CN220548087U - Coping tool and electric tool for performing coping cutting - Google Patents

Abstract

A coping tool and a power tool for performing coping cutting, the power tool for performing coping cutting includes a main housing, a motor disposed in the main housing, a drive shaft driven by the motor around a rotation axis, a handle extending from the main housing, and a grinding disc coupled around the rotation axis and driven by the drive shaft. The motor is an external rotor brushless dc motor capable of rotating at a speed of 4000 surface feet per minute with a torque of 1.5 in lbs.

Description

Coping tool and electric tool for performing coping cutting

Cross Reference to Related Applications

The present application claims priority from U.S. provisional patent application Ser. No. 63/486,302, U.S. provisional patent application Ser. No. 63/386, 038, U.S. provisional patent application Ser. No. 63/398,073, U.S. provisional patent application Ser. No. 63/348,548, U.S. provisional patent application Ser. No. 63/398,073, and U.S. provisional patent application Ser. No. 63/348,548, U.S. provisional patent application Ser. No. 3, 2022, and 2022, all of which are incorporated herein by reference.

Technical Field

The present utility model relates to a power tool, and more particularly to a countermeasure tool.

Background

The pair is a technique for connecting two pieces of wood pieces at various angles. This technique involves removing material along the contour of the leading edge of the trim, which has proven to be effective when the corners are not square.

Disclosure of Invention

The present utility model provides in a technical aspect a power tool for performing a countermeasure cut, including a main housing, a motor disposed within the main housing, a drive shaft driven by the motor about a rotational axis, a handle extending from the main housing, and a grinding disc coupled to and driven by the drive shaft about the rotational axis. The motor is an external rotor brushless dc motor capable of rotating at a speed of 4000 surface feet per minute with a torque of 1.5 in lbs.

The power tool also includes a battery removably coupled to the handle and configured to provide power to the motor.

The power tool also includes a tool chuck on the drive shaft for receiving the abrasive disc such that the drive shaft provides a direct drive from the motor to the abrasive disc.

The power tool also includes a fan disposed within the main housing between the abrasive disc and the motor, wherein the fan is driven by the drive shaft to generate an air flow.

The fan is coupled to the drive shaft.

The fan is connected with the main shaft of the millstone.

The fan is integrated with the abrasive disc.

The power tool also includes a dust cap coupled with the main housing and disposed at least partially around the abrasive disc.

In the power tool, the air flow generated by the fan flows into the dust cap, bypasses the abrasive disc, and passes through an outlet in fluid communication with the dust collector.

In the power tool, the dust cap includes a cutting zone opening at which the abrasive disc is exposed, allowing the workpiece to pass through and engage the abrasive disc.

The dust cap includes a movable section operable to change the size and/or shape of the cutting zone opening.

The present utility model provides, in another aspect, a handling tool including a main housing, a motor disposed within the main housing that rotates about a rotational axis, a handle extending from the main housing, a grinding disc coupled to and driven by a drive shaft about the rotational axis, and a dust cover coupled to the main housing and disposed at least partially around the grinding disc. The dust cap includes a channel extending along the dust cap adjacent the abrasive disc and a cutting zone opening through which a workpiece may be engaged with the abrasive disc. The channel is U-shaped and surrounds the periphery of the grinding disc. The size and/or shape of the cutting zone opening may be adjustable to accommodate the workpiece.

In this coping tool, dust and debris are generated from the workpiece during the coping operation, which travels tangentially from the abrasive disc to the passage of the dust cap and towards an outlet in fluid communication with the dust collector.

In the counter tool, the dust cap includes a plurality of movable segments operable to change the size and/or shape of the cutting zone opening.

In the counter tool, the plurality of movable segments are movable between a first position in which the abrasive disc substantially covers and a second position in which the abrasive disc is at least partially exposed, wherein the plurality of movable segments are biased toward the first position.

In this counter tool, a plurality of movable segments are telescopically coupled together and nested within one another when moved to the second position.

The present utility model provides, in another aspect, a handling tool including a main housing, a motor disposed within the main housing that rotates about a rotational axis, a handle extending from the main housing, a abrasive disc coupled to and driven by a drive shaft about the rotational axis, a fan disposed within the main housing and configured to generate an airflow, and a dust cover pivotally connected to the main housing and disposed at least partially around the abrasive disc. The dust cap includes a channel extending along the dust cap and a cutting zone opening through which a workpiece may engage the abrasive disc. The size and/or shape of the cutting zone opening may be adjusted in response to rotation of the dust cap between the first position and the second position.

In this counter tool, the channel is U-shaped and surrounds the periphery of the abrasive disc.

In the counter tool, the dust cap is adjacent the abrasive disc in a first position such that the channel receives the abrasive disc, wherein the dust cap is spaced from the abrasive disc in a second position, and wherein the dust cap is biased toward the first position.

In the handling tool, dust and debris generated from the workpiece during handling operations passes through the passageway of the dust cap and along the airflow to an outlet in fluid communication with the dust collector.

Other features and aspects of the present utility model will become apparent by consideration of the following detailed description and accompanying drawings.

Drawings

Fig. 1 is a perspective view of a coping system according to one embodiment of the utility model.

Fig. 2 is a side view of a portion of the coping system as shown in fig. 1.

Fig. 3 is a perspective view of a handling system according to another embodiment of the present utility model.

Fig. 4 is another perspective view of the handling system shown in fig. 3, showing the handling system coupled to a saw frame.

Fig. 5A is a top view of the countermeasure system shown in fig. 3 in a first position.

Fig. 5B is a top view of the countermeasure system shown in fig. 3 in a second position.

Fig. 6 is a front perspective view of a coping system according to another embodiment of the utility model.

Fig. 7 is another perspective view of the coping system as shown in fig. 6.

FIG. 8 is an enlarged perspective view of a cutting accessory for a countermeasure tool for use with the countermeasure system shown in FIG. 6, in accordance with an embodiment of the utility model.

Fig. 9 is a side view of a cutting accessory for a coping tool for use with the coping system as shown in fig. 6 according to another embodiment of the utility model.

Fig. 10 is a top view of a workpiece with a counter cut.

Fig. 11 is a perspective view of a handling system according to another embodiment of the present utility model.

Fig. 12 is a top view of a joystick device for use with the countermeasure system shown in fig. 11.

Fig. 13 is a perspective view of a coping system according to another embodiment of the utility model, showing a coping tool having a barrel-shaped handle.

Fig. 14A is a perspective view of the coping system as shown in fig. 13, showing the coping tool with a palm grinder handle.

Fig. 14B is a perspective view of the coping system as shown in fig. 13, showing the coping tool with a compact or low-level handle.

Fig. 14C is a perspective view of the coping system as shown in fig. 13, showing the coping tool having a pistol grip.

Fig. 14D is a perspective view of the coping system as shown in fig. 13, showing the coping tool having the tilting handle.

Fig. 14E is a perspective view of the handling system as shown in fig. 13, showing a handling tool having wing handles.

Fig. 15 is a perspective view of the countermeasure system shown in fig. 13, showing the motor housing coupled to the barrel handle.

Fig. 16A is a cross-sectional view of the countermeasure system taken along line 16A-16A as shown in fig. 15, showing the drive mechanism at least partially disposed within the motor housing.

FIG. 16B is a cross-sectional view of the countermeasure system taken along line 16B-16B as shown in FIG. 15, showing the drive mechanism and airflow passage at least partially disposed within the motor housing.

Fig. 17 is a side view of the handling system as shown in fig. 13, showing the motor axis and the work piece support plane defined by the motor housing.

Fig. 18 is an enlarged front view of the handling system shown in fig. 13, showing the first and second support surfaces angled relative to the workpiece support plane.

Fig. 19A is a perspective view of a coping system according to another embodiment of the utility model showing a coping tool having a sanding plate proximate a handle.

Fig. 19B is a view of a sanding disc for use with the coping system as shown in fig. 19A in accordance with another embodiment of the present utility model.

FIG. 20 is a perspective view of a coping system according to another embodiment of the utility model showing a coping tool having a cutting accessory and a dust cap surrounding a portion of the cutting accessory for collecting dust and debris.

Fig. 21 is a sectional view of the countermeasure system along line 21-21 as shown in fig. 20, showing the outer rotor BLDC motor.

FIG. 22 is another perspective view of the countermeasure system as shown in FIG. 20, showing the dust cap including a series of movable segments.

Fig. 23 is another cross-sectional view of the handling system shown in fig. 20, showing a fan connected to a cutting accessory.

FIG. 24 is a perspective view of a coping system according to another embodiment of the utility model, showing a coping tool having a cutting accessory and a dust cover pivoted relative to the cutting accessory.

Figure 25 is a cross-sectional view of the handling system taken along line 25-25 as shown in figure 24, showing the dust cap in a first position.

Figure 26 is a cross-sectional view of the handling system taken along line 25-25 as shown in figure 24, showing the dust cap in a second position.

FIG. 27 is a perspective view of a countermeasure system according to another embodiment of the utility model showing a countermeasure tool having a sanded band near a handle and a vacuum shroud for dust and debris removal.

FIG. 28 is another perspective view of the handling system shown in FIG. 27, showing a belt assembly driving the sand light strip to expose the cut area.

Fig. 29A is a perspective view of a handling system according to another embodiment of the present utility model.

Fig. 29B is a plan view of a rough gauge for the coping system as shown in fig. 29A.

Fig. 29C is a top view of the coping system shown in fig. 29A on the stand.

Fig. 29D is a plan view of a template guide for the coping system as shown in fig. 29A.

Fig. 30 is a perspective view of a handling system according to another embodiment of the present utility model.

Fig. 31 is a perspective view of the handling system as shown in fig. 30, showing a workpiece analyzed by a sensor of the handling system.

Fig. 32 is an enlarged view of the coping system as shown in fig. 30, showing coping operations automatically performed on the workpiece.

Before any embodiments of the disclosure are explained in detail, it is to be understood that the embodiments described herein are not limited in scope or application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The devices described herein are capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

Detailed Description

Fig. 1 illustrates a coping system 10 for coping with cuts 14 (e.g., base plate, trim, crown molding, etc.) on a workpiece 18. The handling system 10 includes a frame 22 having a table 26 for securing a workpiece 18 by a clamp 30 and a base 29 to which a pivot mechanism 34 is secured. As shown in fig. 1 and 2, the pivot mechanism 34 includes a base portion 38 secured to the base 29, a rotating portion 42 having a support bar 46 extending outwardly from the rotating portion 42, and an accessory portion 50 connectable to a counter tool 54 (e.g., a die grinder, sander, etc.). The counter tool 54 rotatably drives a cutting accessory 58 (e.g., a sand disc, milling cutter head, etc.) for performing a counter cut 14 on the workpiece 18.

Referring to fig. 2, the pivot mechanism 34 constrains the counter tool 54 to remain a fixed distance from the frame 22 (e.g., the length of the support bar 46) so that a user can make the cut of the counter tool 14 on the workpiece 18 consistent. The coping system 10 allows the user to rotate the support bar 46 about the pivot path 62 and ultimately rotate the coping tool 54 while preventing translational movement of the coping tool 54 along the length of the support bar 46. Further, the attachment portion 50 of the pivot mechanism 34 allows the user to rotate the counter tool 54 360 degrees about the support rod 46 to allow the user to precisely manipulate the counter tool 54 relative to the workpiece 18. Briefly, the swivel portion 42 of the illustrated embodiment is a ball joint that allows unrestricted rotation and swiveling of the support bar 46 relative to the base portion 38. In some embodiments, the counter-tool 54 may be oriented toward or away from the pivot mechanism 34 along the support bar 46 (e.g., via a telescoping mechanism, a sliding mechanism, etc.) such that the counter-tool 54 is not at a fixed distance from the pivot mechanism 34.

Fig. 3-5B illustrate an alternate embodiment of a countermeasure system 1110 similar to that of fig. 1-2, with the differences described below. The handling system 10 includes a ball joint pivot mechanism 34, while the handling system 1110 includes a pivot mechanism 1134 comprised of a plurality of pivot joints, some of which are spring assisted to support the weight of the tool. Similar components and features to the coping system 10 of fig. 1 will be added with "1100".

Referring to fig. 3 and 4, the illustrated embodiment of the coping system 1110 includes a frame 1122 coupled to an equipment support 1129 (e.g., saw frame, table, etc.) and a coping tool 1154 movably supported relative to the frame 1122. Frame 1122 is an adjustable frame such that the width and height of frame 1122 may be varied to accommodate various workpieces 1118 relative to equipment support 1129. Frame 1122 includes a clamp 1130 that is disposed over device support 1129 and counter-tool 1154. The clamp 1130 is configured to securely clamp the workpiece 1118 relative to the frame 1122 during a handling operation. The handling system 1110 further includes a pivot mechanism 1134 having a base portion 1138, a first pivot joint 1140 defining a first pivot axis P1, a second pivot joint 1142 defining a second pivot axis P2, and a third pivot joint 1144 defining a third pivot axis P3. Base portion 1138 couples frame 1122 to device support 1129. The first pivot joint 1140 is coupled to the second pivot joint 1142 by an elongated plate 1145, and the second pivot joint 1142 is coupled to the third pivot joint 1144 by a bracket 1147. The first pivot axis P1 is parallel to the second pivot axis P2, and the third pivot axis P3 is perpendicular to the first and second pivot axes P1, P2. The support rod 1146 couples the counter-tool 1154 to the pivot mechanism 1134.

Some advantages of the pivot mechanism 1134 include enabling the user to position the coping tool 1154 substantially perpendicular to the coping path C1 (as in fig. 5A and 5B) so that the user can make the appropriate coping cut 1114. As shown in fig. 5B, the rotation center 1139 of the pivot axes P2 and P3 is moved in three-dimensional space by the joints 1140, 1142, 1144, thereby realizing that the rotation center 1139 is perpendicular to the coping path C1. Further, with multiple degrees of freedom, the pivot mechanism 1134 can enable the counter path C2 of the counter knife 1154 to follow the counter path C1 more closely.

With continued reference to fig. 3 and 4, the third pivot joint 1144 includes a spring damper system 1150 to counteract the weight of the counter-tool 1154 relative to the user, thereby reducing fatigue of the user over time. That is, the spring-damper system 1150 is capable of biasing the counter-tool 1154 upwardly toward the workpiece 1118. In addition, the spring damper system 1150 also can dampen movement of the counter tool 1154 to allow for more accurate cutting. In other words, the spring-damper system 1150 may slightly resist or slow the movement of the counter-tool 1154 as the user attempts to move the counter-tool 1154 relative to the workpiece 1118.

Fig. 6-8 illustrate a countermeasure system 110 according to an alternative embodiment. Components and features similar to the coping system 10 of fig. 1 will be added with "100". The handling system 110 includes a table 126, the table 126 having a guide rail 128 for guiding the workpiece 118 (e.g., a substrate) and a clamp 130 for securing the workpiece 118 on the table 126 so that a user can accurately handle the cut 14 on the workpiece 118. The coping system 110 further includes a gantry 170 mounted to the table 126 by a plurality of mounting brackets 172 disposed on opposite sides of the table 126 and a coping tool 154 (e.g., router, jig saw, etc.) having a cutting accessory 158, the cutting accessory 158 being mounted to the gantry 170 by the connection portion 150. The illustrated cutting accessory 158 is a router bit, while in other embodiments the cutting accessory 158 may be a drill bit, a fluted bit, or a cutting blade, as described in further detail below. The portal frame 170 includes one or more horizontal members 174 (fig. 7) extending along a pair of axes 180 and a plurality of vertical members 178, the plurality of vertical members 178 extending obliquely relative to the one or more horizontal members 174 along a lancing axis 184. The counter tool 154 may be slidably mounted on the horizontal member 174 of the gantry 170 via the connection portion 150 such that a user can translate the counter tool 154 along the counter axis 180 relative to the workpiece 118.

In addition to translating the counter tool 154 along the counter axis 180, the user may also adjust the depth of cut by sliding the counter tool 154 along a cutting axis 184 (fig. 6) relative to the workpiece 118 for fine tuning of the counter cut 114. The counter tool 154 may be slid along the vertical member 178 toward or away from the workpiece 118 to adjust the depth of plunge according to the depth of plunge selected by the user. By limiting translational movement of the counter tool 154 and the cutting accessory 158 along the counter axis 180, a user can minimize fatigue from moving the counter tool 154 in multiple planes while minimizing the number of macro adjustments of the depth of cut along the cut-in axis 184 and the angle of the cutting accessory 158, resulting in a more consistent and accurate counter cut 114. Accordingly, the handling tool 154 may be maneuvered along both the horizontal member 174 and the vertical member 178, allowing a user to precisely handle the cut 114 along the workpiece 118 via the cutting accessory 158.

As shown in fig. 9, the cutting accessory 158 may alternatively be a cutting blade 158' for handling the tool 154. The cutting blade 158' is driven by the counter tool 154 in a reciprocating manner to make a counter cut 114' on the workpiece 118 '. The cutting blade 158' has a first face 186, a second face 188, and an accessory portion 190. The first face 186 of the cutting blade 158' includes a first plurality of teeth 191 extending along the first face 186. The second face 188 of the cutting blade 158' includes a cutting portion 193, the cutting portion 193 including a second plurality of teeth 192 and a flat portion 194 devoid of any teeth. The first plurality of teeth 191 may have a different pitch and direction than the second plurality of teeth 192. During coping cuts 114', the user manipulates the coping tool 154 through the workpiece 118 (fig. 10) in a first direction 195 such that the first plurality of teeth 191 of the first face 186 engage the workpiece 118 to make the coping cuts 114'. Depending on the geometry of the coping cut 114', the user may need to move the cutting blade 158' in a second direction 197, e.g., opposite the first direction 195. When moving in the second direction 197, the user may use the cut portion 193 or the planar portion 194 of the second face 188. If the cutting portion 193 is engaged with the workpiece 118', the cutting blade 158' removes material in the second direction 197, thereby changing the geometry of the countering cut 114'. If the planar portion 194 is used, the cutting blade 158 'is inhibited from removing material in the second direction 197 to maintain the existing geometry that should account for the cut 114'.

Fig. 11-12 illustrate a response system 210 according to an alternative embodiment. The same components and features as the coping system of fig. 1 will be added with "200". The handling system 210 includes a gantry 270 for supporting the frame 222, the frame 222 having a table 226 with a plurality of rails 228 thereon for guiding the positioning of the workpiece 218 (e.g., substrate) for handling the cut 214 by a user. The coping system 210 also includes a linkage 300 for positioning a coping tool (e.g., a saw having a saw blade, not shown) relative to the workpiece 218 for coping with the cut 214. The linkage 300 includes a plurality of links 303 having user inputs 304 configured as joysticks, output pivot points 308 fixed to saw slide (not shown) configured to manipulate the counter tool and saw blade relative to the workpiece 218 in response to movement from the user inputs 304, and fixed pivot points 312 fixed to the gantry 270.

With respect to fig. 11, linkage 300 is configured as a pantograph. The pantograph typically includes a mechanical linkage that is dependent on user input, the device tracking user input in the input path and generating a scaled copy of the same of the input path in a scaled output path on the auxiliary output side. In coping with system 310, a user applies a force to user input 304 along input path 306 that rotates link 303 about fixed pivot point 312 on gantry 270 and tracks a scaled version of input path 306 into output path 318 through output pivot point 308. The output pivot point 308 moves the saw slide directly according to the output path 318, and then the saw blade moves relative to the work piece 218 in response to movement from the user input 304. In some embodiments, the scaling factor of input path 306 relative to output path 318 may be 3:1.

By configuring linkage 300 as a pantograph, linkage 300 improves user control of the tool by reducing the complex motions required for the response. In particular, the user can move the user input 304 three times the distance that the saw blade actually travels. For example, the user input 304 has a travel distance of 3/16 inch when the user moves 1/16 inch on the output pivot point 308 and makes a subsequent cut on the workpiece 218. The additional distance on the user input 304 of the linkage 300 allows the output pivot point 308 to be more accurate, enabling the countermeasure cut 214 to be performed with accuracy. In addition, pantograph linkage 300 reduces the force that the user needs to apply to the saw slide to overcome stiction. Specifically, the magnitude of the force is reduced by a scaling factor (e.g., 3:1) of the linkage 300. For example, in the coping system 210, the 1.5 pound force applied by the user to the user input 304 is reduced by a factor of 3:1, which translates to 0.5 pound force applied to the saw slide. This is advantageous because moving the saw slide against static friction can cause the slide to jerk to one side, potentially damaging the work piece 218 and preventing it from properly joining together with an adjacent work piece 218.

Fig. 13-18 illustrate a response tool 410 according to an alternative embodiment. As shown in fig. 13, the coping tool 410 includes a main housing 412 defining a handle 416, and a trigger assembly 420 disposed on the handle 416. In the illustrated embodiment, the handle 416 is configured as a barrel handle, while in other embodiments, the handle 416 may alternatively be a palm sander handle (fig. 14A), a compact or low-position handle (fig. 14B), a pistol handle (fig. 14C), a tilt handle (fig. 14D), a wing handle (fig. 14E), or other style handle. The trigger assembly 420 allows a user to control the speed of the drive mechanism 424 by varying the degree of actuation of the trigger assembly 420 (fig. 16). The coping tool 410 also includes a rechargeable battery pack 428 that supplies power to the drive mechanism 424 (fig. 13). In the illustrated embodiment, the drive mechanism 424 is a rotary drive mechanism. In other embodiments, the drive mechanism 424 may alternatively be a reciprocating drive mechanism. The battery pack 428 may include any of a number of different nominal voltages (e.g., 12V, 18V, etc.) and may be configured to have any of a number of different chemical compositions (e.g., lithium ions, nickel cadmium, etc.). In an alternative embodiment (not shown), the drive mechanism 424 may be powered by a remote power source (e.g., a household power outlet) via a power cord. The main housing 412 also houses control electronics (e.g., PCBA, micro-switch, etc.).

Referring to fig. 15 and 16A-B, the coping tool 410 further includes a motor housing 430 coupled to the main housing 412. The motor housing 430 houses the drive mechanism 424 and includes a foot 434 on which a workpiece can slide and a support arm 438 extending from the foot 434. 16A-B, the drive mechanism 424 includes a motor 442 (e.g., an outer rotor BLDC motor, an inner rotor BLDC motor, etc.), a motor shaft 446 driven by the motor 442, a fan 444 disposed on the motor shaft 446, a tool chuck 450 disposed at a distal end of the motor shaft 446, and a cutting accessory 458 (e.g., a milling head, a drill bit, a router bit, etc.) removably coupled to the tool chuck 450. The motor 442, motor shaft 446, and cutting accessory 458 are all coaxially aligned along a rotational axis R1. In the illustrated embodiment, cutting accessory 458 is a milling head capable of removing material in a plane perpendicular to its axis of rotation R1. The fan 444 is configured to rotate with the motor shaft 446 and to generate an air flow 448 as the motor 442 rotates. Leg 434 includes an air flow channel 472 to direct air flow 448 generated by fan 470 to outlet 452. An air flow channel 472 extends from the rear of the leg 434 through the support arm 438 as shown in fig. 16B. Outlet 452 is positioned at rotational axis R1 and directs air flow 448 onto workpiece 418. The air flow 448 dissipates dust and debris generated during handling operations and provides a clear view of the workpiece 418 to the user.

With continued reference to fig. 15 and 16A-B, one end of the cutting accessory 458 is coupled to the tool chuck 450 and the other end of the cutting accessory 458 is rotatably supported by the support arm 438 through the ball bearing 460. The ball bearing 460 inhibits the cutting accessory 458 from deviating from the rotational axis R1 when a force is applied perpendicular to the cutting accessory 458. In other words, during a cutting operation, work piece 418 applies a force to cutting accessory 458 that is perpendicular to rotational axis R1, and support arm 438 maintains alignment of cutting accessory 458 with rotational axis R1, thereby reducing tool bit chatter and improving counter-measure cut 414 (fig. 14C). In addition, the support arm 438 protects the user from inadvertently touching the distal end or side of the cutting accessory 458. In other embodiments, the cutting accessory 458 may be a cutting blade 158' that is driven in a reciprocating manner.

As shown in fig. 17 and 18, leg 434 includes a first bearing surface 462 and a second bearing surface 466. In the illustrated embodiment, first support surface 462 and second support surface 466 are angled relative to each other such that leg 434 is not a continuous planar surface (although it may be in some embodiments). Specifically, both the first support surface 462 and the second support surface 466 are inclined downward with respect to the horizontal reference plane W1. That is, the first support surface 462 forms a first angle A1 relative to the plane W1 and the second support surface 466 forms a second angle A2 relative to the plane W1. In the illustrated embodiment, the first angle A1 and the second angle A2 are each 5 degrees, while in other embodiments, the first angle A1 and the second angle A2 may have other equal or unequal values. Additionally, in other embodiments, the first and second support surfaces 462, 466 may be rotatable relative to the plane W1 such that the first and second angles A1, A2 are adjustable, for example, by a detent mechanism, a sliding mechanism, or other similar mechanism. Thus, the first and second support surfaces 462, 466 may be movable or pivotable to adjust the first and second angles A1, A2 infinitely or discretely relative to the plane W1.

With continued reference to fig. 17 and 18, leg 434 is fixed relative to rotational axis R1 of cutting accessory 458. In other embodiments, leg 434 may instead pivot to change angle A3 (FIG. 17) relative to rotational axis R1. The angle A3 may be changed by a stop mechanism or other similar mechanism to move between preset values, such as 90 degrees, 52 degrees, 45 degrees, or 38 degrees. In other embodiments, leg 434 can be adjusted to an infinite number of positions to change angle A3 relative to rotational axis R1.

During operation, work piece 418 may be supported by first support surface 462 or second support surface 466 to facilitate a preferred counter-measure cut 414 along one end of work piece 418 so that work piece 418 may be properly abutted against adjacent work piece 418. The user may then cut along the length of work piece 418 so that work piece 418 can properly abut a wall or ceiling. Of course, one advantage of handling system 10 is that a significant amount of material should be removed from work piece 418 by cut 414, and grinding work piece 418 requires multiple passes along work piece 418 and creates more dust and debris. Thus, the handling tool 410 saves time for the user.

Fig. 19A illustrates a counter tool 510 according to an alternative embodiment. As shown in fig. 19A, the counter tool 510 includes a main housing 512 defining a handle 516, a trigger assembly 520 disposed on the handle 516, and a motor housing 530 coupled to the main housing 512. The trigger assembly 520 allows a user to control the speed of the motor 542 (e.g., outer rotor BLDC motor, inner rotor BLDC motor, etc.) by varying the degree of actuation of the trigger assembly 520. The counter tool 510 also includes a rechargeable battery pack 528 that powers the motor 542. The battery 528 may include any of a number of different nominal voltages (e.g., 12V, 18V, etc.) and may be configured to have any of a number of different chemical compositions (e.g., lithium ions, nickel cadmium, etc.). The main housing 512 also houses control electronics (e.g., PCBA, micro-switch, etc.) that control the operation of the motor 542.

Some advantages of employing an outer rotor BLDC motor over an inner rotor BLDC motor are that the outer rotor motor provides the desired (and in some cases increased) speed and torque output with less footprint. For example, an external rotor BLDC motor may provide a speed of 4000 surface feet per minute at a torque of 1.5 in lbs. This speed may be achieved when a three inch diameter cutting accessory 558 is used. In addition, the length of the outer rotor motor tends to be shorter than that of a conventional inner rotor motor.

With continued reference to fig. 19A, the motor shaft 546 is driven by a motor 542 and includes a tool chuck 550 disposed at a distal end of the motor shaft 546. A cutting accessory 558 (e.g., a sand disk, a router bit, etc.) is removably coupled to the tool chuck 550. In the illustrated embodiment, the cutting accessory 558 is a sanding disc capable of removing material in a plane perpendicular to its axis of rotation R1. The motor 542, motor shaft 546, and cutting accessory 558 are all coaxially aligned along the rotational axis R1. The counter tool 510 also includes a foot 534 that can support a workpiece. In particular, the workpiece may rest against the leg 534 during the cutting operation. Legs 534 extend from main housing 512 and are disposed adjacent at least a portion of the outer circumference of cutting accessory 558. Leg 534 is also disposed between trigger assembly 520 and cutting accessory 558 and protects the user from inadvertent contact with cutting accessory 558. In this arrangement, the cutting accessory 558 is advantageously positioned adjacent the handle 516 and trigger assembly 520, which increases control of the tool 510 relative to a workpiece.

Fig. 19B illustrates a cutting accessory 560 according to another embodiment of the present utility model. The cutting accessory 560 is a sanding disk similar to the cutting accessory 558 but also includes a cutting edge 562. Specifically, cutting edge 562 is disposed at the outer periphery of cutting accessory 560, and abrasive region 564 is disposed radially inward from cutting edge 562 and extends to aperture 566. In other words, the abrasive region 564 is disposed radially outward from the aperture 566, and the cutting edge 562 is disposed radially outward from the abrasive region 564 to the outer periphery of the cutting accessory 560. The two faces of the cutting accessory 560 are identical such that each face includes a cutting edge 562 and an abrasive region 564. This allows the user to use both sides of the cutting accessory 560 during handling operations, while the minimal amplitude of operation corresponds to the tool 510. A plurality of notches 568 are provided along the outer periphery of cutting accessory 560 to facilitate cutting of a workpiece and cooling of cutting edge 562. The aperture 566 can receive the tool chuck 550 and a fastener can be threadably coupled to the tool chuck 550 to clamp the cutting accessory 560 to the tool chuck 550 for rotation therewith. The fastener clamps onto the bearing area 570 adjacent the aperture 566. Cutting edge 562 is comprised of a first material and abrasive region 564 is comprised of a second material. In some embodiments, the first material is stronger, stiffer than the second material, while in other embodiments, the first material and the second material are the same. In some embodiments, the first material is carbide and the second material is abrasive grains (e.g., alumina grains, etc.). Nevertheless, in some embodiments, the abrasive regions 564 may be replaceable gum sand discs with abrasive grains such that the sand discs may be removed and replaced with new sand discs as they wear. The abrasive regions 564 may have different abrasive particles. However, in some embodiments, abrasive areas 562 may have greater grit on one face and less grit on the other face.

Fig. 20-23 illustrate a counter tool 610 according to an alternative embodiment. As shown in fig. 20, the counter tool 610 includes a main housing 612 defining a handle 616, a trigger assembly 620 disposed on the handle 616, and a motor housing 630 coupled to the main housing 612. The trigger assembly 620 allows a user to control the speed of the motor 642 (e.g., an outer rotor BLDC motor as shown in fig. 21 and 23) by varying the degree of actuation of the trigger assembly 620. The counter tool 610 also includes a rechargeable battery pack 628 that powers the motor 642. The battery 628 may include any of a number of different nominal voltages (e.g., 12V, 18V, etc.) and may be configured to have any of a number of different chemical compositions (e.g., lithium ions, nickel cadmium, etc.). The main housing 612 also houses control electronics (e.g., PCBA, micro-switch, etc.) that control the operation of the motor 642.

With continued reference to fig. 20-23, motor shaft 646 is driven by motor 642 and includes a tool chuck 650 disposed at a distal end of motor shaft 646. A cutting accessory 658 (e.g., a sand disk, router bit, etc.) is removably coupled to the cutter cartridge 650. In the illustrated embodiment, the cutting accessory 658 is a sanding disc capable of removing material in a plane perpendicular to its axis of rotation R1. The counter tool 610 may alternatively receive a cutting accessory 560 (fig. 19B). The motor 642, motor shaft 646 and cutting accessory 658 are all coaxially aligned along the rotational axis R1. The countermeasure tool 610 also includes a fan 632 for generating an airflow 648 and a dust cover 676 disposed at least partially around the cutting accessory 658. The fan 632 is disposed within the main housing 612 behind the cutting accessory 658 such that the fan 632 is disposed between the cutting accessory 658 and the motor 642. In some embodiments, the fan 632 is directly coupled to the motor shaft 646 or the main shaft 652 of the cutting accessory 658 (fig. 21), while in other embodiments, the fan 632 may alternatively be integrated with the cutting accessory 658 or directly coupled to the cutting accessory 658 (fig. 23). The dust cap 676 at least partially protects the user from inadvertent contact with the cutting accessory 658. The dust cap 676 includes a channel 682 (fig. 20 and 22) disposed along the dust cap 676 that receives and surrounds the outer periphery of the cutting accessory 658. In other words, the channel 682 is U-shaped to enclose the outer perimeter of the cutting accessory 658.

With continued reference to fig. 20-22, during a cutting operation, an air flow 648 generated by a fan 632 draws dust and debris from workpiece 618 into dust cap 676. The dust cap 676 includes a cutting region opening 636 into which the cutting accessory 658 is exposed. That is, a user may perform a cutting operation by passing workpiece 618 through cutting zone opening 636 and engaging cutting accessory 658. In the embodiment shown in fig. 20, the size and shape of the cutting zone openings 636 are fixed. In other embodiments, the dust cap 676 may include a series of arcuate segments 634, which may or may not be spring loaded, allowing the size of the cutting zone opening 636 to vary and accommodate different workpieces 618. In particular, the series of arcuate segments 634 can be movable between a first position in which the cutting accessory 658 is substantially covered and a second position in which the cutting accessory 658 is at least partially exposed. A series of arcuate segments 634 are biased toward the first position. The series of arcuate segments 634 are telescopically coupled together such that adjacent arcuate segments 634 are nested within one another in the second position. The counter tool 610 also includes an outlet 672 in fluid communication with a dust cap 676 and is capable of directing dust and debris to a vacuum source or dust collector 678 (e.g., dust bag, dust bin, etc.).

During operation, trigger assembly 620 is depressed to activate motor 642, thereby driving motor shaft 646, fan 632, and cutting accessory 658. Thus, the air flow 648 causes ambient air to flow through the dust cap 676, the fan 632, the outlet 672, and ultimately through the dust collector 678 or vacuum source. By contacting the workpiece 618 with the cutting accessory 658, dust and debris are generated and directed along the airflow 648, which dust and debris will be collected by the dust collector 678 or vacuum source.

Fig. 24-26 illustrate a counter tool 710 according to an alternative embodiment. As shown in fig. 24, the coping tool 710 includes a main housing 712 defining a handle 716, a trigger assembly disposed on the handle 716, and a motor housing 730 coupled to the main housing 712. The trigger assembly allows a user to control the speed of the motor 742 (e.g., an outer rotor BLDC motor as shown in fig. 23) by varying the degree of actuation of the trigger assembly. The countermeasure tool 710 also includes a rechargeable battery pack 728 that supplies power to the motor 742. The battery 728 may include any of a number of different nominal voltages (e.g., 12V, 18V, etc.) and may be configured to have any of a number of different chemical compositions (e.g., lithium ions, nickel cadmium, etc.). The main housing 712 also houses control electronics (e.g., PCBA, micro-switch, etc.) that control the operation of the motor 742.

24-26, a cutting accessory 758 (e.g., a sand disk, router bit, etc.) is removably coupled to the counter tool 710. In the illustrated embodiment, cutting accessory 758 is a sanding plate capable of removing material in a plane perpendicular to its axis of rotation R1. The counter tool 710 may alternatively receive the cutting accessory 560 (fig. 19B). The motor 742 and the cutting accessory 758 are coaxially aligned along the rotational axis R1. The handling tool 710 also includes a dust shield 776 disposed at least partially around the cutting accessory 758. Dust cap 776 at least partially protects the user from inadvertent contact with cutting accessory 758. The dust cap 776 is pivotably coupled to the main housing 712 such that the dust cap 776 is movable between a first position (fig. 25) in which the dust cap 776 is adjacent the cutting accessory 758 and a second position (fig. 26) in which the dust cap 776 is spaced from the cutting accessory 758. The outlet 772 is in fluid communication with the dust cap 776 and is capable of directing dust and debris to a vacuum source or dust collector 778 (e.g., dust bag, dust bin, etc.). Workpiece 718 may be engaged with cutting accessory 758 via cutting region 736 to perform a cutting operation. The cutting region 736 may change size and shape to accommodate different workpieces 718 as the dust cap 776 moves between the first and second positions. Dust cap 776 also includes rounded tip 780 and channel 782 that extend along dust cap 676 adjacent cutting accessory 758. When the workpiece 718 contacts the rounded tip 780, the dust cap 776 is biased from the first position to the second position, as shown in fig. 26. In addition, when dust cap 776 is in the first position, channel 782 receives cutting accessory 758 such that cutting accessory 758 is surrounded by channel 782 proximate the outer perimeter of dust cap 776. In other words, channel 782 is U-shaped to enclose the outer perimeter of cutting accessory 758.

During operation, workpiece 718 is in contact with cutting accessory 758, which generates dust and debris that moves at high speed in a direction tangential to the point of contact between workpiece 718 and cutting accessory 758, as shown by arrow A1 in FIGS. 25 and 26. The channels 782 of the dust cap 776 receive the dust and debris and redirect it to the outlet 772. At this time, dust and debris are passively collected in the dust container 778. In other embodiments, dust and debris may be alternatively collected by the dust collector 778 or vacuum source by an induced airflow.

FIGS. 27-28 illustrate a counter tool 810 according to an alternative embodiment. As shown in fig. 27, the coping tool 810 includes a main housing 812 defining a handle 816, a trigger assembly 820 disposed on the handle 816, and a motor housing 830 (fig. 28) coupled to the main housing 812. The trigger assembly 820 allows a user to control the speed of the motor 842 by varying the degree to which the trigger assembly 820 is actuated. The countermeasure tool 810 also includes a rechargeable battery pack 828 (fig. 28) that powers the motor 842. The battery 828 may include any of a number of different nominal voltages (e.g., 12V, 18V, etc.) and may be configured to have any of a number of different chemical compositions (e.g., lithium ions, nickel cadmium, etc.). The main housing 812 also houses control electronics (e.g., PCBA, micro-switch, etc.) that control the operation of the motor 842.

With continued reference to fig. 27-28, the motor 842 drives the belt assembly 846 to perform a cutting operation on the workpiece. The belt assembly 846 includes a drive pulley 850, a first driven pulley 854, a second driven pulley 856, and a sanding belt 858 wrapped around the pulleys 850, 854, 856. A sanding belt 858 is removably attached to the wheels 850, 854, 856. In the illustrated embodiment, the exposed portion of the sand belt 858 between the first and second driven wheels 854, 856 defines a cutting region 870 (fig. 28) that is capable of removing material. The cutting region 870 is unobstructed and advantageously proximate to the user's hand, which increases the control of the cutting region 870 relative to the workpiece. The cutting region 870 is also directly above the handle 816 and aligned with the handle 816 such that the longitudinal axis 872 of the handle 816 intersects the cutting region 870. A platen 874 is also provided between the first and second driven wheels 854, 856 on the underside of the sanding belt 858 so that the sanding belt 858 can be pressed against a workpiece without undue deformation and wear of the sanding belt 858. The remaining length of the sand tape 858 is wrapped by the main housing 812 and dust cover 876 (fig. 27). A vacuum source may be coupled to the dust cap 876 to remove dust and debris during a cutting operation.

Fig. 29A-29D illustrate a countermeasure system 910 according to an alternative embodiment. Components and features similar to the coping system 10 of fig. 1 will be added with "900". Fig. 29A shows a countermeasure system 910 that includes a protective screen 912, a gantry system 914, a debris collection system 916, and a fixture assembly 920. The gantry system 914 includes a counter-tool 954, a tool holder 922 for supporting the counter-tool 954, a first slide 924, a second slide 926 vertically disposed on the first slide 924, and a handle 928. The tool holder 922 is slidably mounted on a first slide 924 which is slidably mounted on a second slide 926. A handle 928 is coupled to the tool holder 922 that allows a user to move the tool holder 922 along the first slide 924 and the second slide 926, allowing for two-dimensional movement of the counter tool 954 in a plane. As shown in fig. 29C, the coping system 910 may be supported on top of the equipment rack 929. In addition, the gantry system 914 includes template features in which counter-cuts of adjacent workpieces (not shown) can be replicated onto the workpiece 918 clamped in the clamp assembly 920, as will be described in further detail below.

Referring to fig. 29A, a protective screen 912 is mounted between the counter tool 954 and the handle 928 and is intended to prevent dust and debris from inadvertently exiting the counter system 910. The debris collection system 916 includes a vacuum system (not shown) and a debris collection bin (not shown). When the handling tool 954 is in operation, a vacuum system (not shown) is simultaneously turned on to collect dust and debris during handling operations. Dust and debris are deposited into a debris collection bin (not shown) and can then be removed for emptying.

With continued reference to fig. 29A, the clamp assembly 920 includes a bottom clamping surface 930 and a top clamping surface 932. The clamp assembly 920 clamps the workpiece 918 in place to avoid impeding the visibility of the workpiece 918. The handling system 910 also includes a rough gauge 936 (fig. 29B) and a template rail 940 (fig. 29D) that act as a barrier to the handling tool 954, inhibiting movement of the handling tool 954 out of the handling of the cut. The rough machining gage 936 approximates the contour of the workpiece and guides the handling tool 954 during initial batch handling operations. The rough gauge 936 may then be removed to achieve a more accurate coping cut. The template rail 940 is coupled to the gantry system 914 to assist the user in repeating the coping cut with the coping tool 954.

Fig. 30-32 illustrate a countermeasure system 1010 according to an alternative embodiment. Components and features similar to the coping system 10 of fig. 1 will be added with "1000". The handling system 1010 includes a tool body 1012, an opening 1016 provided through the tool body 1012, and a cutting accessory 1058 (fig. 32) provided within the tool body 1012. The coping system 1010 also includes a controller and a sensor 1020 (e.g., camera, etc.; fig. 31) disposed within the tool body 1012 that is configured to analyze the workpiece 1018 to perform an optimal coping cut 1014. The controller receives input signals (fig. 32) corresponding to the contour and dimensions of the workpiece 1018 from the sensor 1020 and then generates output signals that control the path of the cutting accessory 1058.

During operation, a user need only insert the workpiece 1018 into the tool body 1012 through the opening 1016 such that the workpiece 1018 is always located within the tool body 1012. Next, the cutting accessory 1058 performs an optimal countermeasure cut 1014 based on the information collected by the sensor 1020 from analyzing the workpiece. The illustrated embodiment creates a system in which the user does not need to know the coping knowledge in advance and can repeat the tool path optimally coping with the cut multiple times on a new workpiece.

Various features of the utility model are set forth in the following claims.

Claims (20)

1. A power tool for performing counter cutting, the power tool comprising:

a main housing;

a motor disposed within the main housing;

a drive shaft driven by the motor about the rotation axis;

a handle extending from the main housing; and

a grinding disc coupled to and driven by the drive shaft about the axis of rotation, the grinding disc having an outer diameter of at least 3 inches,

wherein the motor is an external rotor brushless dc motor capable of rotating at a torque of 1.5 in lbs. at 4000 surface feet per minute.

2. The power tool of claim 1, further comprising a battery removably coupled to the handle and configured to provide power to the motor.

3. The power tool of claim 1, further comprising a tool chuck on the drive shaft for receiving the abrasive disc such that the drive shaft provides a direct drive from the motor to the abrasive disc.

4. The power tool of claim 1, further comprising a fan disposed within the main housing between the abrasive disc and the motor, wherein the fan is driven by the drive shaft to generate the airflow.

5. The power tool of claim 4, wherein the fan is coupled to the drive shaft.

6. The power tool of claim 4, wherein the fan is coupled to the spindle of the abrasive disc.

7. The power tool of claim 4, wherein the fan is integrated with the abrasive disc.

8. The power tool of claim 4, further comprising a dust cap coupled to the main housing and disposed at least partially around the abrasive disc.

9. The power tool of claim 8, wherein the air flow generated by the fan flows into the dust cap, bypasses the abrasive disc, and passes through an outlet in fluid communication with the dust collector.

10. The power tool of claim 8, wherein the dust cap includes a cutting zone opening at which the abrasive disc is exposed, allowing the workpiece to pass through and engage the abrasive disc.

11. The power tool of claim 10, wherein the dust cap includes a movable section operable to change the size and/or shape of the cutting zone opening.

12. A handling tool, comprising:

a main housing;

a motor disposed in the main housing and rotating around a rotation axis;

a handle extending from the main housing;

a grinding disc coupled to and driven by the motor about a rotational axis; and

a dust cap coupled to the main housing and at least partially disposed about the abrasive disc, the dust cap comprising:

a channel extending along the dust cap adjacent the abrasive disc, and

a cutting zone opening through which the workpiece can be engaged with the abrasive disc,

wherein the channel is U-shaped and surrounds the periphery of the abrasive disc, and

wherein the size and/or shape of the opening of the cutting zone is adjustable to accommodate the workpiece.

13. The coping tool of claim 12, wherein dust and debris are generated from the workpiece during coping operations that travel tangentially from the abrasive disc to the passageway of the dust cover and toward an outlet in fluid communication with the dust collector.

14. The coping tool of claim 12, wherein the dust cover comprises a plurality of movable segments operable to change the size and/or shape of the cutting zone opening.

15. The coping tool of claim 14, wherein the plurality of movable segments are movable between a first position in which the abrasive disc substantially covers and a second position in which the abrasive disc is at least partially exposed, wherein the plurality of movable segments are biased toward the first position.

16. The coping tool of claim 14, wherein the plurality of movable segments telescopically couple together and nest with each other when moved to the second position.

17. A handling tool, comprising:

a main housing;

a motor disposed in the main housing and rotating around a rotation axis;

a handle extending from the main housing;

a grinding disc coupled to and driven by the motor about a rotational axis;

a fan mounted within the main housing and configured to generate an air flow; and

a dust cap pivotally connected to the main housing and at least partially disposed about the abrasive disc, the dust cap comprising:

a passage extending along the dust cap

A cutting zone opening through which the workpiece can be engaged with the abrasive disc,

wherein the size and/or shape of the cutting zone opening is adjustable in response to rotation of the dust cap between the first position and the second position.

18. The coping tool of claim 17, wherein the channel is U-shaped and surrounds the periphery of the abrasive disc.

19. The coping tool of claim 18, wherein the dust shield is adjacent to the abrasive disc in a first position such that the channel receives the abrasive disc, wherein the dust shield is spaced from the abrasive disc in a second position, and wherein the dust shield is biased toward the first position.

20. The coping tool of claim 19, wherein dust and debris generated from the workpiece during coping operations passes through the passageway of the dust cover and along the airflow to an outlet in fluid communication with the dust collector.