WO2003020479A9

WO2003020479A9 - Forming complex shapes

Info

Publication number: WO2003020479A9
Application number: PCT/AU2002/001212
Authority: WO
Inventors: Con Anton
Original assignee: Con Anton
Priority date: 2001-09-04
Filing date: 2002-09-04
Publication date: 2003-07-17
Also published as: WO2003020479A2; WO2003020479A3; AUPR748401A0

Abstract

A means of forming complex shapes for cutting wood work pieces by use of a bandsaw, the forming means including: a carriage (13) onto which material to be cut can be located for movement through the saw blade (50); a guide means (51) on the underside of the carriage having an downwardly directed flexible flange (65) which guide means has a number of outwardly directed members (67) which can be connected to the carriage to enable the flange to be caused to take a required shape. Wherein the shaped flange can cooperate with members on the saw bed (22) causing the carriage and the material thereon to pass along a path corresponding to the shape to direct the bandsaw along a corresponding path through the work piece.

Description

FORMING COMPLEX SHAPES

Field of the Invention

This invention relates to improvements in handsaws and in methods of forming complex shapes. It is particularly directed at a means and method of forming complex shapes in wood by use of a bandsaw.

Related Documents

In my earlier patent application Patent Cooperation Treaty (PCT) application no. PCT/AU99/00776 1 describe a method of providing a carriage associated with a bandsaw whereby complex shapes can be formed. This arrangement is satisfactory but is particularly useful where a large number of similar shapes are to be formed.

Background Art

In furniture and cabinet making, it is frequently necessary to precisely form compound curved surfaces on a workpiece. For example, in professional, large volume cabinet making operations it is necessary to produce cabinet doors that have a variety of differently styled, generally arch-shaped centre panels. The centre panels are supported between the stiles and rails of the door and are often of complex shape. In large volume operations the panels must conform to close tolerances so that they can be interchangeably fitted to their mating separately fabricated stiles and rails.

In the past, particularly in cabinet making, the curved surfaces on door panels and the like were formed using spindle shapers or routers. When routers were used, the router was moved relative to the fixed workpiece with templates being used to guide the path of travel of the router cutter. This approach was less than satisfactory, particularly in large volume operations. One drawback of this approach was that the cutting operation was somewhat cumbersome and at least semi-skilled workers were required to properly set up and manipulate the router. Another drawback was that both the set-up and cutting operation was time consuming and great care had to be exercised to make certain that neither the workpiece nor the template shifted during the cutting step. Desired precision was typically difficult to achieve and therefore, rejection rates were high. Another drawback resided in the fact that, because the cutter was required to move relative to the workpiece, the provision of adequate safety guards for the cutter was difficult or impossible.

In other professional, small volume cabinet making operations it is necessary to produce complex shaped pieces for artistic works or decorative parts of a cabinet that has a variety of differently styled pieces, Generally it has been necessary for an expert in the field to draw out the design and by eye hand direct a bandsaw along the complex shape. If anyone but an expert or craftsman undertook this precise operation it would usually end in an unusable piece. Even the expert will probably require substantial sanding of the cut piece to finish the complex shape.

Objects of the Invention It is an object of the invention to provide a method of forming complex shapes with a bandsaw or the like wherein the set up is rapid and cheap and is suitable even for a very small number of similar shapes

It is also an object of the invention to provide means and method of forming complex shapes in wood by use of a bandsaw whereby material can be drawn through a bandsaw or the like whilst forming shapes, which facilitates the formation of a number of shapes and speeds the operation of the saw. Summary of the Invention

In accordance with the first aspect of the invention there Is provided, associated with a bandsaw, a carriage onto which material to be cut can be located for movement through the saw blade a guide means on the underside of the carriage having an downwardly directed flexible flange which guide means has a number of outwardly directed members which can be connected to the carriage to enable the flange to be caused to take a required shape so that, as this cooperates with members on the saw bed causes the carriage and the material thereon to pass along a path corresponding to the shape of the flange.

In a particular form of the invention the outwardly directed members of the guide means each extends a distance such that there outer ends can be located on a template of a shape to be cut and which will ensure that the cut of the bandsaw will be along the line required at a spacing which is required.

In a second aspect of the invention there is provided, in association with a bandsaw, a driven wheel which can be located to one side of the saw blade and which can bear on material to be cut by the saw and to cause this material to be drawn through the saw.

The drive wheel can be directly or indirectly driven and can be driven at different speeds. Associated with the saw table beneath this wheel there can be roller means to assist the movement of the material therethrough.

Also provided in association with this arrangement are blade guides to prevent undue movement of the saw as material passing therethrough adopts different angles. There is provided a guide means, which is adapted to be associated with a saw table and can be adapted to be connected to a carrier member, which, in operation, is located on the saw table.

The guide means comprises an outwardly directed flexible flange from each side thereof, adjacent one edge thereof, project spaced members which are adapted to locate the means relative to the carrier.

In a first form of the invention the spaced members can extend outwardly from each side of the flange and can be spaced by a distance approximately equal to the width of the members. Preferably the spaced members have a length such as to provide correct location of the guide member from the saw assembly.

The arrangement is such that the guide member can adopt any required curve and, when the guide means is in the required position, it can be located π the underside of the carrier by means of staples, adhesive, nails or in any other way connected through orto the spaced members.

In a particular form of the invention the required shape to be cut can be marked on the underside of the carrier and the ends of the spaced members extending from the flange can be located along the line and stapled relative thereto so that the guide member adopts a shape which is identical to the shape on the carrier but is spaced therefrom by the outward extension of the flanges.

This shape can be complex as the only restriction to the deformation of the guide is effectively the space between the spaced members and, if required, the spaced members could be formed to permit an extreme deformation. As previously discussed, the spaced members are in pairs extending outwardly from each side of the flange and the spacing is effectively equal to the width of the members.

With these symmetrical arrangements it means that the guide means can be used in either sense without any problems.

In a first alternative the spaced members can extend alternatively from each side of the flange of the guide member and in a further alternative form, the spaced members can be rectangular in shape, they could have arches at outer ends or they could simply have formed outer ends so as not to provide sharp angles.

All of such arrangements can be used with the invention,

The arrangement is adapted to be used with four pins or rollers in spaced pairs which are on the saw bed and which are adapted to be located on either side of the flange of the guide member. As mentioned above, the carrier has means whereby the timber to be cut can be clamped thereto.

The arrangement is such that, before the beginning of the cut, the pins are located on either side of the flange of the guide member and as the carrier and its associated guide member are constrained to move along the saw bed with the flange being passed through the pins, so the timber carried thereby is constrained to move in an identical manner and as this is passing through the saw blade is cut to match the shape of the guide member.

Depending on the maximum curve required the depth of the saw blade can vary, a narrow blade permitting smaller radii and a wider bade giving a more satisfactory long turns performance. It will be seen that the concept of the invention can be set up extremely cheap, the flexible guide means material can be cheap and this can be set up on a flat base and, as mentioned above, simply stapled, adhesively secured or otherwise connected to the base. Thus, it is quite feasible to set up the guide of the invention even if there are only a few, or on occasions one, item which needs to be cut as the device of the invention ensures that the cut is extremely accurate which is difficult to do by hand even for a skilled operator on marked material and effectively impossible for a non-skilled operator.

If there are a number of items to be cut then, offcourse the benefit is vastly increased and if there are a large number, the benefit becomes extremely high indeed.

Also, because the flexible guide means is very cheap and the carrier can be a piece of ply or the like it is possible to maintain the device set up, should it be required at a later date to duplicate the particular shape.

In a second aspect of the Invention to be used in association with the first aspect described herein, or even with the form of the invention described in my earlier PCT application referred to above, it is provided above the saw bed, preferably on a rotatable arm a driven wheel which can be adjusted relative to the position of the bed to be brought into position on the material to be cut and to act to draw this through the saw blade.

In one particular form of the invention the arm for the driven wheel is mounted relative to the saw bed from above and preferably has a pivotal connection which is effectively located behind the saw blade with the arm extending forwardly and downwardly from this. At its point of connection, the arm can be locked in any required position and an adjustment handle can be provided to do this,

At the free end of the arm is located the drive feed wheel which can have a resilient tyre or the like on its surface and which is mounted on an axis which can be on a plane parallel to the saw bed and can be located effectively adjacent the saw blade.

That is the wheel when rotated, rotates about a plane effectively parallel to the plane of the saw blade and if it is in contact with timber mounted on a carrier or the like can cause the timber to be drawn forward into the saw blade.

Ad the wheel can be located closely adjacent the blade, if the timber is caused to move relative to the blade then the wheel will cause effectively no obstruction to such movement.

The wheel can preferably be driven by a pulley and V-belt mounted coaxially therewith or, could have a direct drive means associated therewith.

If required, on the saw bed can be provided rollers or balls on which the carrier carrying the timber to be cut rests so that at the position adjacent the wheel there is little frictional resistance due to downward pressure on the wheel.

The arrangement is particularly suitable for use with a guide and carrier of the type previously referred to, or referred to in my PCT application, where the carrier is moved along adjacent the saw blade and is constrained to move to follow the guide. Thus the timber to be cut, which is mounted thereon, is drawn passed the blade and the curve required is automatically formed by the blade because of the variation of movement of the carrier and thus the timber connected thereto.

In this aspect of the invention, the drive feed wheel is located so that the carrier and timber to be cut is a relatively close fit therebeneath, the tyre of the wheel can take into account variations in thickness and the bottom rollers permit ready movement through the device so that, as the timber is initially fed into the saw, after the carriage is in association with the guide means then the wheel takes up the movement of the timber and causes it to be drawn through the saw and cut.

Even if the shape to be cut is very complex, because of the relative location of the drive wheel to the blade and the arrangement of the carrier and the guide, the shape can readily be followed and an extremely accurate cut is obtained.

Of course the speed of the wheel can be adjusted to take into account the speed of the blade and the rate of feed, which is required for the timber and can be modified to take into account changes in the sharpness of the blade if this is required.

It will be seen that the application of the two aspects of the invention to a machine permits ready duplication of complex shapes, very rapid set up of different shapes, should these be required, without great expense so that the guides can be maintained for later use if this should be necessary.

Brief Description of the Drawings

In order that the invention is more readily understood an embodiment thereof will be described by way of illustration only with reference to the drawings wherein: Figure 1 is a diagrammatic perspective view of a guide means for use in a means and method of forming complex shapes in wood by use of a bandsaw in accordance with a first embodiment of the invention;

Figure 2a and 2b are overhead plan views of the guide means of Figure 1 in a linear configuration or complex shape configuration;

Figure 3a, 3b and 3c are various possible shapes of the guide means of Figure 1 ;

Figure 4A is a diagrammatic side view of a means for forming complex shapes in wood by use of a bandsaw in accordance with an embodiment of the invention;

Figure 4B is a diagrammatic side view of the means for forming complex shapes in wood by use of a bandsaw of Figure 4A.

Figure 5 is a cross sectional view of a means for forming complex shapes in wood by use of a bandsaw in accordance with an embodiment of the invention.

Figures 6A and 6B is an underneath plan view of the means for forming complex shapes in wood by use of a bandsaw in accordance with Figure 5.

Best Method of Performing the Invention

In accordance with a preferred embodiment of the invention there is provided a means of forming complex shapes for cutting woodwork pieces by use of a bandsaw. The forming means includes a carriage 13 onto which material 14 to be cut can be located for movement through the saw blade 50 and a guide means 51 as shown in Figure 1 attached on the underside of the carriage 13. The guide means 51 in use having an downwardly directed flexible flange 65. The guide means 51 further having a number of outwardly directed members 67, which can be connected to the carriage 13 to cause the flange to take a required shape. The shaped flange can cooperate with members 22 in the form of rollers on the saw bed 51 causing the carriage 13 and the material 14 thereon to pass along a path corresponding to the shape to direct the bandsaw 50 along a corresponding path through the work piece.

The forming means includes the outwardly directed members 67 of the guide means each extending a distance such that their outer ends can be located on a template of a shape to be cut which ensures that the cut of the bandsaw 50 will be along the line required at a spacing thereto.

A critical part of the invention is the guide means as shown in Figures 1 ,2a and 2b, adapted to be associated with a saw table and to be connected to a carrier member, which, in operation, is located on the saw table. The guide means includes an outwardly directed flexible flange from each side thereof, and projecting spaced members adjacent one edge thereof, which are adapted to locate the means relative to the carrier.

The spaced members of the guide means extend outwardly from each side of the flange and are spaced by a distance approximately equal to the width of the members. The spaced members have a predetermined length such as to provide a required location of the guide member from the saw assembly.

As shown in Figures 2a and 2b the guide member is able to adopt any required linear path or any required curve. The shape can be complex and the only restriction to the deformation of the guide 51 being effectively the space between the spaced members 67 and, if required, the spaced members 67 could be formed to permit an extreme deformation. When the guide means 51 is in the required position, it is able to be located on the underside of the carrier 13 by means of staples, adhesive, nails or in any other way connected through orto the spaced members 67. This connection can be readily removable.

In use the required shape to be cut is able to be marked on the underside of the carrier 13 and the ends of the spaced members 67 extending from the flange 65 located along the line and stapled relative thereto so that the guide member adopts a shape which is identical to the shape on the carrier but is spaced therefrom by the outward extension of the flanges.

As shown in Figures 3a, 3b and 3c the spaced members 67 are in pairs extending outwardly from each side of the flange and the spacing is effectively equal to the width of the members or alternatively from each side of the flange of the guide member. The spaced members being substantially rectangular in shape however this is not critical.

Whilst particular forms of the invention have been described, it is to be understood that variations and modifications can be made in these without departing from the spirit and scope of the invention. In this regard the invention includes such variations and is only limited by the claims following.

Claims

Claims:

1. A means of forming complex shapes for cutting wood work pieces by use of a bandsaw, the forming means including: a carriage onto which material to be cut can be located for movement through the saw blade; a guide means on the underside of the carnage having a downwardly directed flexible flange which guide means has a number of outwardly directed members which can be connected to the carriage to enable the flange to be caused to take a required shape; wherein the shaped flange can cooperate with members on the saw bed causing the carriage and the material thereon to pass along a path corresponding to the shape to direct the bandsaw along a corresponding path through the work piece.

2. A forming means according to claim including the outwardly directed members of the guide means each extending a distance such that their outer ends can be located on a template of a shape to be cut which ensures that the cut of the bandsaw will be along the line required at a spacing which Is required,

3. A guide means, adapted to be associated with a saw table and to be connected to a carrier member, which, in operation, is located on the saw table, the guide means including an outwardly directed flexible flange from each side thereof, and projecting spaced members adjacent one edge thereof, which are adapted to locate the means relative to the carrier.

4. A guide means according to claim 3 with the spaced members extending outwardly from each side of the flange and spaced by a distance approximately equal to the width of the members.

5. A guide means according to claim 3 or 4 with the spaced members having a predetermined length such as to provide a required location of the guide member from the saw assembly.

6. A guide means according to claim 3, 4 or 5 with the guide member able to adopt any required curve and, when the guide means is in the required position, able to be located on the underside of the earner by means of staples, adhesive, nails or in any other way connected through orto the spaced members.

7. A guide means according to any one of claims 3 to 6 with the required shape to be cut able to be marked on the underside of the carrier and the ends of the spaced members extending from the flange located along the line and stapled relative thereto so that the guide member adopts a shape which is identical to the shape on the earner but is spaced therefrom by the outward extension of the flanges.

S. A guide means according to claim 7 with the shape being complex and the only restriction to the deformation of the guide being effectively the space between the spaced members and, if required, the spaced members could be formed to permit an extreme deformation.

9. A guide means according to any one of claims 3 to 8 with the spaced members being in pairs extending outwardly from each side of the flange and the spacing is effectively equal to the width of the members.

10. A guide means according to any one of claims 3 to 8 with the spaced members extending alternatively from each side of the flange of the guide member.

11. A guide means according to any one of claims 3 to 8 with the spaced members being substantially rectangular in shape.

12. In association with a bandsaw, a driven wheel located to one side of the saw blade and which can bear on material to be cut by the saw and to cause this material to be drawn through the saw.

13. The drive wheel according to claim 12 with the wheel being directly or indirectly driven at required different speeds.

14. An apparatus for cutting work pieces, comprising;

(a) a supporting frame, and a workpiece support surface mounted on a moveable carriage;

(b) cutting means mounted on said frame for cutting engagement with said work pieces as said carriage moves along said guide member;

(c) guide member including directing flange and attachment means for mounting on said supporting frame for moving said work pieces on the carriage along the path defined by the guide member to cause cutting means to cut workpiece along a corresponding line.

15 A method of forming Gomplex shapes for cutting woodwork pieces by use of a bandsaw, the method including the steps of: providing a carriage onto which material to be cut can be located for movement through the saw blade; attaching a guide means on the underside of the carriage having a downwardly directed flexible flange which guide means has a number of outwardly directed members for connection to the carriage to enable the flange to be caused to take a required shape; driving the carriage such that the shaped flange cooperates with members on the saw bed causing the carriage and the material thereon to pass along a path corresponding to the shape; wherein the bandsaw is directed along a corresponding path through the work piece to cut the work piece according to a shape corresponding with the guide means..

16. A method of forming complex shapes for cutting woodwork pieces by use of a bandsaw substantially as hereinbefore described with reference to the drawings.

17. A means of forming complex shapes for cutting wood work pieces by use of a bandsaw substantially as hereinbefore described with reference to the drawings.

18. A guide means, adapted to be associated with a saw table and to be connected to a carrier member substantially as hereinbefore described with reference to the drawings.