that a first or upper table may be fine adjusted with respect to a second or lower table. The lower table is rotatably coupled to the base and includes a cam surface thereon. The lower table also supports a shaft having a pinion fixed at one end of the shaft. The upper table is rotatably coupled to the lower table, and a bevel gear and a cam are positioned between the upper table and the lower table such that the pinion engages the bevel gear and the cam co-rotates with the bevel gear. The cam is engageable with the cam surface of the lower table upon rotation of the cam.

Fine adjustment of the upper table with respect to the lower table may be accomplished by rotating the shaft, which in turn rotates the bevel gear and the cam relative to the cam surface. The engagement of the cam and cam surface, therefore, may cause the upper table to rotate in fine increments relative to the lower table. To allow macro adjustment of the upper and lower tables with respect to the base, detents and detent override structure may be incorporated into the miter saw.

FIGS. 55A-55B illustrate yet another construction of a fine adjustment assembly M 18 for a miter saw. The fine adjustment assembly M 18 incorporates a substantially vertically-oriented shaft relative to the table during normal operation of the miter saw. The shaft is rotatably coupled to the table and includes at one end a pinion gear and at an opposite end an adjustment dial. The pinion gear is engageable with an arcuate rack on the base.

Fine adjustment of the table with respect to the base may be accomplished by rotating the dial, which in turn rotates the pinion gear relative to the arcuate rack.

FIGS. 56A-56M illustrate various constructions of the actuator or adjustment knob M 138 for fine- or micro-adjustment of the miter angle and the actuator or detent release for releasing the detent assembly (to enable movement of the miter saw to another miter angle). Also, FIGS. 56A-56F and 56 H- 56 M illustrate the display R 22 of the miter angle and, in some constructions, illustrate the display R 22 of the miter angle for fine adjustment.

In addition, FIGS. 56A-56M illustrate various constructions for a handle or grip surface for engagement by an operator to adjust the miter angle, hold the saw, carry the saw, etc. As shown in FIGS. 56H-56M , the handle may be movable relative to the turntable, for example, between a use and a storage and/or transport position.

In addition, as shown in FIG. 56L , the handle may be adjustable to the left or right side so that the handle is in a better position for gripping by an operator's left hand or right hand. In the use position, a portion of the handle may engage or may be moved to engage a work surface or the work table to provide added stability for the saw.

FIGS. 57A-57N illustrate a base, a table rotatably coupled to the base, and another construction of a fine adjustment assembly M 18 .

FIGS. 58A-58C illustrate a base, a table rotatably coupled to the base, and yet another construction of a fine adjustment assembly M 18 and a detent override mechanism. As shown in FIG. 58A , the fine adjustment assembly M 18 in a disengaged position and the detent override mechanism detent override assembly M 146 in a locked position. FIG. 58B illustrates the fine adjustment assembly M 18 in the engaged position and the detent override assembly M 146 in a locked-out or unlocked position.

FIGS. 59A-59J illustrate a further construction of a fine adjustment assembly M 18 including a wedge lock M 352 . The fine adjustment assembly M 18 includes a worm gear rotatably coupled to the base coaxial with the miter axis. A worm pinion is rotatably coupled to the table of the miter saw. One end of the worm pinion meshes with the worm gear, while a dial or knob is fixed to the other end of the worm pinion to impart rotation to the worm pinion.

A wedge M 356 is positioned between the worm gear and the base for movement toward and away from the worm gear. A lever is pivotably coupled to the table and the wedge, such that the lever may actuate the wedge toward or away from the worm gear. The wedge is configured to frictionally engage the worm gear and the base to lock the worm gear to the base.

Fine adjustment of the table with respect to the base may be accomplished by pivoting the lever, thus causing the wedge to move inwardly toward the worm gear to frictionally engage the worm gear and the base to lock the worm gear to the base. An operator may then rotate the knob, which in turn rotates the worm pinion relative to the worm gear. Since the worm gear is locked to the base, the worm pinion and the table may be adjusted about the miter axis in fine increments relative to the base.

To allow macro adjustment of the table with respect to the base, the operator may pivot the lever to disengage the wedge from the worm gear and the base to unlock the worm gear from the base. Thus, free movement of the table relative to the base is allowed. To re-lock the table to the base, the operator may release the lever to return the wedge to a position in which it is engaged with the worm gear and the base.

FIG. 60 illustrates another construction of a fine adjustment assembly M 18 including a supplemental miter angle lock.

FIGS. 61-63 illustrate various locking arrangements, such as electrical locking arrangements, which may be used to hold the table T 18 in a selected miter angle position relative to the base T 14 and/or to hold the bevel arm B 14 in a selected bevel angle position relative to the table T 18 .

FIGS. 64A-64C illustrate a miter angle scale incorporating a plurality of user-adjustable detents M 360 . A miter angle sensor module M 364 for determining the position at which the table T 18 is positioned relative to the base T 14 . The sensor module communicates with the miter angle indicator and controller module. The detent position magnets M 368 may be positioned by the user (or during manufacture) at given miter angle positions. The user can set any given miter position in the controller, much like programming a pre-set radio station. A locking mechanism may be provided to hold the turntable in the desired miter angle position.

FIGS. 65A-65E illustrate constructions of a miter scale M 20 formed with integral miter angle detent recesses M 54 . Slots in the miter scale enable the miter scale to be adjustably connected to the base T 14 so that the miter angle can be “zeroed” to provide an accurate angle relative to components of the saw 10 (e.g., the saw blade SB, the support surface on the fence assembly F, etc.) during or after manufacture.

As shown in FIG. 65A , the miter scale M 20 may define a plurality of detent recesses M 54 each corresponding to selected miter angle (e.g., 0 degrees; left 15 degrees, 22.5 degrees, 30 degrees and 45 degrees; right 15 degrees, 22.5 degrees, 30 degrees, 45 degrees, and 60 degrees; etc.).

FIGS. 66A-66B an infinitely adjustable miter angle stop assembly M 372 . The stop may be mounted along the miter scale M 20 and may be fixed in a position to stop movement of the table T 18 relative to the base T 14 in a selected miter angle position. The miter stop may be positioned anywhere along the miter scale.

FIGS. 5E , 5 G- 5 H and 5 J illustrates a miter adjustment assembly M having left and right operator's handles. A detent release is supported on each handle.

For the fine adjustment assembly M 18 including a roller concept, a rubber or other elastomeric overmold could be added to the friction wheel to increase holding power.

A supplemental lock can be added to a worm-clutch fine adjustment mechanism. Such a lock works by clamping (via turning a threaded knob) against the shaft whose axis on which the clutch lies. This operation can add more force to the clutch than a spring can provide by itself. The result is that the clutch is clamped with a much higher force which produces much greater holder force. The fine adjustment mechanism is still operable, even in the clamp position, because the shaft can still rotate.

Bevel Adjustment Assembly B

FIGS. 67-80 illustrate at least portions of constructions of a bevel adjustment assembly B for adjustment of the angle of the saw blade SB relative to the work piece WP about a generally horizontal angle.

As shown in FIGS. 67A , 68 B and 71 B- 71 C, the bevel adjustment assembly B includes a bevel arm B 14 on which the saw unit D 14 is supported for movement between the raised, non-cutting position and the lowered, cutting position about an axis D 28 . The bevel arm B 14 (and the saw unit D 14 and the saw blade SB) is supported by the base and table assembly T for pivoting movement about a bevel axis B 18 to adjust the angle of the saw blade SB relative to the work piece WP.

In the illustrated construction, the bevel arm B 14 is supported by the table T 18 for movement with the table T 18 relative to the base T 14 and is supported by the sliding support assembly T 66 for sliding movement relative to the table T 18 to provide a sliding compound miter saw 10 . A table mount housing B 22 is supported by table T 18 (e.g., by the slide tubes T 70 ). The bevel arm B 14 includes a bevel arm housing B 26 pivotally connected to the table mount housing B 22 . A bevel angle indication assembly B 27 including a bevel scale B 28 and a pointer B 29 indicates the bevel angle to the user.

A locking mechanism B 30 is provided between the bevel arm B 14 and the table T 18 to releasably hold the bevel arm B 14 (and the saw unit D 14 and the saw blade SB) in a bevel angle position relative to the table T 18 . In the illustrated construction, the locking mechanism B 30 includes a brake mechanism B 34 . The brake mechanism B 34 may be a mechanical, electrical, or a hydraulic-type brake mechanism.

In the illustrated construction, the brake mechanism B 34 includes a brake disk B 38 connected to the table mount assembly B 22 and a brake caliper assembly B 40 connected to the bevel arm housing B 26 . The caliper assembly B 40 includes a caliper housing B 41 fixed to the bevel arm housing B 26 and a movable caliper B 42 . The caliper B 42 is movable to selectively frictionally engage the brake disk B 38 to lock the bevel arm housing B 26 in a bevel angle position relative to the table mount assembly B 22 . As shown, the caliper B 42 directly frictionally engages the brake disk B 38 . In other constructions (not shown), other structure, such as brake pads, may be positioned between the caliper B 42 and the brake disk B 38 , such that the pads engage the brake disk B 38 .

As shown in FIGS. 1-5 , 69 , 71 A, and 72 A- 72 B, the locking mechanism B 30 includes an actuating mechanism B 46 to operate the brake mechanism B 34 between a locked condition, in which the bevel arm B 14 (and the saw unit D 14 and the saw blade SB) is locked in a bevel angle position relative to the table T 18 , and an unlocked or release condition, in which the bevel arm B 14 (and the saw unit D 14 and the saw blade SB) is movable between bevel angle positions relative to the table T 18 .

In the locked condition, the actuating mechanism B 46 operates to cause the caliper B 42 to frictionally engage the brake disk B 38 to substantially prevent pivoting movement about the bevel axis B 18 . In the release condition, the actuating mechanism B 46 operates to reduce the frictional force applied by the caliper B 42 to the brake disk B 38 to allow pivoting movement about the bevel axis B 18 .

The actuating mechanism B 46 includes an actuator, handle, paddle or lever B 50 , which is engageable by an operator. In the constructions illustrated in FIGS. 1-4 , the lever B 50 is substantially U-shaped or T-shaped and is engageable from the left or right of the bevel arm B 14 .

The actuating mechanism B 46 also includes a linkage mechanism B 54 , which transmits movement of the lever B 50 by the user to the brake mechanism B 34 . In the illustrated construction, the linkage assembly B 54 includes a flexible cable B 58 connected between the lever B 50 and the brake mechanism B 34 (to the caliper B 42 ) in a manner similar to a bicycle brake assembly. The cable B 58 extends from the brake mechanism B 34 through at least a portion of the bevel arm housing B 26 to the location of the lever B 50 on the saw 10 .

The locking mechanism B 30 also includes a biasing mechanism B 62 for biasing a portion of the locking mechanism B 30 (e.g., the brake mechanism B 34 , the actuating mechanism B 46 ) toward the locked condition. In the illustrated construction, the biasing mechanism B 62 includes a spring assembly B 66 between the caliper housing B 41 and the caliper B 42 which biases the caliper B 42 toward the locked condition. Because of the biasing force toward the locked condition, the user must cause the actuating mechanism B 46 to move the caliper B 42 to the release condition and must maintain the caliper B 42 in the release condition (e.g., by continuing to engage the lever B 50 ) during adjustment of the bevel angle.

It should be understood that, in other constructions (not shown), the biasing mechanism B 62 may include another type of member applying a biasing force (e.g., a magnetic force, an electrical force, another type of spring force, etc.). It should also be understood that, in other constructions (not shown), the biasing mechanism B 62 may apply the biasing force to another component (e.g., the lever B 50 , the linkage assembly B 54 , etc.).

As shown in FIGS. 1-4 , the lever B 50 is a handle or paddle supported on the bevel arm B 14 . The lever B 50 is pivotable about a lever axis B 70 between positions corresponding to the locked condition and the release condition of the brake mechanism B 34 . In these constructions, the lever B 50 is supported to the rear of the axis D 28 . As such, the user must reach to the rear of the saw 10 to engage and operate the lever B 150 .

FIGS. 71A , 72 and 81 - 83 illustrate an alternate location of the lever B 50 which is in front of the axis D 28 . In the illustrated construction, the lever B 50 is positioned on the operator's handle H 14 . As such, while engaging the handle H 14 with one hand, the user may engage and hold the lever B 50 in the release position and move the saw unit D 14 (and the bevel arm B 14 ) to adjust the bevel angle. The user is free to use the other hand to, for example, adjust or grasp the work piece WP. When the lever B 50 is released by the operator, the biasing mechanism B 62 causes the caliper B 42 to re-engage the brake disk B 38 to lock the bevel angle.

In other constructions (such as that shown in FIGS. 5H and 5J ), the lever B 50 may be located on another portion of the saw 10 forward of the axis D 28 . This other portion of the saw 10 may be a portion which the user would engage to adjust the bevel angle. As shown in FIGS. 5H and 5J , a U-shaped handle H 50 is connected to the saw unit D 14 and may be engaged by a user to assist in adjusting the bevel angle. The lever B 50 is supported on the U-shaped handle H 50 . As such, while engaging the U-shaped handle H 50 with one hand, the user may engage and hold the lever B 50 in the release position and move the saw unit D 14 (and the bevel arm B 14 ) to adjust the bevel angle. In the construction illustrated in FIG. 5J , lever B 50 is movable in both directions by the user to operate the brake mechanism B 34 .

FIG. 5A illustrates T-shaped handle H 42 which the user may engage to adjust the bevel angle and which may include the lever B 50 .

In another construction (not shown), the lever B 50 may be supported on the upper guard D 30 . As such, while engaging the upper guard D 30 with one hand, the user may engage and hold the lever B 50 in the release position and move the saw unit D 14 (and the bevel arm B 14 ) to adjust the bevel angle. Again, the user is free to use the other hand to, for example, adjust or grasp the work piece WP.

To accommodate the forward position of the lever B 50 , the linkage assembly B 54 extends from the brake mechanism B 34 to forward-positioned lever B 50 . In the illustrated construction, the flexible cable B 58 extends through the bevel arm B 14 and through a portion of the motor housing D 26 to the handle H 14 and is connected to the lever B 50 .

FIGS. 73 , 75 and 76 E illustrate alternate constructions of the brake mechanism B 34 , such as a pull brake mechanism. In the illustrated constructions, the brake mechanism B 34 includes a brake surface B 70 connected to the table mount housing B 22 and a cooperating brake surface, such as a brake pad B 74 , supported by the bevel arm housing B 26 . The brake pad B 74 is movable into and out of frictional engagement with the brake surface B 70 to lock and release, respectively, the bevel arm B 14 and the table T 18 . FIG. 76E illustrates a drum brake which is cam actuated to release the brake.

As shown in FIGS. 73-75 , the linkage mechanism B 54 includes substantially rigid link members B 78 connected between the brake pad B 74 and the lever B 50 . As shown in FIGS. 73A-73B , the lever B 50 may include a cam B 82 to translate pivoting movement of the lever B 50 to linear movement of the link member B 78 and the brake pad B 54 . As shown in FIG. 74 , the link members B 78 are pivoting link members to translate pivoting movement of the lever B 50 to linear movement of the link member B 78 and the brake pad B 54 . As shown in FIG. 75A , the link member B 78 is moved linearly (e.g., by pulling upwardly on the knob end B 80 ) to move the brake pad B 74 relative to the brake surface B 70 .

FIGS. 76A-76G illustrate alternative constructions of the locking mechanism B 30 . FIGS. 76A-76D illustrate rheonetic locking mechanisms. In such mechanisms, Magnetic Rheonetic (MR) Fluid changes from a liquid (to allow for adjustment) to a near-solid (to provide a locking force) in the presence of a magnet.

FIGS. 76F-76G illustrate other types of mechanical locking mechanisms, such as a cam lock system (shown in FIG. 76F ) and a cone brake system (shown in FIG. 76G ).

FIGS. 77A-77B illustrate an assembly which may be used if the relative positions of the lever B 50 and the locking assembly B 30 are adjustable (e.g., the saw unit D 14 is slidably supported on a sliding support assembly T 66 which is slidable relative to the bevel arm B 14 (such as that shown in FIG. 5D )). An electrical signal may be transmitted through the slide tubes T 70 from the lever B 50 on the slidable saw unit D 14 to the locking mechanism B 30 on the non-sliding bevel arm B 14 .

As shown in FIGS. 67-69 , in some constructions, the bevel adjustment assembly B also includes a bevel detent assembly B 82 which is engageable to positively hold the bevel arm B 14 in a selected bevel angle position relative to the table T 18 . In at least selected bevel angle positions, the bevel detent assembly B 82 supplements the locking force applied by the locking mechanism B 30 , such as the frictional locking force applied by the brake mechanism B 34 .

The bevel detent assembly B 82 includes a projection which is selectively engageable in a recess corresponding to a selected bevel angle. As shown in FIGS. 67A-67B , the brake disk B 38 defines one or more detent recesses B 86 each of which correspond to a selected bevel angle position. A movable detent pin B 90 provides the projection which is engageable in the recess(es) B 86 , in a detent engaged position to lock the bevel arm B 14 in a selected bevel angle position, and disengageable from the recess(es) B 86 , in a detent disengaged position to allow adjustment of the bevel angle position.

An detent pin actuator assembly is provided to move the detent pin B 90 between the engaged and disengaged positions. In the illustrated construction, the detent pin actuator assembly is provided by the actuating mechanism B 46 . In operation, as the actuating mechanism B 46 is operated to release the brake assembly B 34 , the actuating mechanism B 46 moves the detent pin B 90 to disengage the recess B 86 . With the brake mechanism B 34 maintained in the release position, the bevel angle is adjustable.

A biasing mechanism, such as a spring B 94 may bias the detent pin B 90 toward engagement with a recess B 86 . If the detent pin B 90 is not aligned with a recess B 86 , the spring B 94 causes the detent pin B 90 to engage or ride on the outer surface of the brake disk B 38 .

The actuating mechanism B 46 may be movable to a detent override position, in which the detent pin B 90 is prevented from engaging the next recess B 86 as the bevel angle is adjusted. The actuating mechanism B 46 may have an intermediate detent actuation position in which the detent pin B 90 , once disengaged from a recess B 86 , is then allowed to engage the next recess B 86 while the bevel angle is adjusted. In the intermediate position, the actuating mechanism B 46 maintains the brake mechanism B 34 is the release position.

As shown in FIGS. 67A-67B and 68 A- 68 B, the detent pin B 90 is generally linearly slidable between the engaged and disengaged positions. In FIG. 69 , the detent pin B 90 is pivotable between the engaged and disengaged positions. FIG. 70 illustrates a detent pin B 90 which is rotatable between the engaged and disengaged positions.

FIGS. 78-80 illustrate various bevel stop arrangements B 98 . In these arrangements, a user may set a selected bevel angle position at which the bevel arm B 14 will be stopped during beveling movement relative to the table T 18 . The arrangements B 98 will operate with the bevel arm B 14 being beveled either to the left or to the right.

In a first construction (shown in FIGS. 78A-78G ), set screws B 102 are positioned in the table mount housing B 22 . A stop arm B 106 moves with the bevel arm B 14 and is adjustable to engage one or more set screws B 102 to stop beveling movement of the bevel arm B 34 relative to the table T 18 at selected bevel angle position. A shift knob B 110 operates a shift cam B 114 to move a shifter B 118 along the bevel axis B 18 . The shifter B 118 moves the stop arm B 106 into and out of a region of engagement with a given set screw B 102 (which determines the bevel angle at which movement is stopped or beyond which movement is prevented without further action by the user).

In another construction (shown in FIGS. 79A-79G ), a stepped stop plate B 122 is provided for selective engagement with the set screws B 102 to stop the beveling movement of the bevel arm B 14 relative to the table T 18 in a selected bevel angle position.

In another construction (shown in FIGS. 80A-80G ), rotatable stop bands B 126 are supported on the bevel arm B 14 and include stops B 130 . The bands B 126 may be rotated relative to the bevel arm B 14 and then fixed in a position to set the bevel angle stop position. The table T 18 includes a projection B 134 which engages a bevel stop B 130 to stop beveling movement of the bevel arm B 14 relative to the table T 18 .

Handle Assembly H

FIGS. 81A-81B illustrate a handle assembly H including a D-shaped operator's handle H 14 connected to an arm D 28 extending from the saw unit D 14 . The handle H 14 has a main grip H 18 on which is supported a main power switch H 22 to operate the saw 10 . A display R 22 is provided on the handle H 14 on a surface H 24 above where a user's hand would grip the main grip H 18 . The position of the display R 22 on the surface H 24 , the orientation of the surface H 24 on the handle H 14 and/or the orientation of the handle H 14 relative to the arm D 28 (e.g., at a non-parallel angle with respect to arm D 28 , and illustrated at almost 90 degrees or more with respect to the arm D 28 ) the improves the visibility of the display R 22 . FIGS. 1-4 and 5 K illustrate a similar handle.

As shown in FIGS. 81A-81B , in the illustrated construction, a bail-style release lever B 50 is located rearward of the main grip H 18 . As explained above, the release lever B 50 may be used to actuate the bevel angle locking mechanism B 30 .

To adjust the bevel angle, the release lever B 50 may be accessed by the same hand on the main grip H 18 . A user may place one hand on the main grip H 18 and reach for the release lever B 50 with out-stretched their fingers. Upon grasping the release lever B 50 , the user may pull the release lever B 50 toward the front of the saw 10 to unlock, disengage or release the bevel locking mechanism B 30 . While the bevel locking mechanism B 30 is unlocked or disengaged, the user may support and adjust the bevel angle of the saw unit D 14 using only the hand grasping the main grip H 18 and the release lever B 50 . To lock or re-engage the bevel locking mechanism B 30 , the user may release the lever B 50 . The miter saw also includes a carry handle H 26 centered over the saw for transporting the saw 10 .

FIGS. 82A-82E illustrate an alternate construction for the D-shaped handle H 14 . The main grip H 18 supports the main power switch H 22 thereon, and a secondary grip H 30 is positioned above the main grip H 18 . The secondary grip H 30 incorporates a release lever B 50 for the bevel locking mechanism B 30 .

To adjust the bevel angle, the release lever B 50 may be accessed by the user by grasping the secondary grip H 30 rather than the main grip H 18 . When it is desired to adjust the bevel angle, the user moves a hand to the secondary grip H 30 (e.g., the operating hand from the main grip H 18 ) and reaches the release lever B 50 . Upon grasping the release lever B 50 , the user may pull the release lever B 50 toward the front of the saw 10 to unlock or disengage the bevel locking mechanism B 30 . While the bevel locking mechanism B 30 is unlocked or disengaged, the user may support and adjust the bevel angle of the saw unit D 14 using only the hand grasping the main grip H 18 and the release lever B 50 . To lock or re-engage the bevel locking mechanism B 30 , the user may release the lever B 50 .

FIGS. 83A-83B illustrate another construction of a handle assembly H. In the illustrated construction, the handle assembly H includes a “joystick” handle H 34 supporting the main power switch H 22 and secondary handle H 38 positioned above the joystick handle H 34 . The secondary handle H 38 incorporates the release lever B 50 for a bevel angle locking mechanism B 30 . The joystick handle H 34 may include a contoured surface H 42 toward the bottom of the handle H 34 for an operator to rest their hand.

Alternatively, the joystick handle H 34 may be open toward the top of the handle H 34 , and the secondary handle H 38 may be located rearwardly of the handle H 34 . Also, the secondary handle may include a T-shape, an L-shape, or a saddle-style grip.

To adjust the bevel angle, the release lever B 50 may be accessed by the user by grasping the secondary grip H 38 rather than the handle H 34 . When it is desired to adjust the bevel angle, the user moves a hand to the secondary grip H 38 (e.g., the operating hand from the handle H 34 ) and reaches the release lever B 50 . Upon grasping the release lever B 50 , the user may pull the release lever B 50 toward the front of the saw 10 to unlock or disengage the bevel locking mechanism B 30 . While the bevel locking mechanism B 30 is unlocked or disengaged, the user may support and adjust the bevel angle of the saw unit D 14 using only the hand grasping the secondary handle H 38 and the release lever B 50 . To lock or re-engage the bevel locking mechanism B 30 , the user may release the lever B 50 .

FIG. 5A illustrates a T-handle H 42 which may assist with adjustment of the bevel angle, transport of the saw 10 , etc. FIGS. 5 E and 5 G- 5 H illustrate a main handle H 46 generally centered over the saw blade SB. FIGS. 5H-5J illustrate a U-shaped handle H 50 connected to the saw unit D 14 which may be engaged by a user to assist in adjusting the bevel angle. The lever B 50 is supported on the U-shaped handle H 50 .

Digital Readout Arrangement R

FIGS. 84-85 illustrate a digital display arrangement or digital readout arrangement R for a saw 10 . The digital readout arrangement R may display information to a user (e.g., a relative position of a portion of the saw 10 , such as the miter angle, the bevel angle, etc., information relating to the operation of the saw, such as motor speed, battery capacity, battery charging status, etc., historical information relating to the saw, such as number of cuts performed, warranty information, etc.).

As shown in FIG. 85A-85C , transducers R 14 (e.g., capacitive, magnetic, hall effect, optical, reflective, resistive, encoders, etc.) may be positioned either coaxial with the respective axes of rotation of the miter angle and the bevel angle or next to or adjacent the moving parts of the miter saw that impart the miter angle and the bevel angle. The miter saw may also include signal-conditioning electronics R 18 operable to convert the signals output by the transducers R 14 into a numerical value corresponding with the miter angle and/or the bevel angle of the saw 10 .

The digital angle readout or display R 22 may be positioned on the saw 10 at locations corresponding with the respective miter adjustment assembly M and bevel adjustment assembly B. For example, as shown in FIG. 84A , a miter angle display R 26 may be positioned on the tongue T 78 , and a bevel angle display R 30 may be positioned near the bevel angle adjusting handle (e.g., the handle H 14 ).

Alternatively, the miter angle display and the bevel angle display may be incorporated into a single display (not shown). Further, a single display, with the capability of switching between displaying miter angle and displaying bevel angle, may be used.

Other information relating to the miter saw (e.g., load current, etc.) or information not relating to the miter saw (e.g., time of day, advertisements, etc.) may also be shown on the display R 22 .

FIGS. 85E-85I illustrate operation of the digital readout arrangement R. FIGS. 85J-85K illustrate circuit diagrams of the digital readout arrangement R.

FIGS. 86A-86D illustrate the positioning a miter angle potentiometer R 34 and a bevel angle potentiometer R 38 (see FIG. 86C ).

FIG. 87 illustrates structure and electronics to accurately measure and display miter angle settings and bevel angle settings. These angle measurements may be obtained by mounting potentiometers on both axes of rotation (i.e., the miter axis T 30 and the bevel axis B 18 ) and electronically displaying the angular displacement about each axis. This may enable an operator to position the miter angle and the bevel angle of the saw unit D 14 to increased levels of accuracy and precision

The degree of accuracy of the electronics is such that the mechanical detents D 54 that are machined into the base T 14 for the miter angle would likely not read to the exact position of the angular detents (e.g., 0.0 degrees, 22.5 degrees, 45.0 degrees, etc.). This would require that the mechanical detents to be held to extremely close tolerances, or, utilize the method discussed herein.

With reference to FIG. 87 , a microswitch R 42 (or other position sensing device such as a proximity sensor, Hall-Effect sensor, or optical/laser emitter-receiver) may be mounted in close proximity to the detent override mechanism such that when the operator locks the saw into a mechanical detent or passes over a mechanical detent, the microswitch may be actuated, thereby resetting or re-calibrating the potentiometer to the desired angle. Alternatively, the position of the microswitch or other sensor may be positioned in a location disposed from the detent override mechanism. This allows, among other things, the system to constantly recalibrate itself to prevent drift, enable more reasonable mechanical tolerances on the detents, ensure that the digital readouts agree with the position of the mechanical detents, and a less accurate or a less expensive potentiometer to be used.

In another construction, the saw 10 may include user-settable detents. As such, a detent may be set wherever an operator may want it, not just an adjustment from a pre-set detent. Furthermore, an operator may find it convenient to set as many or as few detents as they wish throughout the miter angle adjustment range. Such user-settable detents may work in conjunction with the bevel pivot, miter pivot, or both.

For example, with reference to detents for the miter angle adjustment, a stepper motor with an encoder may be positioned on the miter axis to provide user-settable detents. The stepper motor may be capable of microstepping in increments at least as fine as the desired detent accuracy. An electronic circuit may be utilized to signal the stepper motor when and which coil or multiple coils to energize. Energizing the proper coil combination may provide resistance to table rotation at the proper instant such that an operator would feel as if they hit or passed through a mechanical detent. Additionally, the coils may be energized in a pattern as an operator approaches one of the detents such the operator feels the effect of a ball riding into a ramp or feels the resistance of the table increase slightly as the detent approaches. Provided sufficient strength of the stepper motor, the motor may also act as the miter lock.

Alternatively, an electromagnetic device may engage a lock, damper, or other friction or mechanical interference geometry when signaled by an electronic circuit. Such an electromagnetic device may be a single solenoid mounted in the tongue of the table. The solenoid may engage anywhere along the perimeter of the table.

Alternatively, a voice-coil mechanism mounted in the tongue of the table may be utilized rather than the solenoid. The voice-coil mechanism has a fast response time, consumes less power, and is more responsive to instructions from an electronic circuit. The voice-coil device may also be energized with varying magnitude based on the position, velocity, and/or acceleration of the table. Like the stepper motor, a circuit may be programmed to simulate the feel of mechanical detents.

Independent benefits of such user-settable detents or electronically programmable detent devices may be the elimination of conflicting signals that a dual angle indication system may create. With a potentiometer or encoder mounted separately from a detent system, it is possible that the saw may be in a mechanical detent defined as 45 degrees (for instance), while the electronics may think and display that the saw is positioned at 45.3 degrees.

As discussed above, FIGS. 64A-64C illustrate a miter angle scale incorporating a plurality of user-adjustable detents M 360 . A miter angle sensor module M 364 for determining the position at which the table T 18 is positioned relative to the base T 14 . The sensor module communicates with the miter angle indicator and controller module. The detent position magnets M 368 may be positioned by the user (or during manufacture) at given miter angle positions. The user can set any given miter position in the controller, much like programming a pre-set radio station. A locking mechanism may be provided to hold the turntable in the desired miter angle position.

FIGS. 88A-88C illustrate alternate sensors, such as switch elements, optical sensors, etc., to sense the position of a detent recess M 54 or B 86 .

FIGS. 89A-89F illustrate various constructions for sensing and communicating to the user the miter angle of the table relative to the base and/or the bevel angle of the saw blade relative to the table. In some constructions, the miter saw may include a capacitive angle measurement and digital readout R 46 , in a manner similar to digital calipers. The rail R 50 of the calipers would be curved around the radius, and the wipers R 54 of the calipers would be mounted on the tongue of the table. Rather than displaying a linear distance, the display R 22 would be programmed to display an angle to which the table is adjusted. A similar digital caliper is described and illustrated in U.S. Pat. No. 4,449,179, the entire contents of which are hereby incorporated by reference.

For example, a dimensionally stable tape with a series of very accurate copper rectangles plated on it using printed circuit technology may be supported on a stationary part (e.g., the base). A sliding part supported on a moving part (e.g., the turntable) has a similar but finer pitch pattern plated on it, and the ratio of capacity between the slider rectangles and the tape rectangles is used to calculate how far the slider has moved relative to the tape. Such an arrangement provides in incremental encoder to determine how far the slider has been moved from the last zero set-point. Such technology is reasonably rugged because there are no sliding contacts which wear.

The arrangement may include a “coolant-proof” digital caliper which alleviates the effects of changes in moisture which may affect the dielectric constant. Wipers may be provided to remove moisture from the scale as the slider moves past. The wipers may remove other debris, such as sawdust.

In the illustrated construction, the tape is wrapped around the arc cylinder. The slider is substantially arc-shaped as well. Because the tape and slider are mounted internally to the miter saw body, these components are protected from mechanical damage during use, storage and transport.

FIGS. 90-92 illustrate alternate constructions for sensing and communicating the relative position of components of the saw 10 . FIGS. 90A-90B illustrate a strip or disk and a reader. FIG. 91 illustrates a rotary encoder and an electronics module. FIG. 92 illustrates a potentiometer and a gear arrangement. A wiring arrangement may connect the sensing arrangement to a “remote” display located a distance from the sensor.

FIGS. 93A-93C illustrate a wiring arrangement for at least a portion of a saw 10 . As illustrated angular position sensors R 58 , such as potentiometers, are provided for determining the miter angle position and the bevel angle position of the saw blade SB. These sensors R 58 communicate with a controller R 62 which, in turn, communicates with a corresponding display R 66 .

A wiring arrangement, such as a coiled wire R 70 , may be provided to accommodate movement between the controller R 62 and a display R 66 and/or a sensor R 58 . In the illustrated construction, the controller R 62 is supported on the saw unit D 14 which is slidable relative to the base T 14 (on which the sensor R 58 is supported) and the table T 18 (on which the display R 66 is supported). The coiled wire R 70 extends through a slide tube T 70 to connect the controller R 62 to the sensor R 58 and display R 66 for the miter angle position.

FIGS. 94-95 illustrate a cover arrangement R 74 for a portion of the digital display arrangement R, such as the miter angle position display R 66 . The display R 66 is supported on the tongue T 78 of the table T 18 . The cover arrangement R 74 includes an upper cover R 78 defining an opening R 82 through which the display R 66 is visible. A lower cover R 86 covers the bottom surface of the tongue T 78 to enclose at least components of the miter adjustment assembly M.

As discussed above, when adjusting the miter angle position, the user will operate the controls (e.g., the lock knob M 46 , the detent lever M 62 , the fine adjust knob M 138 , etc.) on the tongue T 78 and will engage the tongue T 78 to move the table T 18 . A scallop-shaped recess R 90 is defined on each side of the opening R 82 . A user may place the thumb of the adjusting hand (which grasps the controls and/or the tongue T 78 ) to maintain visibility of the display R 66 before, during and after adjustment of the miter angle position.

The upper cover R 78 is that same for the sliding compound miter saw shown in FIGS. 94A-94E and for the compound miter saw shown in FIG. 95 . However, the lower cover R 86 is somewhat smaller for the compound miter saw.

The display R 66 may be powered by the power source for the saw 10 (e.g., line power, battery power, etc.). Alternatively, the display R 66 may be powered by a separate power source. For example, a separate replaceable battery may be provided. A solar type arrangement may be provided (like that on many calculators), and an on-board illumination assembly L may provide the power to the solar arrangement. Power may be generated through operation of the saw 10 (e.g., rotation of the saw blade SB, movement of the table T 18 or bevel arm B 18 , movement of the saw unit D 14 along the slide tubes T 70 (e.g., with a transformer, using low voltage, etc.)).

The digital readout arrangement R and electronic functions may also provide simple calculations using one or two keys or buttons by an operator. Such simple calculations may be the angle complement finder, a conversion to rise-run a display, a conversion to degrees-minute display, etc. In other constructions, the electronics may provide complex calculations and a multi-key or button pad may be required. Such calculations may include miter and bevel calculations for crown molding.

The digital readout arrangement R and transducer system may include a zero adjustment and/or a span adjustment. The display R 22 for the electronics may be an LCD display and may be operable to display a picture or diagram of the workpiece and/or the worksite. The system may be operable to record and/or display information about the miter saw (e.g., the number of cuts, the run time, the estimated remaining brush life, number of impacts or drops, if any) or other information (e.g., guides to operating the saw, advertising about other products, accessories or services, etc.).

The digital readout arrangement R can display various operating characteristics of the miter saw such as, for example, rpm, depth of cut, miter angle, bevel angle, etc. The display might indicate faults with the miter saw or required maintenance. In addition, the display might provide a low-voltage or low power indication in case cases in which the line voltage may compromise intended performance at the miter saw.

The digital readout arrangement R or display may provide a watt-hour/run-time meter. A device would be provided for monitoring the power consumed and/or the run-time of the miter saw over a period of time. The device could be a separate in-line device, or it could be integrated into the miter saw. The device could be used as a tool usage tracking device by both the user and a service department.

The readout may provide a perpendicularity indicator which would provide an indication (e.g., visual, audible, etc.) to the user when the saw blade is perpendicular to the workpiece (e.g., at zero degrees bevel angle and zero degrees miter angle). The electronics may also provide an indication of leveling of the tool on a work surface. The device may also provide a metal detector which may be integrated or an accessory, which would detect the presence of metal in a workpiece. Such a device may provide an indication to the user and/or interrupt operation of the miter saw.

The digital readout system may be zeroed at any point on the table with respect to the miter angle and/or bevel angle. The position of the table may be an input to a calculator. The electronics may also be programmable to provide user-desired characteristics (e.g., selected rpm, soft start, breaking time, etc.). The miter saw may include a separate power source, such as a battery, to power electronics.

The electronics may provide control of operation, such as incorporation of feedback, soft-start (to extend the run-time of a battery or to conserve power), auto-reversing, etc.

A separate sensor may be provided for sensing characteristics of the workpiece or work area, such as, for example, the desired angles, lengths, widths for cutting a workpiece. This separate sensor may communicate with the electronics module. Such communication may be wireless, hard-wired with the sensor remaining in a position around the work area, hard-wired with the sensor being connected to the electronics package on the miter saw itself, etc.

Illumination Assembly L

FIGS. 1-5 , 27 and 96 - 107 illustrate various arrangements for illuminating a portion of the saw 10 , such as the table T 18 , the work piece WP, an angular adjustment scale (e.g., the miter scale M 20 , a bevel scale B 28 (as shown in FIG. 5A ), etc.). As discussed below, in some constructions, the arrangement may provide an indication of the line of cut.

As shown in FIGS. 27 and 96 - 99 , the illumination assembly L may include a light assembly L 14 for illuminating a portion of the saw 10 . The light assembly L 14 includes one or more lighting elements L 18 . The lighting elements L 18 may include an incandescent lighting element, a LED lighting element, etc.

In the illustrated construction, the lighting element(s) L 18 are supported for movement with the saw unit D 18 . The lighting element(s) L 18 may be supported at various locations on the saw unit D 18 . FIGS. 27 and 96 - 99 illustrate various placements of the lighting element(s) L 18 .

As shown in FIGS. 96C and 107 , the lighting element(s) L 18 may be selectively powered during operation of the saw 10 . The light assembly L 14 includes a switch arrangement L 22 for controlling the supply of power to the lighting element(s) L 18 . The switch arrangement L 22 may simply be an on/off switch, as shown in FIG. 96C . In other constructions (see FIGS. 107A-107F ), the switch arrangement L 22 may operate the lighting element(s) in multiple power modes (e.g., “full on” power mode, an intermediate power mode (a single intermediate power level or variable intermediate power levels), and off).

In still other constructions (not shown), the saw 10 may include a sensor and controller arrangement to determine and set the appropriate power mode for the lighting element(s) L 18 (e.g., based on ambient light, based on the available supply of power to the saw 10 (e.g., remaining battery capacity), etc.). Such an arrangement may also control and select the “off” mode (e.g., when the saw 10 is left unused for a period of time, at a point during cutting when illumination is not required, etc.).

As shown in FIGS. 100-107 , the illumination assembly L may include an assembly for indicating a line of cut (e.g., a laser assembly L 26 ). The laser assembly L 26 may include one or more laser element(s) L 30 . As shown in FIGS. 100 and 100 , the laser element(s) L 30 may be supported at various locations on the saw 10 .

In FIG. 100A , the laser element(s) L 30 are mounted toward the rear of the saw unit D 14 to project forwardly to illuminate or indicate a cut line on the work piece WP. Alternatively, as shown in FIG. 101A , the laser element(s) L 30 may be mounted toward the front of the saw unit D 14 to project rearwardly to illuminate the cut line.

As shown in FIGS. 102-104 , the laser assembly L 26 may include a self-contained laser module L 34 separate from the saw 10 . The laser module L 34 may be coupled to the saw 10 as an aftermarket accessory or as original equipment from the manufacturer of the saw 10 .

As shown in FIGS. 105A-105C , the laser assembly L 26 may alternatively be mounted either toward the rear or the front of saw unit D 14 to project toward a polished faceted surface or “nut” L 38 Rotation of the saw blade SB may then result in a cut line being indicated on the work piece WP.

As shown in FIGS. 106A-106C , the laser assembly L 26 may be positioned within the arbor D 38 of the saw blade SB to project toward a reflective surface (e.g., a mirror L 42 ), which may reflect the laser along the saw blade SB to indicate a cut line on the work piece WP.

As shown in FIG. 107A-107F , laser assembly L 26 may include a switch arrangement L 22 for controlling the supply of power to the laser assembly L 26 . In some constructions, the switch arrangement L 22 may simply be an on/off switch.

In other constructions (see FIGS. 107A-107F ), the switch arrangement L 22 may operate the laser element(s) L 30 in multiple power modes (e.g., “full on” power mode, an intermediate power mode (a single intermediate power level or variable intermediate power levels), and off) to provide a variable intensity laser. Such a variable intensity laser allows an operator to align a work piece WP with the position of the saw blade SB under varying lighting conditions (e.g., indoor and outdoor lighting). The switch arrangement L 22 may provide a number of laser intensity levels to vary the intensity of the laser line to accommodate the user's preferences when using the saw 10 in a given ambient light (e.g., an indoor or outdoor setting).

In still other constructions (not shown), the saw 10 may include a sensor and controller arrangement to determine and set the appropriate power mode for the laser element(s) L 30 (e.g., based on ambient light, based on the available supply of power to the saw 10 (e.g., remaining battery capacity), etc.). Such an arrangement may also control and select the “off” mode (e.g., when the saw 10 is left unused for a period of time, at a point during cutting when laser illumination is not required, etc.).

Transport Assembly TR

FIGS. 108-110 illustrate various constructions of a transport assembly TR for the saw 10 .

As shown in FIGS. 108-109 , the transport assembly TR may include a carry strap TR 14 to facilitate transportation of the saw 10 by a user. The carry strap TR 14 may include a shoulder strap TR 18 that is, for example, 1″-3″ wide, and that has an adjustable length of, for example, 4′-6′. The carry strap TR 14 may include a single shoulder strap T 18 (as shown in FIG. 108 ) or multiple shoulder straps T 18 (as shown in FIG. 109 ).

A heavily-padded shoulder pad TR 22 may be movable along the shoulder strap TR 18 . A non-slip surface may be provided on the shoulder pad TR 22 to substantially prevent slippage of the shoulder pad TR 22 on the user's shoulder.

As shown in FIGS. 108C and 109C , the shoulder strap TR 18 may be connected to the saw 10 a quick-connect assembly TR 26 (e.g., two or more quick-connect swivel latches) that engage corresponding attachment structure on the saw 10 (e.g., eyelets on the base T 14 ) in predetermined balance locations. The quick-connect assembly TR 26 may include locking features (e.g., a threaded engagement similar to a locking carbineer) to avoid accidental detachment of the shoulder strap TR 18 from the base T 14 .

FIGS. 110A-110G illustrate other constructions of a transport assembly TR, such as a case, a bag, etc., for the saw 10 .

As shown in FIG. 110A-110B , the transport arrangement TR may include a bag TR 30 similar to a piece of rolling luggage. The bag TR 30 forms an enclosure T 34 in which the saw 10 is supported. The enclosure T 34 may be formed with a contoured recess for receiving the outer contour of the saw 10 and for holding saw 10 in position.

A locking arrangement (not shown) may be provided for holding the saw 10 in position. For example, straps may be provided to hold the saw 10 in place. In other constructions, movable retainer surfaces (e.g., pivotable arms) may engage surfaces on the saw 10 to hold it in place and may be moved out of to allow removal of the saw 10 .

In the illustrated construction, wheels TR 38 are supported on the outside of the bag TR 30 . A handle TR 42 , such as a telescoping handle, is provided on the bag. Hooks TR 46 may be provided on the exterior of the bag TR 30 for supporting accessory equipment such as cords, lights, etc. The bag TR 30 may be formed of heavy-duty cloth, hard plastic, metal, etc.

As shown in FIGS. 110 C and 110 E-G, the transport arrangement TR may be provided by a plastic case TR 50 . The case TR 50 or a portion of the case, such as the cover TR 54 , may perform other functions. For example, the portion TR 54 may provide a step stool (as shown in FIG. 110C ), storage for other equipment and/or accessories, etc.

As shown in FIG. 110D , the transport arrangement TR may be provided by an open dolly-type apparatus TR 58 . This apparatus TR 58 includes a frame TR 62 on which the saw 10 is secured. Wheels TR 38 are provided on the frame TR 62 , and the frame TR 62 includes a handle TR 42 .

A locking arrangement (not shown) may be provided for holding the saw 10 in position on the frame TR 62 . For example, straps may be provided to hold the saw 10 in place. In other constructions, movable retainer surfaces (e.g., pivotable arms) may engage surfaces on the saw 10 to hold it in place and may be moved out of to allow removal of the saw 10 . Also, a removable cover (not shown) may be provided to cover the saw 10 .

Battery

In some constructions (not shown), the saw 10 may be operable to charge power tool batteries and/or may be powered by a power tool battery. The battery charging portion of the saw 10 may be similar to that disclosed in U.S. Patent Application Publication No. U.S. 2003/0090234 A1, published May 15, 2003 (Ser. No. 10/289,621, filed Nov. 7, 2002), the entire contents of which are hereby incorporated by reference.

In general, the battery charger portion would be constructed for a heavy-duty use in a harsh working environment in which the saw 10 is being used. The charger portion may be operable to support and charge multiple voltage batteries such as, for example, 12V-50V, or similar power tool or other equipment batteries of various chemistries (NiCd, NiMH, Li-based,

The saw 10 may include one or more battery ports (e.g., on the base T 14 , on the saw unit D 14 , etc.) on which a battery is supported on the saw 10 . A battery charging circuit may be supported by the saw 10 (e.g., in the base T 14 , in the motor housing D 26 ) and may be electrically connected between the power source (e.g., AC line power) and the battery port to supply power to the battery to charge the battery.

In some constructions, the battery may also be operable to power the saw 10 . Power may be supplied from the battery through the battery port to the motor D 18 and/or other components of the saw 10 to power the motor D 18 and/or components of the saw 10 . In some constructions, a separate battery power port may be provided on another portion of the saw 10 . In such a construction, the battery would be mounted on the battery power port and would supply power to the motor D 18 and/or other components of the saw 10 .

Information about the battery and/or the battery charger portion (e.g., remaining battery capacity, the status of battery charging, etc.) may be communicated to the user through the digital display arrangement or digital readout arrangement R or through a separate indicator assembly (e.g., a charging status indicator such as that on existing battery chargers, a fuel gauge on the battery, etc.).

It should be understood that the various independent aspects of the present invention discussed above may be utilized independently of one another or in combination with one or more other independent aspects of the invention.