US20140360819A1 - Brake cartridges and mounting systems for brake cartridges - Google Patents
Brake cartridges and mounting systems for brake cartridges Download PDFInfo
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- US20140360819A1 US20140360819A1 US13/914,343 US201313914343A US2014360819A1 US 20140360819 A1 US20140360819 A1 US 20140360819A1 US 201313914343 A US201313914343 A US 201313914343A US 2014360819 A1 US2014360819 A1 US 2014360819A1
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- US
- United States
- Prior art keywords
- cartridge
- brake
- blade
- pawl
- key
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16P—SAFETY DEVICES IN GENERAL; SAFETY DEVICES FOR PRESSES
- F16P3/00—Safety devices acting in conjunction with the control or operation of a machine; Control arrangements requiring the simultaneous use of two or more parts of the body
- F16P3/12—Safety devices acting in conjunction with the control or operation of a machine; Control arrangements requiring the simultaneous use of two or more parts of the body with means, e.g. feelers, which in case of the presence of a body part of a person in or near the danger zone influence the control or operation of the machine
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B55/00—Safety devices for grinding or polishing machines; Accessories fitted to grinding or polishing machines for keeping tools or parts of the machine in good working condition
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27B—SAWS FOR WOOD OR SIMILAR MATERIAL; COMPONENTS OR ACCESSORIES THEREFOR
- B27B5/00—Sawing machines working with circular or cylindrical saw blades; Components or equipment therefor
- B27B5/29—Details; Component parts; Accessories
- B27B5/38—Devices for braking the circular saw blade or the saw spindle; Devices for damping vibrations of the circular saw blade, e.g. silencing
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D49/00—Brakes with a braking member co-operating with the periphery of a drum, wheel-rim, or the like
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/081—With randomly actuated stopping means
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/081—With randomly actuated stopping means
- Y10T83/088—Responsive to tool detector or work-feed-means detector
- Y10T83/089—Responsive to tool characteristic
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/606—Interrelated tool actuating means and guard means
- Y10T83/613—Work guard
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/768—Rotatable disc tool pair or tool and carrier
- Y10T83/7684—With means to support work relative to tool[s]
- Y10T83/773—Work-support includes passageway for tool [e.g., slotted table]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/768—Rotatable disc tool pair or tool and carrier
- Y10T83/7734—With guard for tool
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/869—Means to drive or to guide tool
- Y10T83/8773—Bevel or miter cut
Abstract
Safety systems for power equipment, components, cartridges and mounting systems for cartridges are disclosed. The safety systems, components, cartridges and mounting systems are specifically applicable for woodworking equipment such as saws. A cartridge system for use in safety systems for power tools might include a cartridge adapted to perform a predetermined action when triggered, where the predetermined action causes the deceleration and/or retraction of a working portion of the power tool, where the cartridge includes a first connector, and where a second connector is mounted in the power tool and adapted to connect to the first connector.
Description
- This is a continuation of U.S. patent application Ser. No. 11/026,006, filed Dec. 31, 2004, titled “Brake Cartridges and Mounting Systems for Brake Cartridges,” which claims the benefit of and priority from U.S. Provisional Patent Application Ser. No. 60/533,575, filed Dec. 31, 2003. The disclosures of these applications are herein incorporated by reference:
- The present disclosure relates to power equipment and more particularly to brake cartridges and mounting systems for brake cartridges used in safety systems for power equipment.
- Safety systems or features are often employed with power equipment such as table saws, miter saws, band saws, jointers, shapers, circular saws and other woodworking machinery, to minimize the risk of injury when using the equipment. Probably the most common safety feature is a guard that physically blocks an operator from making contact with dangerous components of the equipment, such as blades, belts or shafts. In many cases, guards effectively reduce the risk of injury, however, there are many instances where the nature of the operations to be performed precludes using a guard that completely blocks access to hazardous machine parts.
- Other safety systems have been developed to detect when a human body contacts a predetermined portion of a machine, such as detecting when a user's hand touches the moving blade on a saw. When that contact is detected, the safety systems react to minimize injury. These types of safety systems often employ a brake mechanism housed in a cartridge and mounted in the machine.
- The present document discloses brake cartridges and mounting systems for brake cartridges used in safety systems for power equipment.
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FIG. 1 is a schematic block diagram of a machine with a fast-acting safety system. -
FIG. 2 is a schematic diagram of an exemplary safety system in the context of a machine having a circular blade. -
FIG. 3 is a perspective view of a brake cartridge. -
FIG. 4 is another perspective view of the brake cartridge shown inFIG. 3 . -
FIG. 5 is a simplified elevation view of a brake cartridge in a table saw. Various components of the table saw, including the cabinet, stand, motor, drive belt, etc., have been removed for clarity. -
FIG. 6 is shows generally the interior components of the brake cartridge shown inFIG. 3 . -
FIG. 7 is a side elevation view of an actuator assembly used in the brake cartridge ofFIG. 3 . -
FIG. 8 is another side elevation view of the actuator assembly shown inFIG. 7 . -
FIG. 9 is a front elevation view of the actuator assembly shown inFIG. 7 . -
FIG. 10 is a back elevation view of the actuator assembly shown inFIG. 7 . -
FIG. 11 is a perspective top, front view of the actuator assembly shown inFIG. 7 . -
FIG. 12 is a perspective bottom, front view of the actuator assembly shown inFIG. 7 . -
FIG. 13 is a perspective back, top view of the actuator assembly shown inFIG. 7 . -
FIG. 14 is a perspective bottom, back view of the actuator assembly shown inFIG. 7 . -
FIG. 15 is a top elevation view of the actuator assembly shown inFIG. 7 . -
FIG. 16 is a bottom elevation view of the actuator assembly shown inFIG. 7 . -
FIG. 17 shows a fuse wire and anchor used in the actuator shown inFIG. 7 . -
FIG. 18 shows a spring housing used in the actuator shown inFIG. 7 . -
FIG. 19 shows a link used in the actuator shown inFIG. 7 . -
FIG. 20 shows a lever used in the actuator shown inFIG. 7 . -
FIG. 21 shows a fulcrum used in the actuator shown inFIG. 7 . -
FIG. 22 shows a nut used in the actuator shown inFIG. 7 . -
FIG. 23 is a side elevation view of the actuator shown inFIG. 7 with a fuse wire in place holding down a lever pin. -
FIG. 24 is a front elevation view of the actuator shown inFIG. 23 . -
FIG. 25 shows a top view of the actuator shown inFIG. 23 . -
FIG. 26 shows a cross-section view taken along the line A-A inFIG. 25 . -
FIG. 27 shows a perspective view of a circuit board used in the brake cartridge shown inFIG. 3 . -
FIG. 28 shows another view of the circuit board used in the brake cartridge shown inFIG. 3 . -
FIG. 29 shows a top view of the circuit board shown inFIG. 27 . -
FIG. 30 shows a bottom view of the circuit board shown inFIG. 27 . -
FIG. 31 shows the actuator ofFIG. 7 with the circuit board ofFIG. 28 . -
FIG. 32 is another view of the actuator ofFIG. 7 with the circuit board ofFIG. 28 . -
FIG. 33 is a side view of the actuator ofFIG. 7 with the circuit board ofFIG. 28 . -
FIG. 34 shows another brake cartridge. -
FIG. 35 shows another view of the brake cartridge ofFIG. 34 . -
FIG. 36 is an elevation view of the interior of the brake cartridge shown inFIG. 34 . -
FIG. 37 is another elevation view of the interior of the brake cartridge shown inFIG. 34 , with the brake pawl removed for clarity. -
FIG. 38 is a perspective view of the brake cartridge shown inFIG. 34 with the brake pawl removed for clarity. -
FIG. 39 is a perspective view of a fuse wire assembly, with the fuse wire bent as it would be when installed in a brake cartridge. -
FIG. 40 shows the fuse wire ofFIG. 39 without the anchor. -
FIG. 41 shows an electrode isolator used in the brake cartridge ofFIG. 34 . -
FIG. 42 is another view of the electrode isolator shown inFIG. 41 . -
FIG. 43 is still another view of the electrode isolator shown inFIG. 41 . -
FIG. 44 is a perspective view of an electrode used in the brake cartridge ofFIG. 34 . -
FIG. 45 is another view of the electrode shown inFIG. 44 . -
FIG. 46 is an enlarged view of a circuit board and actuator used in the brake cartridge ofFIG. 34 , showing the placement of the electrode isolator. -
FIG. 47 shows a lever pin used in the brake cartridge ofFIG. 34 . -
FIG. 48 shows a link used in the brake cartridge ofFIG. 34 . -
FIG. 49 shows a link assembly used in the brake cartridge ofFIG. 34 . -
FIG. 50 shows a side view of the link assembly inFIG. 49 . -
FIG. 51 shows a top elevation view of the actuator used in the brake cartridge inFIG. 34 . -
FIG. 52 shows a side elevation view of the actuator inFIG. 51 , taken along the line A-A. -
FIG. 53 shows a foam washer that may be used in the brake cartridge shown inFIG. 34 . -
FIG. 54 shows an electrode that is used to detect blade-to-pawl spacing in the brake cartridge shown inFIG. 34 . -
FIG. 55 shows an enlarged side view of a brake cartridge with a switch contactor and cam bushing. -
FIG. 56 shows a perspective view of a switch contactor. -
FIG. 57 shows a front elevation view of the switch contactor ofFIG. 56 . -
FIG. 58 shows a side elevation view of the switch contactor ofFIG. 56 . -
FIG. 59 shows a perspective view of a cam bushing. -
FIG. 60 shows a front elevation view of the cam bushing ofFIG. 59 . -
FIG. 61 shows a side elevation view of the cam bushing ofFIG. 59 . -
FIG. 62 shows a perspective view of a brake pawl for a dado blade stack. -
FIG. 63 shows another perspective view of the brake pawl ofFIG. 62 . -
FIG. 64 shows still another perspective view the brake pawl shown inFIG. 62 . -
FIG. 65 shows a right side elevation view of a brake cartridge mounted on bracket plates and connected to an arbor block. -
FIG. 66 shows a front elevation view of the structure shown inFIG. 65 . -
FIG. 67 shows a left side elevation view of the structure shown inFIG. 65 . -
FIG. 68 shows a back elevation view of the structure shown inFIG. 65 . -
FIG. 69 shows a perspective view of a cam bushing. -
FIG. 70 shows a front elevation view of the cam bushing inFIG. 69 . -
FIG. 71 shows a perspective view of a key. -
FIG. 72 shows an elevation view of the key inFIG. 71 . -
FIG. 73 shows two bracket plates. -
FIG. 74 is a right side elevation view of the bracket plates inFIG. 73 . -
FIG. 75 is a left side elevation view of the bracket plates inFIG. 73 . -
FIG. 76 is a bottom elevation view of the brake cartridge and other structure shown inFIG. 65 , with part of the cartridge housing removed. -
FIG. 77 shows an arbor link. -
FIG. 78 shows another view of the arbor link ofFIG. 77 . -
FIG. 79 shows a perspective view of a plug. -
FIG. 80 shows another perspective view of the plug shown inFIG. 79 . -
FIG. 81 shows a top elevation view of the plug shown inFIG. 81 . -
FIG. 82 shows half of a cartridge housing isolated from other structure. -
FIG. 83 shows the right side of another cartridge. -
FIG. 84 shows the left side of the cartridge shown inFIG. 83 . -
FIG. 85 shows a front view of the cartridge shown inFIG. 83 . -
FIG. 86 shows a key used in mounting a cartridge in a machine. -
FIG. 87 shows another view of the key shown inFIG. 86 . -
FIG. 88 shows still another view of the key shown inFIG. 86 . -
FIG. 89 shows a cam bushing used in the cartridge shown inFIG. 83 . -
FIG. 90 shows another view of the cam bushing shown inFIG. 89 . -
FIG. 91 shows still another view of the cam bushing shown inFIG. 89 . -
FIG. 92 shows a switch actuator used in the cartridge shown inFIG. 83 . -
FIG. 93 shows a blade-to-pawl spacing electrode. -
FIG. 94 shows a circuit board and actuator used in the cartridge shown inFIG. 83 . -
FIG. 95 shows a bottom view of the cartridge board and actuator shown inFIG. 94 . -
FIG. 96 shows a detailed view of the portion ofFIG. 95 labeled “C”. -
FIG. 97 shows the circuit board ofFIG. 94 without the actuator. -
FIG. 98 shows an electrode isolator. -
FIG. 99 shows another view of the electrode isolator shown inFIG. 98 . -
FIG. 100 shows still another view of the electrode isolator shown inFIG. 98 . -
FIG. 101 shows a spring housing. -
FIG. 102 shows another view of the spring housing shown inFIG. 101 . -
FIG. 103 shows still another view of the spring housing shown inFIG. 101 . -
FIG. 104 shows a lever pin used in the cartridge shown inFIG. 83 . -
FIG. 105 shows a link used in the cartridge shown inFIG. 83 . -
FIG. 106 shows a right side view of the internal mechanism of a table saw with a cartridge mounted in the saw. -
FIG. 107 shows a left side view of the internal mechanism of the table saw shown inFIG. 106 . -
FIG. 108 shows an arbor block from a saw and a brake cartridge mounted to the arbor block. -
FIG. 109 shows another view of the arbor block and brake cartridge mounting shown inFIG. 108 . -
FIG. 110 shows a brake cartridge and mounting brackets. -
FIG. 111 shows another view of the brake cartridge and mounting brackets shown inFIG. 110 . -
FIG. 112 shows still another view of the brake cartridge and mounting brackets shown inFIG. 110 , with the cartridge removed. -
FIG. 113 shows yet another view of the brake cartridge and mounting brackets shown inFIG. 110 , with the cartridge removed. -
FIG. 114 shows a front view of a cable used in the mounting brackets shown inFIGS. 112 and 113 . -
FIG. 115 shows a back view of a cable used in the mounting brackets shown inFIGS. 112 and 113 . - A machine that incorporates a safety system to detect and react to a dangerous condition, such as human contact with a designated portion of the machine, is shown schematically in
FIG. 1 and indicated generally at 10.Machine 10 may be any of a variety of different machines, such as table saws, miter saws, band saws, jointers, shapers, routers, hand-held circular saws, up-cut saws, sanders, etc.Machine 10 includes anoperative structure 12 having a working or cuttingtool 14 and amotor assembly 16 adapted to drive the cutting tool.Machine 10 also includes asafety system 18 configured to minimize the potential of a serious injury to a person using the machine.Safety system 18 is adapted to detect the occurrence of one or more dangerous conditions during use of the machine. If such a dangerous condition is detected,safety system 18 is adapted to engageoperative structure 12 to limit any injury to the user caused by the dangerous condition. -
Machine 10 also includes asuitable power source 20 to provide power tooperative structure 12 andsafety system 18.Power source 20 may be an external power source such as line current, or an internal power source such as a battery. Alternatively,power source 20 may include a combination of both external and internal power sources. Furthermore,power source 20 may include two or more separate power sources, each adapted to power different portions ofmachine 10. - It will be appreciated that
operative structure 12 may take any one of many different forms. For example,operative structure 12 may include a stationary housing configured to supportmotor assembly 16 in driving engagement with cuttingtool 14. Alternatively,operative structure 12 may include one or more transport mechanisms adapted to convey a work piece toward and/or away from cuttingtool 14. -
Motor assembly 16 includes at least one motor adapted to drive cuttingtool 14. The motor may be either directly or indirectly coupled to the cutting tool, and may also be adapted to drive work piece transport mechanisms. The particular form of cuttingtool 14 will vary depending upon the various embodiments ofmachine 10. For example, cuttingtool 14 may be a single, circular rotating blade having a plurality of teeth disposed along the perimetrical edge of the blade. Alternatively, the cutting tool may be a plurality of circular blades, such as a dado blade or dado stack, or some other type of blade or working tool. -
Safety system 18 includes adetection subsystem 22, areaction subsystem 24 and acontrol subsystem 26.Control subsystem 26 may be adapted to receive inputs from a variety of sources includingdetection subsystem 22,reaction subsystem 24,operative structure 12 andmotor assembly 16. The control subsystem may also include one or more sensors adapted to monitor selected parameters ofmachine 10. In addition,control subsystem 26 typically includes one or more instruments operable by a user to control the machine. The control subsystem is configured to controlmachine 10 in response to the inputs it receives. -
Detection subsystem 22 is configured to detect one or more dangerous or triggering conditions during use ofmachine 10. For example, the detection subsystem may be configured to detect that a portion of the user's body is dangerously close to or in contact with a portion of cuttingtool 14. As another example, the detection subsystem may be configured to detect the rapid movement of a workpiece due to kickback by the cutting tool, as is described in U.S. patent application Ser. No. 09/676,190, the disclosure of which is herein incorporated by reference. In some embodiments,detection subsystem 22 may informcontrol subsystem 26 of the dangerous condition, which then activatesreaction subsystem 24. In other embodiments, the detection subsystem may be adapted to activate the reaction subsystem directly. - Once activated in response to a dangerous condition,
reaction subsystem 24 is configured to engageoperative structure 12 quickly to prevent serious injury to the user. It will be appreciated that the particular action to be taken byreaction subsystem 24 will vary depending on the type ofmachine 10 and/or the dangerous condition that is detected. For example,reaction subsystem 24 may be configured to do one or more of the following: stop the movement of cuttingtool 14,disconnect motor assembly 16 frompower source 20, place a barrier between the cutting tool and the user, or retract the cutting tool from its operating position, etc. The reaction subsystem may be configured to take a combination of steps to protect the user from serious injury. Placement of a barrier between the cutting tool and teeth is described in more detail in U.S. Patent Application Publication No. 2002/0017183 A1, entitled “Cutting Tool Safety System,” the disclosure of which is herein incorporated by reference. Retracting the cutting tool is described in more detail in U.S. Patent Application Publication No. 2002/0017181 A1, entitled “Retraction System for Use in Power Equipment,” and U.S. Patent Application Ser. No. 60/452,159, filed Mar. 5, 2003, entitled “Retraction System and Motor Position for Use With Safety Systems for Power Equipment,” the disclosures of which are herein incorporated by reference. - The configuration of
reaction subsystem 24 typically will vary depending on which action or actions are taken. In the exemplary embodiment depicted inFIG. 1 ,reaction subsystem 24 is configured to stop the movement of cuttingtool 14 and includes abrake mechanism 28, abiasing mechanism 30, a restrainingmechanism 32, and arelease mechanism 34.Brake mechanism 28 is adapted to engageoperative structure 12 under the urging of biasingmechanism 30. During normal operation ofmachine 10, restrainingmechanism 32 holds the brake mechanism out of engagement with the operative structure. However, upon receipt of an activation signal byreaction subsystem 24, the brake mechanism is released from the restraining mechanism byrelease mechanism 34, whereupon, the brake mechanism quickly engages at least a portion of the operative structure to bring the cutting tool to a stop. - It will be appreciated by those of skill in the art that the exemplary embodiment depicted in
FIG. 1 and described above may be implemented in a variety of ways depending on the type and configuration ofoperative structure 12. Turning attention toFIG. 2 , one example of the many possible implementations ofsafety system 18 is shown.System 18 is configured to engage an operative structure having acircular blade 40 mounted on a rotating shaft orarbor 42.Blade 40 includes a plurality of cutting teeth (not shown) disposed around the outer edge of the blade. As described in more detail below,braking mechanism 28 is adapted to engage the teeth ofblade 40 and stop the rotation of the blade. U.S. Patent Application Publication No. 2002/0017175 A1, entitled “Translation Stop For Use In Power Equipment,” the disclosure of which is herein incorporated by reference, describes other systems for stopping the movement of the cutting tool. U.S. Patent Application Publication No. 2002/0017184 A1, entitled “Table Saw With Improved Safety System,” U.S. Patent Application Publication No. 2002/0017179 A1, entitled “Miter Saw With Improved Safety System,” U.S. Patent Application Publication No. 2002/0059855 A1, entitled “Miter Saw with Improved Safety System,” U.S. Patent Application Publication No. 2002/0056350 A1, entitled “Table Saw With Improved Safety System,” U.S. Patent Application Publication No. 2002/0059854 A1, entitled “Miter Saw With Improved Safety System,” U.S. Patent Application Publication No. 2002/0056349 A1, entitled “Miter Saw With Improved Safety System,” U.S. Patent Application Publication No. 2002/0056348 A1, entitled “Miter Saw With Improved Safety System,” and U.S. Patent Application Publication No. 2002/0066346 A1, entitled “Miter Saw With Improved Safety System,” U.S. Patent Application Publication No. 2003/0015253 A1, entitled “Router With Improved Safety System,” U.S. Patent Application Publication No. 2002/0170400 A1, entitled “Band Saw With Improved Safety System,” U.S. Patent Application Publication No. 2003/0019341 A1, entitled “Safety Systems for Band Saws,” U.S. Patent Application Publication No. 2003/0056853 A1, entitled “Router With Improved Safety System,” U.S. Provisional Patent Application Ser. No. 60/406,138, entitled “Miter Saw With Improved Safety System,” and U.S. Provisional Patent Application Ser. No. 60/496,550, entitled “Table Saws With Safety Systems,” the disclosures of which are herein incorporated by reference, describesafety system 18 in the context of particular types of machines. - In the exemplary implementation,
detection subsystem 22 is adapted to detect the dangerous condition of the user coming into contact withblade 40. The detection subsystem includes a sensor assembly, such ascontact detection plates blade 40 to detect any contact between the user's body and the blade. Typically, the blade, or some larger portion of cuttingtool 14 is electrically isolated from the remainder ofmachine 10. Alternatively,detection subsystem 22 may include a different sensor assembly configured to detect contact in other ways, such as optically, resistively, etc. In any event, the detection subsystem is adapted to transmit a signal to controlsubsystem 26 when contact between the user and the blade is detected. Various exemplary embodiments and implementations ofdetection subsystem 22 are described in more detail in U.S. Patent Application Publication No. 2002/0017176 A1, entitled “Detection System For Power Equipment,” U.S. Patent Application Publication No. 2002/0017336 A1, entitled “Apparatus And Method For Detecting Dangerous Conditions In Power Equipment,” U.S. Patent Application Publication No. 2002/0069734 A1, entitled “Contact Detection System for Power Equipment,” U.S. Patent Application Publication No. 2002/0190581 A1, entitled “Apparatus and Method for Detecting Dangerous Conditions in Power Equipment,” U.S. Patent Application Publication No. 2003/0002942 A1, entitled “Discrete Proximity Detection System,” U.S. Patent Application Publication No. 2003/0090224 A1, entitled “Detection System for Power Equipment,” and U.S. Provisional Patent Application Ser. No. 60/533,791, entitled “Improved Detection Systems for Power Equipment,” the disclosures of which are all herein incorporated by reference. -
Control subsystem 26 includes one ormore instruments 48 that are operable by a user to control the motion ofblade 40.Instruments 48 may include start/stop switches, speed controls, direction controls, light-emitting diodes, etc.Control subsystem 26 also includes alogic controller 50 connected to receive the user's inputs viainstruments 48.Logic controller 50 is also connected to receive a contact detection signal fromdetection subsystem 22. Further, the logic controller may be configured to receive inputs from other sources (not shown) such as blade motion sensors, work piece sensors, etc. In any event, the logic controller is configured to controloperative structure 12 in response to the user's inputs throughinstruments 48. However, upon receipt of a contact detection signal fromdetection subsystem 22, the logic controller overrides the control inputs from the user and activatesreaction subsystem 24 to stop the motion of the blade. Various exemplary embodiments and implementations ofcontrol subsystem 26, and components that may be used incontrol system 26, are described in more detail in U.S. Patent Application Publication No, 2002/0020262 A1, entitled “Logic Control For Fast Acting Safety System,” U.S. Patent Application Publication No. 2002/0017178 A1, entitled “Motion Detecting System For Use In Safety System For Power Equipment,” U.S. Patent Application Publication No. 2003/0058121 A1, entitled “Logic Control With Test Mode for Fast-Acting Safety System,” U.S. Provisional Patent Application Ser. No. 60/496,568, entitled “Motion Detecting System for use in a Safety System for Power Equipment,” and U.S. Provisional Patent Application Ser. No. 60/533,598, entitled “Switch Box for Power Tools with Safety Systems,” the disclosures of which are all herein incorporated by reference. - In the exemplary implementation,
brake mechanism 28 includes apawl 60 mounted adjacent the edge ofblade 40 and selectively moveable to engage and grip the teeth of the blade.Pawl 60 may be constructed of any suitable material adapted to engage and stop the blade. As one example, the pawl may be constructed of a relatively high strength thermoplastic material such as polycarbonate, ultrahigh molecular weight polyethylene (UHMW) or Acrylonitrile Butadiene Styrene (ABS), etc., or a metal such as fully annealed aluminum, etc. It will be appreciated that the construction ofpawl 60 may vary depending on the configuration ofblade 40. In any event, the pawl is urged into the blade by a biasing mechanism in the form of aspring 66. In the illustrative embodiment shown inFIG. 2 ,pawl 60 is pivoted into the teeth ofblade 40. It should be understood that sliding or rotary movement ofpawl 60 might also be used. The spring is adapted to urgepawl 60 into the teeth of the blade with sufficient force to grip the blade and quickly bring it to a stop. - The pawl is held away from the edge of the blade by a restraining mechanism in the form of a
fusible member 70. The fusible member is constructed of a suitable material adapted to restrain the pawl against the bias ofspring 66, and also adapted to melt under a determined electrical current density. Examples of suitable materials forfusible member 70 include NiChrome wire, stainless steel wire, etc. The fusible member is connected between the pawl and acontact mount 72. Preferably,fusible member 70 holds the pawl relatively close to the edge of the blade to reduce the distance the pawl must travel to engage the blade. Positioning the pawl relatively close to the edge of the blade reduces the time required for the pawl to engage and stop the blade. Typically, the pawl is held approximately 1/32-inch to ¼-inch from the edge of the blade byfusible member 70, however other pawl-to-blade spacings may also be used. -
Pawl 60 is released from its unactuated, or cocked, position to engageblade 40 by a release mechanism in the form of afiring subsystem 76. The firing subsystem is coupled to contactmount 72, and is configured to meltfusible member 70 by passing a surge of electrical current through the fusible member.Firing subsystem 76 is coupled tologic controller 50 and activated by a signal from the logic controller. When the logic controller receives a contact detection signal fromdetection subsystem 22, the logic controller sends an activation signal to firingsubsystem 76, which meltsfusible member 70, thereby releasing the pawl to stop the blade. Various exemplary embodiments and implementations ofreaction subsystem 24 are described in more detail in U.S. Patent Application Publication No. 2002/0020263 A1, entitled “Firing Subsystem For Use In A Fast-Acting Safety System,” U.S. Patent Application Publication No. 2002/0020271 A1, entitled “Spring-Biased Brake Mechanism for Power Equipment,” U.S. Patent Application Publication No. 2002/0017180 A1, entitled “Brake Mechanism For Power Equipment,” U.S. Patent Application Publication No. 2002/0059853 A1, entitled “Power Saw With Improved Safety System,” U.S. Patent Application Publication No. 2002/0020265 A1, entitled “Translation Stop For Use In Power Equipment,” U.S. Patent Application Publication No. 2003/0005588 A1, entitled “Actuators For Use in Fast-Acting Safety Systems,” and U.S. Patent Application Publication No. 2003/0020336 A1, entitled “Actuators For Use In Fast-Acting Safety Systems,” the disclosures of which are herein incorporated by reference. - It will be appreciated that activation of the brake mechanism will require the replacement of one or more portions of
safety system 18. For example,pawl 60 andfusible member 70 typically must be replaced before the safety system is ready to be used again. Thus, it may be desirable to construct one or more portions ofsafety system 18 in a cartridge that can be easily replaced. For example, in the exemplary implementation depicted inFIG. 2 ,safety system 18 includes areplaceable cartridge 80 having ahousing 82.Pawl 60,spring 66,fusible member 70 and contact mount 72 are all mounted withinhousing 82. Alternatively, other portions ofsafety system 18 may be mounted within the housing. In any event, after the reaction system has been activated, the safety system can be reset by replacingcartridge 80. The portions ofsafety system 18 not mounted within the cartridge may be replaced separately or reused as appropriate. Various exemplary embodiments and implementations of a safety system using a replaceable cartridge, and various brake pawls, are described in more detail in U.S. Patent Application Publication No. 2002/0020261 A1, entitled “Replaceable Brake Mechanism For Power Equipment,” U.S. Patent Application Publication No. 2002/0017182 A1, entitled “Brake Positioning System,” U.S. Patent Application Publication No. 2003/0140749 A1, entitled “Brake Pawls for Power Equipment,” and U.S. Provisional Patent Application Ser. No. 60/496,574, entitled “Brake Cartridges for Power Equipment,” the disclosures of which are herein incorporated by reference. - While one particular implementation of
safety system 18 has been described, it will be appreciated that many variations and modifications are possible. Many such variations and modifications are described in U.S. Patent Application Publication No. 2002/0170399 A1, entitled “Safety Systems for Power Equipment,” U.S. Patent Application Publication No. 2003/0037651, entitled “Safety Systems for Power Equipment,” and U.S. Patent Application Publication No. 2003/0131703 A1, entitled “Apparatus and Method for Detecting Dangerous Conditions in Power Equipment,” the disclosures of which are herein incorporated by reference. -
FIGS. 3 and 4 show areplaceable brake cartridge 100 that may be used inreaction subsystem 24 to stop and/or retract a cutting tool away from the point of accidental contact with a user.Brake cartridge 100 is specifically applicable for use with table saws like those described in U.S. Provisional Patent Application Ser. No. 60/496,550, entitled “Table Saws With Safety Systems and Blade Retraction,” filed Aug. 20, 2003, and with table saws like those described in U.S. Provisional Patent Application Ser. No. 60/533,811, entitled “Improved Table Saws with Safety Systems,” the disclosures of which are herein incorporated by reference. -
FIG. 5 shows a simplified view of a table saw including a table 102 and ablade 104 extending up through the table. The blade is mounted on arotatable arbor 106 that is held in bearings (not shown) mounted in anarbor block 108, as is known in the art. The arbor block is pivotally connected by a pin 11Q to arear trunnion 112. The rear trunnion is connected to afront trunnion 114, and the two trunnions are mounted on front and rear trunnion blocks 116 and 118, respectively. Many components of the table saw have been removed fromFIG. 5 for clarity, including the structure connecting the front and rear trunnions, the motor, the drive belt, the cabinet, the stand, etc. The saw is constructed so that a user may adjust the elevation and tilt of the blade relative to the tabletop as is known in the art or as is disclosed in the references incorporated herein by reference. -
FIG. 5 showscartridge 100 mounted in the table saw onpin 110. The cartridge is held in place by abracket 120 supported bypin 110 and connected toarbor block 108. As can be seen inFIG. 5 ,brake cartridge 100 is positioned close to the perimeter ofblade 104 so that if the detection subsystem in the saw detects a dangerous condition, the brake cartridge can react quickly to engage and stop the blade. The cartridge and bracket are configured so that the position of the cartridge relative to the blade is maintained when the blade elevation or tilt changes. For example, the bracket and cartridge are supported bypin 110 so that the bracket and cartridge can pivot up or down when the arbor block and blade pivot up or down. - As shown in
FIGS. 3 and 4 ,cartridge 100 includes ahousing 122. The housing is typically made from a molded thermoplastic, such as ABS or PCABS, and it encloses various components, as explained below.Housing 122 is made of twohalves -
Cartridge 100 includes anend 128 defining an annular opening that is configured to slide over a pin to mount the cartridge in a saw, such aspin 110 shown inFIG. 5 . The cartridge also includes a tab 130 (shown inFIGS. 3 , 4 and 6) configured to slide over a flange onbracket 120 to help hold the cartridge in place in the saw. -
Brake cartridge 100 also includes abrake pawl 132 designed to engage and stop a spinning blade. Specifically, the pawl is designed to pivot out into contact with the teeth of a spinning blade so that the teeth cut into the pawl and bind, thereby stopping the blade from spinning.Pawl 132 is formed from fully annealed aluminum, which is sufficiently soft for the teeth of a spinning blade to cut into while also being sufficiently strong to stop the blade. However, as stated above, the pawl may be made from a number of materials. It has been found that pawls made from fully annealed aluminum stop the blade significantly faster than pawls made from other materials such as thermoplastic. For example, a pawl made from a thermoplastic such as ABS may stop a 10 inch, 28 tooth blade spinning at approximately 3500 rpms in approximately 5 milliseconds, while a pawl made from fully annealed aluminum may stop the same blade in approximately 2 to 3 milliseconds or less. It has also been learned that pawls made of fully annealed aluminum work significantly better in stopping 200 tooth blades and plywood blades than pawls made from thermoplastic because the aluminum is less likely to collect in the gullets between the teeth of the blade. -
Brake pawl 132 includes anannular aperture 134 that is sized to fit over the outside ofend 128, as shown inFIGS. 3 and 4 . In this manner,brake pawl 132 may pivot aroundend 128. The brake pawl and housing are assembled by insertingend 128 of one half ofhousing 122 intoaperture 134, insertingend 128 of the other half ofhousing 122 into the aperture, and then joining the two halves together. -
End 128 includes aslot 133 that extends completely through the end from one side of the housing to the other. Slot 133 functions to preventpawl 132 from binding onend 128. If debris collects betweenend 128 andpawl 132, or if heat causesend 128 to expand more than the pawl expands so that the brake pawl binds onend 128, then as brake pawl pivots out or away fromhousing 122, end 128 will compress because of the slot and thereby release the pawl. Thus,slot 133 helps insure thatpawl 132 is always able to pivot out into contact with the blade.End 128 also may have a recessed section on its outer surface to minimize any friction betweenend 128 andpawl 132. -
Pawl 132 includes acurved surface 136 configured to match the curvature of the perimeter of a blade. Thus, when the pawl pivots out into contact with the blade, the entire surface will contact the blade at the same time and stop the blade quicker than if only part of the surface contacted the blade. - A plurality of holes, such as
hole 138, are cut intopawl 132 immediately belowsurface 136. These holes create what may be thought of as a collapse zone. The holes make it easier for the teeth of a spinning blade to cut into the pawl and bind. -
Pawl 132 also includes several large holes, such ashole 140. These holes minimize the mass of the pawl so that with a given force the pawl can accelerate into the blade faster. The large holes also create another collapse zone so that the pawl can deform to absorb the energy of the spinning blade. It is desirable for the pawl to absorb the energy of the blade by deforming because otherwise stopping the blade may bend or damage the arbor on which the blade is mounted or the pin on which the cartridge is mounted. -
Pawl 132 may take different shapes for different blades. The pawl shown inFIGS. 3 and 4 is designed for blades with 10 inch diameters. The pawl may be wider and longer for 7 or 8 inch dado blades, for example.FIGS. 62 through 64 show apawl 133 designed for an 8 inch dado stack up to 13/16ths of an inch wide. The pawl is designed to be mounted on a cartridge housing likehousing 122 discussed above. The pawl is thicker and longer so that it is adjacent the perimeter of the dado stack when the cartridge is installed in the saw. -
FIG. 6 showsbrake cartridge 100 with one half of the housing removed so that internal components are visible. These components include anactuator assembly 150 andelectronics 152. -
Actuator assembly 150 is the portion ofcartridge 100 that causespawl 132 to move into the blade upon the detection of a dangerous condition. The actuator assembly includes a coil spring held in compression by a lever pin on a fulcrum. A link extends up through the coil of the spring and over one end of the lever, and a fuse wire is looped over the other end of the lever. When a dangerous condition is detected, a surge of electricity burns the fuse wire, releasing the lever pin. The spring then expands, pushing the pawl out, into the teeth of the spinning blade. -
Actuator assembly 150, and the individual components that make up the assembly, are shown in more detail inFIGS. 7 through 26 . The actuator assembly is shown in cross-section inFIG. 26 . The assembly includes a coil spring 152 (shown inFIG. 26 ) that exerts approximately 150 pounds of force when compressed. Of course, various springs that exert different forces can be used. Generally, the greater the force the faster the actuator, but the more difficult it is to hold the spring in compression and release the spring quickly. -
Compressed spring 152 is housed in aspring housing 154 shown individually inFIG. 18 . The spring housing is a generally cylindrical housing with an interior cavity shaped and sized to accommodatespring 152 and hold the spring stable when compressed. Anannular flange 156 is recessed slightly from the top of the spring housing, with the flange extending inwardly around the inside of the housing, leaving ahole 158. The annular flange defines the bottom of a recess in which is placed a cap 160 (shown individually inFIG. 21 ).Cap 160 may be stamped from sheet metal, and it includes aflat edge 162. The recess in the spring housing includes a corresponding flat edge so that the cap can be placed in the recess in one orientation only.Cap 160 also includes afulcrum 164 having anotch 166. A lever pin 170 (shown individually inFIG. 20 ), made from hardened steel, such as ⅛-inch-diameter music wire, includes anotch 172, and the lever pin is positioned onfulcrum 164 so thatnotch 166 in the fulcrum and notch 172 in the lever pin mesh.Notch 166 in the fulcrum is “V” shaped so that the lever pin will nest intonotch 166. - A link 174 (shown individually in
FIG. 19 ) includes a hardenedsteel wire 176 that is curved to form an inverted “U” shape. The ends of the wire are insert molded into abase 178, and the ends may be kinked or bent to minimize the possibility of the wire pulling out of the base. The wire loop may be made of music wire, and should have a tensile strength sufficient to hold the coil spring in compression over time.Base 178 also may be referred to as a yoke because it spans across a portion ofbrake pawl 132, as shown inFIGS. 3 , 4 and 6. The yoke includes four holes, likehole 180 shown inFIGS. 12 , 14 and 19.Brake pawl 132 includes corresponding holes. Pins or screws are inserted through the holes to join the yoke to the brake pawl. The bottom of the yoke also includes aridge 182 to strengthen the yoke, and the surface of the brake pawl over which the yoke spans is shaped to accommodate the ridge. -
Link 174 is inserted up throughcoil spring 152 and over the end oflever pin 170, as shown inFIG. 26 .Lever pin 170 includes asecond notch 184 over which link 174 extends, and the end oflever pin 170 betweennotches wire 176.Notch 184 is sized and configured so thatlink 174 may come off the lever pin cleanly when the lever pin is released, as explained below. -
Link 174 also includes a raisedcentral portion 186 that helps position the spring relative to the link and helps hold the spring stable when it is compressed, as shown inFIG. 26 . The raised central portion is sized and configured to correspond to the inner dimensions ofcoil spring 152. Raisedcentral portion 186 includes atapered surface 188 that makes it easier to insert the raised central portion into the coil spring. -
Base 178 of the link includes a slightly raised,circular section 190 with atapered edge 192.Section 190 is configured to correspond to the base ofspring housing 154, as shown inFIG. 26 .Tapered edge 192 is configured to mesh with the bottom edge of anut 194, also shown inFIG. 26 . The nut is shown individually inFIG. 22 , and it includesinternal screw threads 196. The bottom ofspring housing 154 includes corresponding,external screw threads 198. - When assembled,
nut 194 is threaded ontospring housing 154, and link 174 is held against the bottom of the spring housing by the lever pin. The nut may then be threaded down until it presses againstbase 178 oflink 174, as shown inFIG. 26 .Nut 194 includes aknurled edge 200 so that the nut can be turned by hand. The nut is threaded down against the base of the link in order to seal the actuator against the entry of dust or other contaminants. A foam, felt, rubber, latex or fabric washer may be inserted and compressed betweennut 194 andbase 178 to further effectuate a seal.Nut 194 also is threaded down againstbase 178 to help hold the compressed spring stable and to take up any play in the linkage between the lever, spring, spring housing, cap, and link resulting from manufacturing tolerances. - A
fuse wire assembly 210 is shown inFIG. 17 , including an inverted “U” shapedwire 212 insert molded into ananchor 214.Wire 212 is a hardened steel wire such as music wire, and the ends of the wire may be kinked or bent to minimize the possibility of the wire pulling out of the anchor.Anchor 214 is shaped to fit into asocket 216 inspring housing 154, and the anchor includesshoulders 218 to help hold the anchor in the socket. - When the fuse wire assembly is initially placed into
socket 216,wire 212 extends up and aroundlever pin 170, as shown inFIGS. 7 through 14 . During assembly of the actuator,wire 212 is twisted above the lever pin and then pulled down over the lever pin and aroundshoulders 220 inspring housing 154, as shown inFIGS. 23 through 26 . (FIGS. 39 and 40 also show how the wire is twisted in the context of an alternative fuse wire assembly.) Twistingwire 212 and pulling it down so that it extends around shoulders 220 causes four strands of the wire to hold down the lever pin.Lever pin 170 includesnotches - When assembled,
actuator 150 holdsspring 152 in compression bylink 174 andfuse wire assembly 210 holdinglever pin 170 onfulcrum 164.Spring 152 and link 174 exert a force tending to pull the lever pin down, but the lever pin is held in place by the fuse wire. The fuse wire is positioned over the lever pin a sufficient distance fromfulcrum 166 in order to provide a mechanical advantage to help hold the lever pin in place. The mechanical advantage allows the fuse wire to be smaller and less strong that it otherwise would have to be. Inactuator 150, the mechanical advantage is approximately 3:1. Thus,notches notch 172 thannotch 184 is fromnotch 172. With a 3:1 mechanical advantage and a spring that exerts a 150-pound force when compressed, the fuse wire would need to hold approximately 50 pounds of force. However, because the fuse wire is twisted so that four strands of the wire together hold the lever down, each strand of wire would need to hold approximately 12 to 13 pounds of force. Music wire of approximately 0.010-inch diameter is believed to have sufficient tensile strength to hold that force. It is advantageous to use a fuse wire with a relatively small diameter because the fuse wire must be fused in order to release the spring and smaller diameter wires are easier to fuse. The mechanical advantage discussed above allows for a small diameter fuse wire to hold a large force. -
Actuator 150 is assembled using a jig that holds the spring in compression whilelever pin 170, link 174 andfuse wire 210 are positioned.Shoulders 220 onspring housing 154 may include a tapered edge 226 (labeled inFIGS. 12 and 18 ) to make it easier to slide the fuse wire onto the shoulders during assembly. The shoulders themselves may be slightly sloped to keep the fuse wire from sliding off the shoulders. The jig is then released, and the spring puts tension on the link and fuse wire to hold the assembly together. When assembled,actuator 150 is quite stable becausespring 152 exerts a significant force onlever pin 170 and because the compressed spring is enclosed inhousing 154. -
Spring housing 154 also includes a raisedflange 228 positioned adjacent the end oflever pin 170, as shown inFIGS. 18 , 23 and 26. Raisedflange 228 functions to preventlever pin 170 from being improperly positioned during assembly. Specifically,flange 228 preventslever pin 170 from being positioned so that it is balanced onfulcrum 164 betweennotch 172 and notch 184. -
Housing 154,link base 178, andfuse wire anchor 214 are typically made from a moldable material that has very little creep, or in other words, is very dimensionally stable over time. It is important that the material be able to maintain its shape and withstand the constant force of the compressed spring on the link and fuse wire. Otherwise, for example, if the shape ofshoulders 220 changed, then the fuse wire could become sufficiently slack so thatlink 174 could slip off the lever pin and accidentally release the spring. The material must also be sufficiently strong so that the fuse wire does not pull out ofanchor 214, and so the link wire does not pull out ofbase 178. The material must also have little moisture absorption and little heat expansion so that the molded parts maintain their shapes and dimensions in various humid, dry, hot or cold climates. In the shown embodiment,housing 154,link base 178 andfuse wire anchor 214 are molded from a phenolic, thermoset material having very little creep. One such material is RX630 from a company called Vyncolit. - In the embodiment shown,
fuse wire assembly 210 is separate fromspring housing 154 to facilitate manufacturing. It is important that the length of fuse wire extending out fromfuse wire anchor 214 be quite precise, otherwise there could be slack in the fuse wire allowing the link to slip off the lever pin. It is easier to make the fuse wire precise if the wire is insert-molded in a separate part. It is also easier to insert the fuse wire into a simple mold such as would be required for the fuse wire anchor. It would be difficult to insert the fuse wire into the mold for the spring housing. Nevertheless, the fuse wire could be insert-molded into the spring housing directly to eliminate the separate fuse wire anchor assembly. - It is also important that the length of
link wire 176 extending out fromlink base 178 be sufficiently precise to prevent the link or fuse wire from slipping free. - Both the fuse and link wires must be sufficiently strong to withstand the tensile loads place on them, respectively. They must also be able to bend into the necessary shapes without breaking.
-
Cap 160 andlever pin 170 must be made of materials sufficiently strong to withstand the loads placed thereon. As stated,cap 160 may be stamped from sheet metal, andlever pin 170 may be machined from hardened steel such as ⅛-inch diameter music wire, for example. -
Nut 194 may be molded from many materials, such as a thermoplastic like ABS. - When assembled,
actuator 150 provides a compact, stable unit. The actuator is cocked and ready to apply a significant force when the fuse wire is severed, as will be explained below. The actuator may remain in its cocked condition for a significant period of time. The actuator is self-contained so that it may be easily placed intobrake cartridge 100. Whileactuator 150 is described in the context of a brake cartridge used in a safety system for power equipment, it is believed thatactuator 150 is a significant improvement in many respects over other actuators, and that there are many other possible uses ofactuator 150. -
FIGS. 27 through 30 show electronics 152 used withactuator 150 inbrake cartridge 100.Electronics 152 include a printedcircuit board 240 on which is mounted various electronic components used in the reaction subsystem described above, includingcapacitor 242. Other components on the circuit board may be those required for a firing circuit, as described above and as described in the references incorporated by reference. -
Circuit board 240 also includes acard edge plug 244 on which would be traces for connecting the electronics to the rest of the saw via a card edge connector.Card edge plug 244 is also shown inFIG. 4 extending out fromhousing 122 of the brake cartridge. The cartridge is electronically connected to other components in the saw by pluggingcard edge plug 244 into a card edge connector mounted in the saw onbracket 120.Cartridge 100 may be sealed aroundcard edge plug 244 by having the card edge extend out of the housing through a piece of foam on the inside wall of the housing, and by having the slot in the housing through which the card edge plug extends be only slightly larger than the card edge plug itself. Of course, various types of plugs may be used in place of a card edge connector. -
Circuit board 240 includes anend 245 shaped to fit into asocket 248 inspring housing 154. (Socket 248 is labeled inFIGS. 18 , 24 and 26.)Socket 248 is configured and positioned relative toshoulders 240 so thatfuse wire 212 spans across the bottom of the socket when the fuse wire is placed aroundshoulders 240.FIGS. 31 through 33 show howend 245 fits intosocket 248.Fuse wire 212 is not shown inFIGS. 31 and 33 in order to show clearly howend 245 fits into the socket. (A fuse wire extending across electrodes is shown inFIG. 46 .) - Two
electrodes circuit board 240 on the side opposite the capacitor. The electrodes are typically formed wires. The electrodes are fitted into the circuit board and electrically connected to the capacitor via conductive traces. When end 245 ofcircuit board 240 is plugged intosocket 248,electrodes FIG. 32 .Fuse wire 212 would then extend over and across the two electrodes so that the fuse wire touches and bridges the electrodes.Socket 248 is configured relative toshoulders 240 on the spring housing, so that when end 245 of the circuit board is inserted into the socket,electrodes Socket 248 may include sloped or shaped surfaces to direct, position and holdend 245 properly in the socket. In this manner,actuator 150 is operatively coupled toelectronics 152. - The coupled
actuator 150 andelectronics 152 may then be dropped into the housing of the brake cartridge. The housing typically would include internal ribs and flanges to position and hold the actuator and electronics in place. - In use, when the detection subsystem detects a dangerous condition, a signal is sent to
electronics 152 in the brakecartridge causing capacitor 242 to discharge to ground by passing current from one electrode to the other throughfuse wire 212. The size of the capacitor is chosen so that the current density discharged to ground is sufficiently high to fuse or break the fuse wire. When the fuse wire breaks,lever pin 170 is freed andspring 152 is released. The spring quickly expands, pushingpawl 132 out into the teeth of the blade. - The configuration of the fuse wire and electrodes as described above allows one break of the fuse wire to release all four strands of the wire holding down the lever pin. The fuse wire then unwraps from over the lever pin as the spring expands. The manner in which the fuse wire is twisted over the lever pin, and the way the fuse wire extends over
shoulders 220 on the spring housing, allows the fuse wire to unwrap cleanly without tangling. - When the fuse wire breaks,
lever pin 170 pivots down aroundfulcrum 164. As shown inFIG. 6 ,cartridge housing 122 includes a dome-shapedsection 254 positionedadjacent lever pin 170 so that the lever pin is free to pivot aroundfulcrum 164 without catching. -
Spring 152 will expand quickly whenfuse wire 212 breaks.Flange 156 andcap 160 provide a surface against which the spring presses when it expands.Housing 122 typically would include ribs and/or flanges to support and securely hold the spring housing in place.Housing 122 also includes atab 130, as discussed above, which helps secure and hold the brake cartridge in the saw.Housing 122 includes ribs, such asribs 256 shown inFIGS. 3 and 4 , to strengthentab 130 so that it can withstand the force of the spring and transfer the force to the bracket holding the cartridge. Using flanges and ribs to strengthentab 130, and securely mounting the cartridge tobracket 120 bytab 130, ensures thatspring 152 pushesbrake pawl 132 out instead of pushing the cartridge back. -
Actuator 150 is capable of applying a significant force very quickly. In the embodiment shown,actuator 50 can supply 150 pounds of force instantly after the fuse wire is fused. This is significant because thequicker actuator 50 can apply the force to move the brake pawl into the spinning blade, the quicker the blade will stop, minimizing any injury. -
Brake cartridge 100 is designed for installation in a right-tilt saw. In other words, the cartridge is designed for a saw where the blade above the table tilts to the right relative to a user standing in front of the saw. The cartridge could be mirrored for a left-tilt saw. - Another brake cartridge is shown in
FIGS. 34 and 35 at 300. Much ofcartridge 300 is similar to previously describedbrake cartridge 100. For example,brake cartridge 300 includes ahousing 302 and abrake pawl 304 joined as described above in connection withcartridge 100. Additionally,housing 302 typically would include a tab liketab 130 shown inFIGS. 3 and 4 , but the tab is not shown in connection withcartridge 300.Cartridge 300 also includes a D-sub plug 303 that may be used instead of the card edge plug described above.Cartridge 300 is also designed for a left-tilt saw instead of a right-tilt saw. Other differences between the two cartridges are discussed below. - The interior of
brake cartridge 300 is shown inFIGS. 36 through 38 , including anactuator 306. The actuator is shown positioned in the cartridge similarly toactuator 150 described above. Ribs, such asribs 308, are shown in the housing to support the actuator and to provide strength to the housing, as discussed above. -
FIG. 39 shows afuse wire assembly 310 used inactuator 306.Fuse wire assembly 310 includes afuse wire 312 insert-molded into ananchor 314.Fuse wire 312 is shown twisted and down, as if it were wrapped over the lever pin and around the shoulders on the spring housing.FIG. 40 shows fusewire 312 withoutanchor 314 so that the ends of the wire are visible. Each end of the fuse wire includesbends 316 that help prevent the wire from pulling out of the anchor. -
Fuse wire 312 is configured to extend over two electrodes on a circuit board so that a surge of electricity can be sent from one electrode to the other through the fuse wire to break the wire, as described above. An electrode used inactuator 306 is shown at 318 inFIGS. 44 and 45 .Electrode 318 is a “U” shaped piece of wire with twoends section 324 extends between ends 320 and 322. - It is important that the fuse wire contact both electrodes. However, if one electrode is soldered on the circuit board higher than the other, then the fuse wire may touch only one electrode. Also, because the electrodes are positioned close to each other on the circuit board, it is also conceivable that the fuse wires may touch or become electrically connected and allow current to pass from one to the other without breaking the fuse wire.
Brake cartridge 300 includes a fuse wire isolator to address these issues. Afuse wire isolator 320 is shown inFIGS. 41 through 43 . -
Fuse wire isolator 320 is a small molded part having twochannels holes 326. The electrodes fit into the channels, and the ends of the electrodes extend through the holes to the circuit board. The channels are configured with sloping side surfaces so that the electrodes are directed into predetermined positions when the electrodes are inserted into the channels. Two sloping surfaces are shown at 328 and 330 inFIG. 43 . The sloping surfaces create a slight bend in the electrodes, as shown at 332 inFIG. 45 . The electrodes may be pre-bent to fit into the channels, or the channels themselves may cause the electrodes to bend. Also, each ofholes 326 has one side that is vertical relative to the bottom of the electrode isolator, and another side that is sloped so that the holes are somewhat cone shaped. The somewhat conical-shaped holes make it easier to insert the electrodes into the holes, and help to direct the electrodes into the proper position, while the narrower terminus of each hole tends to hold the electrode in place.Channels FIG. 43 . When the electrodes are soldered onto the circuit board, the solder will typically extend outward from the electrodes. If the electrodes are positioned too closely, then the solder surrounding one electrode may touch and electrically connect to the solder surrounding another electrode, which could prevent the electrodes from passing current through the fuse wire. Offsetting the electrodes as shown inFIG. 43 permits the electrodes to be positioned closer together than they otherwise could be because the solder pads will be offset. - The fuse wire isolator also includes a
slot 334 extending transversely acrosschannels Fuse wire 312 fits intoslot 334, andslot 334 directs the fuse wire across the electrodes. The fuse wire isolator, includingslot 334, is shaped to hold the electrodes in positions where the fuse wire must contact and extend over both electrodes. The fuse wire isolator may be thought of as creating a path over the electrodes for the fuse wire to follow. -
FIG. 46 shows fusewire isolator 320 mounted on the bottom of a circuit board withfuse wire 312 extending across the electrodes. Several components fromactuator 306 have been removed to show the fuse wire isolator clearly. -
FIG. 47 shows alever pin 340 used inactuator 306.Lever pin 340 includes anotch 342 for the fulcrum,notches Notch 348 inlever pin 340 is more rounded than correspondingnotch 184 inlever pin 170 shown inFIG. 20 . The more rounded notch accommodates the alternative link assembly discussed below. -
FIGS. 49 and 50 show alink assembly 350 used inactuator 306.Link assembly 350 includes alink 352 insert molded into abase 351.Link 352 is a thin, stamped metal part, and is shown isolated inFIG. 48 . The material from which the link is made should be sufficiently strong to withstand the tension and force of the spring when the actuator is assembled. One possible material is 20% cold worked steel or stainless steel. The link includes anaperture 354 that fits overnotch 348 on the lever pin. Using a stampedmetal link 352 instead of a link wire avoids the issue of bending the wire into an inverted “U” shape, which may weaken or even crack the wire at the bend.Link 352 also includesholes 356 that are buried inbase 351 during molding. The material forming the base flows intoholes 356 during molding; thereby minimizing the chance that link 352 will pull out of the base.Base 351 includesholes 358 through which pins or screws are inserted to join the base to the brake pawl, as described above.Holes 358 are somewhat oval shaped to allow for some lateral movement of the base relative to the brake pawl. Lateral movement may result from plastic or thermoset parts such asbase 351 expanding or contracting at rates different from the aluminum brake pawl. -
FIG. 51 shows a top view ofactuator 306.Lever pin 340 is balanced on a fulcrum withlink 352 over one end of the lever andfuse wire 312 over the other end of the link.FIG. 52 is a cross-section side view of assembledactuator 306 taken along the line A-A inFIG. 51 .FIG. 52 shows how the various components fit and work together to form the actuator. -
FIG. 53 shows a foam, felt, rubber, latex orfabric washer 360 that may be placed around the capacitor in the cartridge. The washer shields the capacitor and dampens any vibrations that may adversely affect the capacitor. -
FIG. 54 shows anelectrode 362 used inbrake cartridge 300 to detect whether the spacing between the blade and brake pawl is appropriate. If the spacing is too great, then a more severe injury could result because it would take longer to move the brake pawl into the blade to stop the blade. Also, a user may install a blade in the saw for which the brake cartridge is not designed. For example, a user may inadvertently install an 8-inch blade in a saw that has a brake cartridge designed for a 10-inch blade. In that case, the brake pawl may not be able to reach the blade if an accident occurs. Checking the blade-to-pawl spacing, and allowing the saw to function only if the spacing is within acceptable limits, addresses these issues. -
FIGS. 37 and 38 show electrode 362 mounted incartridge 300.Electrode 362 includes twotabs 364 that are soldered onto the circuit board used in the cartridge. Aportion 366 extends up and away fromtabs 364 and is dimensioned so that it can pass throughslot 367 in the housing, as shown inFIGS. 37 and 38 .Slot 367 may include flanges extending into the cartridge to create a slot longer than the wall thickness of the cartridge housing (as shown inFIG. 55 ). A longer slot provides a better dust seal aroundportion 366. The housing of the cartridge includes an outwardly extendingflange 365 that extends aroundelectrode 362 to protect the electrode and to provide more of a labyrinth seal to prevent dust from entering the cartridge throughslot 367. - The end of the electrode opposite
portion 366 includes a foldedtab 368 that fits intosocket 370 in the housing. Asection 370 of the electrode extends betweenportion 366 andtab 368 outside of the cartridge and between the housing and the brake pawl, as shown.Section 370 is slightly arched to insure it touches the brake pawl when the brake pawl and housing are joined.Section 370 also includes raisedtabs 372 that extend up to contact the brake pawl. When the brake pawl and housing are joined, the tabs will contact the pawl and scrap along the pawl as the pawl pushes the tabs andsection 370 down toward the housing, thereby helping to ensure contact between the electrode and the pawl. - To assemble the cartridge,
electrode 362 is soldered to the circuit board and then the entire circuit board and actuator are placed in one half of the cartridge housing by sliding the electrode intoslot 367 andsocket 370. The other half of the cartridge then closessocket 370 andslot 367, trapping the electrode in place. -
Electrode 362 electrically connects the brake pawl to the electronics in the brake cartridge. That connection, in turn, permits the brake pawl to act as a sensor to detect whether the blade is within a specified distance. As explained above, and as explained in the documents incorporated by reference, an electrical signal is placed on the blade and used by the detection subsystem to detect when a person contacts the blade. That same signal will induce a corresponding signal on the brake pawl because the perimeter of the blade and the surface of the brake pawl will create a capacitive coupling. In other words, the signal on the blade will capacitively induce a signal on the brake pawl. The signal on the brake pawl can then be measured to determine whether the blade is sufficiently close to the pawl. Additional information about detecting blade-to-pawl spacing is set forth in the documents incorporated by reference. -
FIG. 55 shows a smalltactile switch 380 mounted oncircuit board 240 inbrake cartridge 300. The switch includes abutton 382 that is pressed and released to toggle the switch.Switch 380 is used to signal the control subsystem that the brake cartridge is fully installed in the saw. If the cartridge is not fully installed in the saw, the saw will not run. - A
switch contactor 384 is positioned adjacent switch and is designed to move up and down, into and out of contact withbutton 382.Switch contactor 384 is made from a thin piece of sheet metal, and is shown isolated inFIGS. 56 through 58 . The switch contactor includes a foldedtab 386, as shown.Tab 386 is the part of the switch contactor that actuallycontacts button 382.Tab 386 is folded to help insure contact is made withbutton 382, and also to apply a somewhat predetermined and controlled force to the button. The tab will flex when itcontacts button 382 and will prevent too much force from being applied tobutton 382. When flexed, the tab will also urge the spring contactor away frombutton 382. -
Switch contactor 384 is mounted on acam bushing 388.Cam bushing 388 is a somewhat cylindrical part, shown isolated inFIGS. 59 through 61 .Cam bushing 388 includes an annularouter flange 390, and an annular snap-ring 392 distal fromflange 390. The cam bushing is mounted in a bore in the housing of the brake cartridge, as shown inFIGS. 34 and 35 . The bore in the housing is shown inFIG. 82 . The cam bushing is pushed into the bore untilflange 390 abuts the outer surface of the housing and snap-ring flange 392 snaps over a corresponding shoulder in the bore. When installed, the cam bushing may rotate in the bore around its longitudinal axis. - The cam bushing includes an
end 394 that extends into the brake cartridge and on whichswitch contactor 384 is mounted.Switch contactor 384 includes anaperture 396 that fits overend 394 of the cam bushing. The periphery ofaperture 396 includes cam surfaces 398 and 400. Aflange 402 onend 394 of the cam bushing is designed to contact the cam surfaces. - When
cam bushing 388 rotates counterclockwise, as seen inFIG. 55 ,flange 402 will rotate without causing the spring contactor to move untilflange 402contacts cam surface 398. Asflange 402contacts cam surface 398 and continues to rotate,flange 402 will slide over the cam surface and cause the switch contactor to move into contact withswitch 380.Switch contactor 384 includes apertures 404 (labeled inFIGS. 56 and 57 ), which are shaped to fit around pins 406 in the housing. The apertures are oval shaped so that the switch contactor may move up and down, into and out of contact withswitch 380, but not side-to-side.Apertures 404 and pins 406 are positioned around the switch contactor to support the contactor as it moves. The switch contactor is held on the pins, and oncam bushing 388, by the other half of the cartridge housing. Whencam bushing 388 rotates clockwise, as seen inFIG. 55 ,flange 402 will contact and slide alongcam surface 400, causingswitch contactor 384 to move out of contact withswitch 380. In this manner, the switch contactor and cam bushing provide a simple mechanism to convert the rotary movement of the cam bushing into translational motion of the switch contactor. A stop may be incorporated on the cam bushing to limit the distance the bushing rotates. -
Cam bushing 388 includes acentral bore 410. It is intended thatcam bushing 388 be rotated with a pin or key that extends intocentral bore 410, and that the key help secure the cartridge to a bracket in the saw. -
FIGS. 65 through 68 show various views of acartridge 301 mounted on afirst bracket plate 500, which, in turn, is associated with asecond bracket plate 501. The bracket plates are shown isolated inFIGS. 73 through 75 .Bracket plates pin 503adjacent arbor block 502. The bracket plates are spaced apart byspacer 505. -
Cartridge 301 is similar tocartridge 300 described above, except thatcartridge 301 includes atab 504 that fits around ashaft 506 extending throughholes 507 inbracket plates Cartridge 301 also includes a slightly modifiedcam bushing 508 shown inFIGS. 69 and 70 , and a key 510 that extends through the central bore in the bushing to turn the bushing and secure the cartridge to the two bracket plates. The key is shown isolated inFIGS. 71 and 72 .Cam bushing 508 is similar tocam bushing 388 described above, except thatcam bushing 508 includes an internalkey slot 512.Key 510 includes aridge 514 that fits inslot 512 in the bushing.Slot 512 allows key 510 to be inserted in only one orientation. -
Cartridge 301 is mounted in the saw onbrackets cam bushing 508 and throughapertures bracket plates Hole 516 is shaped to accommodateridge 514, as shown inFIG. 74 .Ridge 514 onkey 510 includesslots FIG. 76 , which shows a bottom view of the cartridge installed onbracket plates cam bushing 508 andbracket plates -
Bracket plates arbor 502 by anarbor link 524. The arbor link is shown with other components inFIGS. 65 through 68 , and is shown isolated inFIGS. 77 through 78 .Arbor link 524 is connected tobracket plate 501 byaperture 526 sliding onpin 506, as shown. -
Arbor link 524 includes anelongate aperture 528 configured to receiveend 530 ofkey 510.End 530 is shaped to fit throughaperture 528 when the key is inserted through the cam bushing and bracket plates.End 530 is also tabbed, as shown inFIGS. 71 and 72 , so that when the key is turned, the tabs lock the key in place overaperture 528 and prevent the key from being retracted. The tabs onend 530 include slopedsurfaces 532 to facilitate turning of the key. The length of the key is chosen and the tabs onend 530 are configured so that when the key is fully inserted, turning the key pulls the cartridge, bracket plates and arbor link together. - Additionally, when key 510 is turned,
ridge 514 causescam bushing 508 to turn, which then causes the switch contactor in the cartridge to press a tactile switch such asswitch 380 to indicate the cartridge is in place, as described above. -
Cam bushing 508 also includes atab 540 that is positioned on the outer flange of the bushing and that remains outside the cartridge. Anaperture 542 is positioned inbracket plate 500 so that the cartridge cannot be mounted on the bracket plate unlesstab 540 aligns withaperture 542, andtab 540 cannot align withtab 540 unless the cam bushing is oriented so that the slide contactor in the cartridge is up, out of engagement with the tactile switch in the cartridge. In this manner, the cartridge can only be installed if the tactile switch in the cartridge is off. A user then must insert and turn key 510 to both lock the cartridge in place and press the tactile switch to signal that the cartridge is properly installed. This prevents the saw from being used when the cartridge is not properly installed in the saw.Aperture 542 is shaped to receivetab 540, and to allowtab 540 to turn when key 510 turnscam bushing 508. -
Arbor link 524 is connected to arbor block 502 by abolt 550 that extends through aslot 552 in the arbor link and threads into a hole in the arbor block, as shown inFIG. 65 . Whenbolt 550 is loose, moving the arbor link will cause the bracket plates and cartridge to move toward or away from a blade mounted in the saw. In this manner, the position of the cartridge relative to the perimeter of the blade can be adjusted to account for slight variances in the size of blades. However, that adjustment is limited byaperture 528 and key 510.Key 510 will not align withaperture 528 if the arbor link is moved too much, so the cartridge can be installed only if the arbor link is within an acceptable range of positions. When the arbor link and cartridge are properly positioned relative to the blade,bolt 550 is tightened to hold the arbor link in place. -
Arbor link 524 also includes aslot 554 that is joined to slot 522.Slot 524 allows the arbor link and cartridge to move so that any residual pressure from the spring on the brake pawl after the cartridge has fired can be released. As explained above, when the cartridge fires, the blade cuts into the brake pawl and stops. However, the spring in the cartridge may not be fully expanded so there may be residual spring force pushing the pawl onto the blade. That force should be released before the brake pawl can be knocked off the blade and the spent cartridge replaced. - After the cartridge has fired, key 510 would be withdrawn from the cam bushing and bracket plates to allow the arbor link to move freely.
Bolt 550 would be loosened and arbor link 524 would be moved so thatbolt 550 slides up intoslot 554. The cartridge would then move away from the blade, releasing any residual spring force. The brake pawl can then be knocked off the blade and the spent cartridge replaced. -
FIGS. 79 through 81 show aplug 600 to which the cartridge connects when the cartridge is installed in the saw.Plug 600 includes a female D-sub connector 602 that corresponds to the male D-sub connector incartridge 301. Aplastic casing 604 is molded over and aroundconnector 602. Casing 604 includes fourposts 606 that are designed to fit into correspondingholes 608 inbracket plates bracket plates sockets 610 configured to acceptprojections 612 on the cartridge housing.Projections 612 are shown inFIG. 82 projecting out from one half of the cartridge housing.Projections 612align plug 600 with the corresponding plug on the cartridge as the cartridge is installed in the saw. Plug 600 also includes threecords 614 which connect to the two arbor electrodes in the detection subsystem and to ground. Plug 600 also includes acord 616 that connects to the switch box for the saw. -
Cartridge 300 is sized somewhat wider and taller thancartridge 100, as shown inFIGS. 34 , 55, 66 and 68, in order to accommodate more electronics and a larger printed circuit board. Essentially all of the electronics for the saw are included on the circuit board incartridge 300, including the electronics for the detection subsystem, the control subsystem, blade-to-pawl spacing, the firing circuit, etc. Placing all or substantially all of the electronics in the cartridge provides the significant advantage of being able to update the electronics easily by simply replacing an old cartridge with a new one. For example, the control subsystem in the saw will typically include a microprocessor controlled by software, as described in the documents incorporated by reference, and if that microprocessor or software is ever updated, then the new microprocessor or software can be implemented in existing saws by simply installing a new brake cartridge. The electronics in the cartridge will automatically connect to the power source, on/off switch or switches, arbor electrodes, and other such items, when the cartridge is plugged in. Placing all or substantially all the electronics in the cartridge also minimizes the number of electrical connections and cords required in the saw. It also keeps the detection electronics near the electrodes to, thereby making the system less susceptible to noise. Placing the electronics together in the cartridge also facilitates implementing the electronics as an application specific integrated circuit because all of the electronics will be located in one place. - Another
possible brake cartridge 1000 is shown inFIGS. 83 and 84 .Cartridge 1000 is similar in structure and function tocartridges Key 1002 is shown isolated inFIGS. 86 through 88 . The key includes anarm 1004 that a person may grasp with a hand to turn the key. The key includesridges 1006 that turn a cam bushing, as discussed above in connection withcam bushing 402.Key 1002 also includessurfaces 1010 that are similar tosurface 532 discussed above. -
Cartridge 1000 also includes aprojection 1012 with anaperture 1014. The aperture is designed to receive a pin that helps mount the cartridge in the saw.Aperture 1014 is somewhat oval shaped with the long dimension of the oval extending generally from the left to the right as seen inFIG. 83 . That oval shape provides some clearance to accommodate the pin. However,aperture 1014 is sized to fit the pin closely in the up and down direction as seen inFIG. 83 . A close fit in that direction prevents the cartridge from having play that could cause it to move away from a blade. -
Cartridge 1000 also includesprojections 1016 which help align the cartridge when it is installed in a machine, as discussed above in connection withprojections 612. -
Cartridge 1000 also includes apawl 1020 generally similar to the other pawls discussed above.Pawl 1020 typically would be made of fully annealed aluminum and would mount in the cartridge so that it can pivot into the teeth of a blade. However,pawl 1020 includesholes hole 1022, as seen inFIG. 83 , up and to the right, thereby absorbing much of the energy of impact. -
Hole 1024 is also configured to collapse to absorb the force of impact, especially if the force of impact is more than it typically would be because a user has mounted two blades on the saw, for instance. As seen inFIG. 83 , thecurved bottom 1025 ofhole 1024 will push out and down as the hole collapses untilsolid region 1026 abutssolid region 1028. Configuringhole 1024 so thatsolid regions -
Pawl 1020 also includes ahole 1030 to reduce the mass of the pawl, and holes likehole 1032 that help grip the blade when it cuts into the pawl. -
Holes -
Cam bushing 1008 is shown isolated inFIGS. 89 through 91 . The cam bushing includes atab 1040 so that the bushing can be installed in the cartridge in one way only. The bushing also includesdetents 1042 which mesh with corresponding bumps on the cartridge shell. The detents cause the bushing to “snap” into place when the bushing reaches the limits of its rotation. The detents and corresponding bumps also keep the bushing from rotating during shipping. - A
switch contactor 1044 is shown inFIG. 92 . It is similar to switchcontactor 384 discussed above except that it includesslots -
FIG. 93 shows anelectrode 1050 similar toelectrode 362 discussed above, except thatelectrode 1050 includestabs 1052 with sharp edges to insure better contact with the pawl.Electrode 1050 is used to detect blade-to-pawl spacing, as explained above. -
FIGS. 94 through 96 show acircuit board 1054 and anactuator 1056, similar to the circuit board and actuator shown inFIG. 46 . Afuse wire 1058 associated with the actuator extends acrosselectrodes 1060 on the circuit board, as best seen inFIG. 96 . The embodiment shown inFIGS. 94 through 96 differs from the embodiments discussed previously in that it includes analternative electrode isolator 1062 and a modifiedspring housing 1064. -
Electrode isolator 1062 is shown mounted on a circuit board inFIG. 97 and is shown isolated inFIGS. 98 through 100 . (FIG. 97 also showselectrode 1050, aconnector 1051 and acapacitor 1049.)Spring housing 1064 is shown isolated inFIGS. 101 through 103 . Electrode isolator includes anotch 1064 configured to receivecircuit board 1054, as shown inFIG. 97 . The electrode isolator includes asecond notch 1066 andshoulders 1070 configured to abut againstsurfaces spring housing 1064. The isolator also includeschannels 1074 to hold the electrodes in place, andchannel 1076 to direct the fuse wire across the electrodes, as discussed above. The electrode isolator includes a projectingportion 1078 that provides space for the electrodes. - This embodiment of the electrode isolator effectively forms part of the bottom of the spring housing and
channel 1076 creates the corners around which the fuse wire extends to cross the electrodes. Configuring the electrode isolator to form the corners around which the fuse wire extends simplifies the process of assembling the cartridge. To assemble the cartridge, the electrode isolator and electrodes are mounted on the circuit board and the fuse wire is placed in the spring housing so that the fuse wire extends up away from the spring housing. The fuse wire is then placed inchannel 1076 and the circuit board and electrode isolator are turned to put one twist in the fuse wire. The circuit board is then pulled down untilnotch 1066 andshoulders 170 on the electrode isolator are positioned againstsurfaces channel 1076 forms the corners around which the fuse wire extends. -
FIG. 104 shows analternative lever pin 1080 that may be used in the actuator.Lever pin 1080 is similar tolever pin 340 discussed above except that it includes arounded end 1082. The rounded end provides strength and support for the lever pin and prevents the end of the lever pin from rounding over or compressing slightly because of the force on the pin. -
FIG. 105 shows analternative link 1084 that is similar to link 352 shown inFIG. 48 except thatlink 1084 includesholes 1086 shaped somewhat differently than the corresponding holes inlink 352. It may be that holes 1086 are easier to form during manufacturing. -
FIGS. 105 and 106 show the internal mechanism of a table saw with abrake cartridge 1000 mounted in the saw. The cartridge is mounted on apin 1102, which is the same pin that supportsarbor block 1104. The cartridge is also supported by a bracket mechanism shown in detail inFIGS. 108 through 113 . - A
first plate 1106 and asecond plate 1108 are bolted together but spaced apart bybolts 1110,spacer 1112,pin 1114 andspacer 1116.Pin 1114 extends out fromfirst plate 1106 to extend throughaperture 1014 incartridge 1000.Pin 1114 includes a raisedshoulder 1118 to space the cartridge away from the first plate and to provide a bolt head to hold the first and second plates together. - The first plate also includes
apertures apertures FIG. 74 .Aperture 1120 is configured to receive key 1002 andaperture 1122 is configured to receive a tab oncam bushing 1008, as described above in connection withFIGS. 73 through 75 . - The first and second plates both include
apertures 1123 sized to fit overpin 1102. The plates mount in the saw by sliding onto that pin, as shown inFIG. 108 . -
First plate 1106 also includes anaperture 1124 configured to receive a plug such asplug 600 discussed above.Plug 600 is sandwiched between the first and second plates and held in place by projections on the plug that extend through apertures in the plates, as explained.Plug 600 is free to move slightly between the first and second plates because the apertures that receive the plug are oversized. The plug is able to move slightly so that it may align itself with a cartridge when a cartridge is installed in the saw. The cartridge and plug align becauseprojections 1016 on the cartridge enter intosockets 610 on the plug. - A modified
plug 1130 is shown inFIGS. 114 and 115 . It is similar to plug 604 except that the back side of the plug includes oneprojection 1132 instead of twoprojections 606 as shown inFIG. 80 .Projection 1132 may be sized as shown inFIG. 115 , or it may be enlarged to provide more space to connect the wires to the plug. In other words, ifprojection 1132 is enlarged, then the plastic overmolding from the front of the plug to the back is thicker and that could provide more space to join the wires to the D-Sub connector.Projection 1132 fits into anoversized aperture 1134 insecond plate 1108, as shown inFIGS. 111 and 112 . - Another difference between
plug 1130 and plug 604 is thatwire 1131 extends out and away from the plug at an angle and through a projection 113, as shown. Extending the wire out at an angle provides additional clearance for the wire in some applications. - A
third plate 1140 includes a “U” shapedportion 1142 that connects to the first and second plates by abolt 1144 andspacer 1146, as shown inFIGS. 112 and 113 . The U-shaped portion captures abarrel nut 1148 and ashoulder bolt 1150 is threaded into the barrel nut.Bolt 1150 extends through an aperture in the arbor block and is held in position relative to the arbor block by washers and clips 1152, as shown inFIGS. 108 and 109 . Whenbolt 1150 turns,barrel nut 1148 will move up and down the bolt and cause the brake cartridge mounted on the first and second plates to move closer to or farther from the periphery of a blade supported by the arbor block. -
Third plate 1140 also includes anaperture 1160 that receives the end of key 1004. The size ofaperture 1160 will control how far the brake cartridge can be moved toward or away from the blade because asbarrel nut 1148 moves onbolt 1150,third plate 1140 will pivot aroundbolt 1144 untilaperture 1160 contacts key 1004. - When
cartridge 1000 is spent, there may still be residual spring force pushing the pawl against the blade. It is desirable to release that spring force before changing the cartridge. To release that spring force, key 1004 is removed. When the key is removed,third plate 1140 is free to move further than it otherwise could becauseaperture 1160 will no longer contact the key. Accordingly, the brackets and brake cartridge may move further away from the blade to release any remaining spring pressure in the cartridge. The amount the brackets may move is defined byaperture 1170. Abolt 1172 extends from the second plate throughaperture 1170. The third bracket may move untilaperture 1170contacts bolt 1172.Aperture 1170 is sized to allow the brackets to move away from the blade sufficiently to release any residual spring pressure. - Thus,
FIGS. 109 through 113 show a simple mechanism to mount a brake cartridge in a machine. - The systems, mechanisms and components disclosed herein are applicable to power equipment, and specifically to woodworking equipment such as saws.
- It is believed that the disclosure set forth above encompasses multiple distinct inventions with independent utility. While each of these inventions has been disclosed in its preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the inventions includes all novel and non-obvious combinations and sub-combinations of the various elements, features, functions and/or properties disclosed herein. No single feature, function, element or property of the disclosed embodiments is essential to all of the disclosed inventions. Similarly, where the claims recite “a” or “a first” element of the equivalent thereof, such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements.
- It is believed that the following claims particularly point out certain combinations and sub-combinations that are directed to one of the disclosed inventions and are novel and non-obvious. Inventions embodied in other combinations and sub-combinations of features, functions, elements and/or properties may be claimed through amendment of the present claims or presentation of new claims in this or a related application. Such amended or new claims, whether they are directed to a different invention or directed to the same invention, whether different, broader, narrower or equal in scope to the original claims, are also regarded as included within the subject matter of the inventions of the present disclosure.
Claims (18)
1. A brake cartridge system for use in safety systems for power tools, the system comprising:
a brake cartridge configured to mount in a power tool and adapted to brake a working portion of the power tool when triggered; and
a key adapted to secure the brake cartridge in the power tool.
2. The brake cartridge system of claim 1 , where the brake cartridge includes an aperture through which at least part of the key passes.
3. The brake cartridge system of claim 2 , where the aperture and key are configured so that the key may pass through the aperture in only one orientation.
4. The brake cartridge system of claim 2 , where the key is adapted to turn to lock the brake cartridge in the power tool.
5. The brake cartridge system of claim 4 , where the brake cartridge and key are configured so that the key can turn only when a predetermined portion of the key has passed through the aperture.
6. The brake cartridge system of claim 1 , where the key includes a handle adapted to be grasped by a user.
7. The brake cartridge system of claim 6 , where the handle is configured so that a user may turn the key.
8. A brake cartridge system for use in safety systems for power tools, the system comprising:
a brake cartridge adapted to brake a working portion of the power tool when triggered;
a mounting pin in the power tool; and
an aperture in the brake cartridge configured so that the brake cartridge can be mounted in the saw by sliding on the mounting pin.
9. The brake cartridge system of claim 8 , further comprising a second mounting pin in the power tool and a second aperture in the brake cartridge configured to fit the second mounting pin.
10. The brake cartridge system of claim 9 , where the pins are spaced apart.
11. A brake cartridge system for use in safety systems for power tools, the system comprising:
a brake cartridge adapted to brake a working portion of the power tool when triggered, where the brake cartridge includes a first connector;
a second connector mounted in the power tool adapted to connect to the first connector in the brake cartridge; and
a mechanism to align the two connectors.
12. The brake cartridge system of claim 11 , where the connectors are D-sub connectors.
13. The brake cartridge system of claim 11 , where the mechanism to align the two connectors includes at least one projection and at least one receptacle, one being associated with the first connector and the other being associated with the second connector, where the receptacle is configured to receive the projection, and where the first and second connectors can move relative to each other as the projection is received by the receptacle.
14. A cartridge system for use in safety systems for power tools, the cartridge system comprising:
a cartridge adapted to be installed in a power tool by a user and further adapted to perform a predetermined action when triggered, where the predetermined action causes the deceleration and/or retraction of a working portion of the power tool;
a first connector associated with the cartridge; and
a second connector mounted in the power tool and adapted to connect to the first connector;
where the first and second connectors are configured so that they automatically connect when a user installs the cartridge in the power tool.
15. The cartridge system of claim 14 , where the first and second connectors are D-sub connectors.
16. The cartridge system of claim 14 further comprising a mechanism to align the first and second connectors.
17. The cartridge system of claim 16 , where the mechanism to align the first and second connectors includes at least one projection and at least one receptacle.
18. The cartridge system of claim 17 , where one of the projection and receptacle is associated with the first connector and the other is associated with the second connector, where the receptacle is configured to receive the projection, and where the first and second connectors can move relative to each other as the projection is received by the receptacle.
Priority Applications (1)
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US13/914,343 US20140360819A1 (en) | 2003-12-31 | 2013-06-10 | Brake cartridges and mounting systems for brake cartridges |
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US11/026,006 US8459157B2 (en) | 2003-12-31 | 2004-12-31 | Brake cartridges and mounting systems for brake cartridges |
US13/914,343 US20140360819A1 (en) | 2003-12-31 | 2013-06-10 | Brake cartridges and mounting systems for brake cartridges |
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US13/914,343 Abandoned US20140360819A1 (en) | 2003-12-31 | 2013-06-10 | Brake cartridges and mounting systems for brake cartridges |
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US11/026,006 Active 2030-07-23 US8459157B2 (en) | 1999-10-01 | 2004-12-31 | Brake cartridges and mounting systems for brake cartridges |
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