WO2007019328A1

WO2007019328A1 - Portable cutting tool device having a pivoting extendable tool carrying assembly

Info

Publication number: WO2007019328A1
Application number: PCT/US2006/030476
Authority: WO
Inventors: Normond Campbell; Thomas J. Smith
Original assignee: Normond Campbell; Smith Thomas J
Priority date: 2005-08-05
Filing date: 2006-08-04
Publication date: 2007-02-15

Abstract

A tool carrying device includes a supporting frame, a pivot joint that connects one point of an extendable track to the supporting frame, a tray, and a front connection that connects another point of the extendable track to the supporting frame. The pivot joint places the axis of rotation of the extendable track at a defined relationship to the supporting frame. When actuated, the front connection maintains the extendable track at a desired orientation relative to the supporting frame and, when de-actuated, allows the extendable track to move to another desired orientation. The tray is attached to, and travels along a path defined by, the extendable track. The tray carries a tool and is movable relative a workpiece. The tool can move into a cutting position, cut the workpiece based on the orientation of the extendable track relative to the supporting frame and can then move away from the workpiece.

Description

MMftffiLE CUTTING TOOL DEVICE HAVING A PIVOTING EXTENDABLE TOOL CARRYING ASSEMBLY

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0001] This invention is directed to a portable device usable to carry a saw or other cutting tool.

2. Related Art

[0002] Modern power tools are designed with two conflicting goals in mind, portability and repeatability. That is, users demand easily-transportable small tools for on-site use so that the user can work on a workpiece, such as lumber, siding, pipe and the like, at the actual work site rather than at a centralized location, even if the central location is at the job site. Second, users demand that these same easily-transportable power tools be suitable for use on large scale applications with consistency and reproducibility that is difficult to obtain from a portable tool. For instance, power hand drills are easily portable but lack the consistency of a drill press when an application demands consistent drilling at a particular depth or at a certain angle.

[0003] Portability may be obtained in a number of ways. First, the tool may be designed to be compact. For example, a power hand saw, such as a circular saw, a trim saw, a saber saw, or the like, is compact and portable, but lacks the consistency of a table saw, which possesses a fixed surface and guide rails. Alternatively, portability can be obtained by designing the tool such that it easily collapses for transportation. This may require that the power tool assembly contain multiple separate components that are easily assembled and dissembled before and after use. Thirdly, a truncated version of a larger tool maybe designed for job-site use. This may include reducing the range of motion that the tool can travel, altering the height of certain features, such as table legs, or placing tighter limits on the dimensions and type of material that can be handled by the tool.

[0004] In addition to portability considerations, another important consideration in power tool design is how the tool interacts with a workpiece. For example, a movable tool may be moved toward a stationary object to be worked on by the tool. Alternately, the workpiece may be moved toward a stationary cutting tool. When a tool is moved relative to a stationary object to be cut, the tool's path of motion usually needs to be well controlled. Conventionally, springs, gears, chains, pulleys, and other mechanical devices have been incorporated into conventional mechanical guide mechanisms to control the path of motion of a moveable tool. SUMMARY OF THE DISCLOSED EMBODIMENTS

[0005] A common problem in many power saw applications is the ability to have a i IIB<f>i¥?':fr a long path of motion that is controlled and reproducible yet is usable in small, contained spaces. For example, in the siding industry, siding installers typically work on small scaffoldings when installing the siding. These scaffoldings are typically only 2-3 feet wide in the direction perpendicular to the face of the building that the siding is being installed onto. These scaffoldings typically include a table or bench extending parallel to the building face on the side of the scaffolding platform opposite the building face and a narrow walkway between the building face and the work bench. This bench or table typically takes up about Vi of the available width of the scaffolding platform. Conventional radial arm saws and mechanical guide devices for portable circular or trim saws are too big to be located on the scaffolding itself. That is, when placed on the table or the scaffolding platform, portions of the saw or the guide device extend beyond the end of the table or bench and into the walkway space of the scaffolding. As such, these conventional devices make it difficult, if not impossible, either to move about on the platform and/or to manipulate the siding to cut it and/or install it, or are simply too bulky to be located on the scaffolding in the first place.

[0006] Accordingly, the typical solution is to place the guide/saw mechanism on the ground near the scaffolding, with one worker dedicated to operating the saw based on instructions received from the workers on the scaffolding. After cutting the siding to the dimensions and angles requested by the scaffolding-based workers, the ground-based worker then hands the cut siding to the workers on the scaffolding.

[0007] Due to the length of the siding, there are typically at least two workers on the scaffolding. They typically wait for the ground-based worker to cut the siding, then take the cut siding from the ground-based worker and install it. One or both of the scaffolding-based workers then measures out the dimensions for the next piece of siding and relays it to the ground-based worker. Accordingly, a significant number of man-hours are wasted while the ground-based worker waits between handing the cut piece of siding to the scaffolding-based workers and getting the next set of dimensions and while the scaffolding-based workers wait for the ground-based worker to cut the next piece of siding.

[0008] It would be advantageous to create a compact guide mechanism which has the capability to move a saw or other cutting tool along a long controlled path of motion in which the user has control over the angle at which the cut is made and the length of the cut and where the range of motion for the saw or other cutting tool is adequately large and reproducible. Such a compact saw/guide mechanism could be located on the scaffolding used to install siding, allowing the conventional three-man crew to be reduced to two men, and allowing the scaffolding-based workers to cut the siding themselves, allowing the two-man crew to more ;e ⁵¹¹B

[0009] This invention provides a compact tool carrying device that provides a long path of motion for a tool.

[0010] This invention separately provides a compact tool carrying device that allows a tool to be located relative to a workpiece at a controlled angle over a large angular range.

[0011] This invention separately provides a tool carrying device that contains a plurality of nested relatively moveable tracks that provide a long controlled path of motion for a tool.

[0012] This invention separately provides a tool carrying device containing multiple sliding tracks that is highly compact.

[0013] This invention separately provides a tool carrying device that uses a pivot point and a pivoting connection assembly that moves along a fixed guide rail to control the angle at which the tool is oriented relative to the workpiece.

[0014] This invention separately provides a compact tool carrying device having a tray usable to carry a tool.

[0015] This invention separately provides a compact tool carrying device that includes a universal cutting tool tray usable to hold a portable power saw or other portable cutting tool.

[0016] This invention separately provides a compact tool carrying device having a cutting tool tray that is movable into and out of a cutting position by the user.

[0017] This invention separately provides a compact tool carrying device having a cutting tool tray and at least one tension spring connected to the cutting tool tray that at least partially supports the weight of the cutting tool tray and a cutting tool placed on the cutting tool tray.

[0018] In various exemplary embodiments of devices and methods according to this invention, a tool carrying device includes a supporting frame structure, a pivot joint assembly, an extendable tack assembly, a cutting tool tray, and a front connection assembly. In various exemplary embodiments, the pivot joint assembly connects the extendable track assembly to the supporting frame structure. In various exemplary embodiments, the pivot joint assembly places the axis of rotation of the extendable tack assembly at a defined point of and/or angle to a working surface of the supporting frame structure. In various exemplary embodiments, the extendable track assembly rotates relative to the supporting frame structure about the axis defined by the pivot joint assembly.

[0019] In various exemplary embodiments, the front connection assembly also connects the extendable tack assembly to the supporting frame structure. In various exemplary embodiments, the front connection assembly is usable to maintain the extendable track aWefflbl^Sf SddsSϋMlgiϊaSorientation relative to the supporting frame structure and allows the extendable track assembly to move relative to the supporting frame structure to another desired angular orientation. In various exemplary embodiments, the cutting tool tray is attached to, and travels along a path defined by, the extendable track assembly. In various exemplary embodiments, the cutting tool tray carries a tool so it is moveable relative a working surface so the tool can move vertically into a cutting position, cut the workpiece at the desired angle defined by the angular orientation of the extendable track assembly relative to the supporting frame structure and can then be moved vertically away from the workpiece.

[0020] In various exemplary embodiments, the pivot joint assembly attaches the extendable track assembly to the overhead rail. In various exemplary embodiments, the front connection locks the extendable track assembly at the desired position along the overhead rail. The combination of the pivot joint assembly, the extendable track assembly, the front connection assembly and the overhead rail allows the nested tracks of the extendable track assembly to be located and maintained at a desired angle to a workpiece at high angular precision. In various exemplary embodiments, the movable cutting tool tray is attached to the extendable track assembly. In various exemplary embodiments, this moveable cutting tool tray is held in position relative to the nested sliding track by one or more tension springs or equivalent structures.

BRIEF DESCRIPTION OF DRAWINGS

[0021] Various exemplary embodiments of a device of this invention will be described in detail, with references to the following figures, wherein:

[0022] Fig. 1 is a perspective view of one exemplary embodiment of a tool carrying device according to this invention;

[0023] Fig. 2 is a side plan/perspective view of the tool carrying device shown in Fig. 1;

[0024] Fig. 3 is a prospective view of one exemplary embodiment of the pivot joint assembly according to this invention;

[0025] Fig. 4 is a perspective view of one exemplary embodiment of the pivot joint assembly and one exemplary embodiment of an extendable track assembly and a cutting tool tray of the tool carrying device of Fig. 1;

[0026] Fig. 5 is a front plan view of one exemplary embodiment of the extendable track assembly and the cutting tool tray of Fig. 4;

[0027] Fig. 6 is a perspective view of one exemplary embodiment of a first component of the exemplary embodiment of the extendable track assembly shown in Figs. 4 and 5; §:} /'^"SgTIM¹S.^"! front plan view of one exemplary embodiment of a second component of the extendable track assembly shown in Figs. 4 and 5;

[0029] Fig. 8 is a perspective view of one exemplary embodiment of a third component of the extendable track assembly shown in Figs. 4 and 5;

[0030] Fig. 9 is a side view of one exemplary embodiment of the extendable track assembly and one exemplary embodiment of the cutting tool tray assembly;

[0031] Fig. 10 is a front plan view of one exemplary embodiment of the fourth component of the extendable track assembly and the cutting tool tray assembly shown; and

[0032] Fig. 11 is a cut-away perspective view of one exemplary embodiment of the cutting tool tray assembly.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0033] Fig. 1 shows one exemplary embodiment of a compact tool carrying device 100 that allows a cutting tool to be moved along a long path of controlled motion and at a controlled cut angle. As shown in Fig. 1, the tool carrying device 100 includes a supporting frame structure 200, a pivot joint assembly 300, an extendable track assembly 1000, a cutting tool tray assembly 400, and a front connection assembly 500. In the exemplary embodiment of the tool carrying device 100 shown in Fig. 1, the pivot joint assembly 300 is mounted under the supporting frame structure 200. The extendable track assembly 1000 is connected to the pivot joint assembly 300. The cutting tool tray assembly 400 is connected to and carried by the extendable track assembly 1000. In various exemplary embodiments, the front connection assembly 500 is attached to both the supporting frame structure 200 and the extendable track assembly 1000. A cutting tool 600, such as, for example, a trim saw, a circular saw, a router, a rotary tool, or any other appropriate cutting tool, can be placed on and carried by the cutting tool tray assembly 400. The cutting tool 600 can be wired or battery powered, although battery powered cutting tools 600 are more advantageously used with the tool carrying device 100.

[0034] Fig. 2 shows a side plan/perspective view of the exemplary embodiment of the tool carrying device 100 shown in Fig. 1, that better shows the structural relationships between the pivot joint assembly 300, the extendable track assembly 1000, the cutting tool tray assembly 400, the front connection assembly 500, the tool 600 and a workpiece 700. It should be appreciated that, in various exemplary embodiments, the workpiece 700 is a board or siding having a width that can extend up to about 12 inches to about 18 inches, or more, and a length that can extend up to about 8 feet to about 12 feet, or more.

[0035] It should be appreciated that the supporting frame structure 200 provides a framework and a set of fixed points of reference for the tool carrying device 100. hi various &m|ιϊlt|®i&oaϊ»^i!αΪ5yB&upporting frame assembly 200 includes a work surface 210, one or more support columns 220, an overhead frame 230, and an overhead rail 240. In various exemplary embodiments, the supporting frame assembly 200 provides a structure that the pivot joint assembly 300 and the front connection 500 can connect to, to define an angle for a cut to be made to the workpiece 700. In various exemplary embodiments, the pivot joint assembly 300 is attached to the underside of the overhead frame 230, while the front connection assembly 500 extends around the overhead rail 240.

[0036] It should be appreciated that the supporting frame structure 200 does not necessarily need to include the work surface 210. Rather, in various other exemplary embodiments, the one or more support columns 220 can be detachably mountable on and/or to a separate work surface, such as a work bench, a work table, a table top or the like. It should also be appreciated that the overhead rail 240 can be implemented using a flat projecting beam, a guide rod of a linear bearing system or any other known or later-developed structure that allows a clamping, locking and/or positioning device to be moved along its length and then clamped, locked or stablely positioned at a desired position or location i.e., maintained at the desired position or location while the tool 600 is used to cut the workpiece 700, along the length of the overhead rail 240.

[0037] It should also be appreciated that, in various exemplary embodiments, a rotational axis 310 of the pivot joint assembly 300 extends through, and lies in the plane of, the front surface of the back edge stop 211 of the work surface 210. When this relative position for the rotational axis 310 of the pivot joint assembly 300 and the back edge stop 211 of the work surface 210 is used, the path of motion of the cutting element or tool 600 carried by the cutting tool tray assembly 400 will intersect the rotational axis 310 of the pivot joint assembly 300 at the back edge stop 211 of the work surface 210, regardless of the location of the extendable track assembly 1000 along the overhead rail 240. As shown in Fig. 1, it should further be appreciated that a center point 242 of the overhead rail 240 lies at a position along the overhead rail 240 where a center line extending between the center point 242 and the axis of rotation 310 is perpendicular to the direction A along the overhead rail 240.

[0038] Fig. 2 illustrates the relationship between the supporting frame assembly 200, the pivot joint assembly 300, the extendable track assembly 1000, and the front connection assembly 500. As shown in Figs. 1 and 2, the extendable track assembly 1000 extends at a selectable angle relative to the supporting frame assembly 200. The pivot joint assembly 300 connects a first point of the extendable track assembly 1000 to the supporting frame assembly 200. Additionally, the front connection 500 connects a second point of the extendable track assembly 1000 to the overhead rail 240. As shown in Figs. 1 and 2, the ,„;,!. _,,r ixfeJida&l€tϊiaclc aisBMψ'MOO is attached to the pivot joint assembly 300 such that the rotational axis 310 of the pivot joint assembly 300 intersects a cutting line that passes through a cutting element cut-out 1520 of the cutting tool tray 1500. Thus, when the cutting tool 600 is mounted on and carried by the cutting tool tray 1500 of the cutting tool tray assembly 400, such that the cutting element of the cutting tool 600 is aligned at the cutting line, a cut in the workpiece formed by the cutting element will intersect the rotational axis 310, regardless of the location of the extendable track assembly 1000 along the overhead rail 240.

[0039] As shown in Figs. 1 and 2, the illustrated exemplary embodiment of the front connection assembly 500 includes first and second body portions 510 and 520 that surround the overhead rail 240. When an actuator 530, such as a knob or any other known or later developed compression or locking device that can move the first and second body portions 510 and 520 towards each other, of the front connection assembly 500 is actuated, such as, for example, by turning a knob, to move the first and second body portions 510 and 520 towards each other, the first and second body portions 510 and 520 tightly grip the overhead rail 240 between them. This maintains the front connection assembly 500 at a particular position along the length of the overhead rail 240.

[0040] The front connection assembly 500 is also attached to a pivot post 1010 that is attached near or at the front end of a first moveable component 1200 of the extendable track assembly 1000. Accordingly, the pivot post 1010, and thus the front end of the extendable track assembly 1000, moves with the front connection assembly 500 as the front connection assembly 500 is moved by a user along the direction A along the length of the overhead rail 240. Because the pivot post 1010 is secured to the front connection assembly 500, when the knob 530 is turned to clamp the front connection assembly 500 to the overhead rail 240 at a particular position along the overhead rail 240, the pivot post 1010, and thus the extendable track assembly 1000, the cutting tool tray assembly 400 and the cutting tool 600 are temporarily positioned at a fixed location and angle relative to the overhead rail 240, and thus to the work surface 210. It should be appreciated that the specific form and structure of the front connection assembly 500 will depend in large measure on the shape and structure of the overhead rail 240. It should also be appreciated that any known or later-developed device or structure can be used as the front connection assembly 500, so long as that device or structure is able to move along the particular overhead rail 240 that is implemented, to lock the overhead rail 240 and rotatingly connect to the pivot post 1010.

[0041] It should further be appreciated that the front connection assembly 500 can be implemented using a biased pin assembly as the clamping, locking or positioning mechanism instead of the first and second body portions 510 and 520. In this embodiment,

a series of depressions, detents, holes, cuts or the like that are formed at locations along the overhead rail 240 that correspond to commonly-used cutting angles between the cutting tool 600 carried by the extendable track assembly 100 and the workpiece 700 to be cut. The biased pin assembly would include a pin, a rod, or the like and a biasing element, such as a spring or the like, that biases the pin, rod or the like toward and into the depression, detent, hole, cut or the like.

[0042] To operate this embodiment, the biased pin is withdrawn from the depression, detent, hole, cut or the like that it currently occupies. The front connection assembly 500, and thus the extendable track assembly 1000, can then be moved along the overhead rail 240 to a desired new position. The front connection assembly 500, and thus the extendable track assembly 1000, is located in the desired new position when the pin is appropriately positioned relative to the depression, detent, hole, cut or the like formed at the desired new position. Then, the pin, rod or the like is released, such that the biasing element urges the pin, rod or the like towards and into the depression, detent, hole, cut or the like. Once the pin, rod or the like has been urged into the depression, detent, hole, cut or the like, the location of the pivot joint assembly 500, and thus the extendable track assembly 1000, is temporarily fixed relative to the overhead rail 240 at the desired new position.

[0043] hi various other exemplary embodiments, the front connection assembly 500 can include threads or gear teeth, hi this case, the overhead rail 240 would typically be threaded or provided with gear teeth as well. For example, in various exemplary embodiments, the front connection assembly 500 could include, within the first and second body portions 510 and 520, a worm gear or the like having its rotational axis extending along the direction A or a pinion gear or the like having its rotational axis extending perpendicular to the direction A. In either case, the threads of the worm gear or the teeth of the pinion gear would interact with the threads or gear teeth of the overhead rail 240 to maintain the front connection assembly 500 at a given location along the length of the overhead rail 240. To move the front connection assembly 500 along the overhead rail 240, the knob 530, which would allow the user to turn the worm gear, pinion gear or the like, would be connected to the worm gear, pinion gear or the like, such that turning the knob 530 would cause the worn gear, pinion gear or the like to rotate, moving the front connection assembly 500, and thus the extendable track system 1000, to a new position along the overhead rail 240.

[0044] Of course, it should be appreciated that, although it is a more complicated structure, the overhead rail 240, instead of an element inside the front connection assembly 500, could be made rotatable. In this embodiment, the interior surface of the body portions 510 and 520 would have threads or gear teeth, while the overhead rail 240 would be threaded Ta. ends. The overhead rail 240 would also have a crank or other device that would allow the user to turn the overhead rail 240.

[0045] It should further be appreciated that in these exemplary embodiments and in the exemplary embodiment shown in Figs. 1 and 2, the overhead rail 240 and/or the overhead frame 230 could be provided with marks or the like that indicate the positions along the length of the support frame assembly 200 of the commonly-used cutting angles. The front connection assembly 500 will typically include a second mark that is aligned with a particular mark on the support frame assembly 200 to obtain the desired cut angle.

[0046] It should also be appreciated that mounting the extendable track assembly 100 to the supporting frame assembly 200 through the combination of the pivot joint assembly 300 and the front connection assembly 500 can provide additional advantages. For example, when, as outlined above, the pivot joint assembly 300 is attached to one component of the extendable track system 1000, while the front connection assembly 500 is attached to a second component of the extendable track system 1000 that can move relative to the first component, the distance between the pivot joint assembly 300 and the front connection assembly 500 is not fixed. It should be appreciated that the distance across the overhead frame 230 and the overhead rail 240 of a path that extends through the rotational axis 310 of the pivot joint assembly 310 depends on the angle of that path to the supporting frame assembly 200.

[0047] As the front connection assembly 500 travels along the overhead rail 240 along the direction A, the angle of the extendable track assembly 1000 relative to the overhead rail 240 changes. The various nested tracks of the extendable track assembly 1000 move relative to each other along a direction B that lies in a plane that is orthogonal to the rotational axis of the pivot joint assembly 300 and at an alterable angle to the overhead rail 240. It should be appreciated that the direction B thus makes an alterable angle with the overhead rail 240. At the same time, as the pivot post 1010 moves with the front connection assembly 500, at least the first moveable component 1200 of the extendable track assembly 1000 moves relative to at least the first stationary component 1100 and the pivot joint assembly 300 to accommodate changes in distance between the rotational axis 310 of the pivot joint assembly 300 and the front connection assembly 500. That is, as the location of the front connection assembly 500 along the overhead rail 240 changes, and thus the angle between the supporting frame assembly 200 and the extendable track assembly 1000, changes, the extendable track assembly 1000 automatically extends and/or retracts to accommodate the resulting changing distance between the pivot axis 310 of the pivot point assembly 300 and the front connection assembly 500. frø^} /"B€WgϊSitiat the extendable track assembly 1000 makes to the supporting frame assembly 200 changes as the front connection assembly 500 is moved along the overhead rail 240. Thus, the distance between the pivot joint assembly 300 and the front connection assembly 500 changes as the front connection assembly 500 is moved along the overhead rail 240. In particular, this distance increases as the front connection assembly 500 moves away from the center point 242. Furthermore, as this distance increases, the extendable track assembly 1000 automatically extends to account for this increased distance. Consequently, more of the extendable track assembly 1000 will thus lie between the pivot joint assembly 300 and the front connection assembly 500. As a result, the extendable track assembly 1000 is better supported as the front connection assembly 500 moves along the overhead rail 240 away from the center point 242. This better support is important, because, as the path length increases, and thus the length of the cut that will need to be made through the workpiece 700 increases, the precision and the accuracy of the cut become more critical to obtaining a usable cut through the workpiece 700.

[0049] As indicated above, as the path length, and thus the length of the cut that will need to be made through the workpiece 700, increases, the precision and the accuracy of the cut become more critical to obtaining a usable cut through the workpiece. It should be appreciated that the cut length increases as the distance of the front connection assembly 500 along the overhead rail 240 from the center point 242 increases. If the extendable track assembly 100 is mounted to the supporting frame assembly 200 through the combination of the pivot joint assembly 300 and the front connection assembly 500, as the distance of the front connection assembly 500 along the overhead rail from the center point 242 increases, a unit displacement of the front connection assembly 500 along the overhead rail 240 corresponds to a decreasing angular displacement of the extendable track assembly 1000 relative to the supporting frame assembly.

[0050] That is, when the front connection assembly 500 is at the center point 242, the path of the extendable track assembly 1000 as it is extended and collapsed, and thus the cut line of the cutting tool 600, is aligned with, or at 0° relative to, the center line. If the width of the support frame assembly 200, i.e., the minimum distance between the axis of rotation 310 and the center of the pivot pin 1010 is 30 cm, then moving the front connection assembly 500 one cm from the center point 242 changes the angle of the cut line relative to the center line by about 2° (~1.9°) to about 2°. However, when the front connection assembly 500 is moved 1 cm from a position 30 cm from the center point 242 to 31 cm from the center point 242, the angle of the cut line relative to the center line changes by about .939°, from 45.0° to about 45.9°. Moreover, when the front connection assembly 500 is moved 1 cm § the center point 242 to 120 cm from the center point 242, the angle of the cut line relative to the center line changes by about .1133°, from about 75.8505° to about 75.9638°.

[0051] Thus, a one centimeter error near the center point 242 results in nearly 100% error, while a one centimeter error at 30 cm from the center point 242 results in about a 2% error, while a one centimeter error at 120 cm from the center point 242 results in about a 0.15% error. Accordingly, as the front connection assembly 500 moves away from the center point 242, the cut length increases and becomes more sensitive to errors in setting the desired cut angle, while setting the desired cut angle becomes less sensitive to errors in positioning the front connection assembly 500.

[0052] In various exemplary embodiments, when operating the tool carrying device 100, the extendable track assembly 1000, and thus, the connected cutting tool tray assembly 400, rotate relative to the supporting frame structure 200. The combination of the pivot joint assembly 300 and the front connection assembly 500, which each connect the extendable track assembly 300 to the supporting frame structure 200, allows the user to controllably set the angle that the extendable track assembly 1000, and thus the angle that the cutting tool tray assembly 400, makes with the supporting frame assembly 200. In the specific exemplary embodiment of the front connection 500 shown in Figs. 1 and 2, to allow the position of the extendable track assembly 1000 along the supporting frame assembly 200 to be modified, the knob 530 of the front connection assembly 500 is loosened. The extendable track assembly 1000 can be pivoted around the pivot joint assembly 300 by moving the released front connection assembly 500 along the direction A along the overhead rail 240.

[0053] In the specific exemplary embodiment of the front connection 500 shown in Figs. 1 and 2, once the front connection assembly 500 is at a desired location along the overhead rail 240, such that the extendable track assembly 1000 is at a desired angular orientation relative to the supporting frame assembly 200, the knob 530 of the front connection assembly 500 is tightened to lock or maintain the position of the front connection assembly 500 at the desired location along the overhead rail 240, and thus lock into or maintain in place the angle of the extendable track assembly 1000 relative to the supporting frame assembly 200. Once the angular orientation of the extendable track assembly 1000 relative to the supporting frame assembly is set, the various tracks 1100-1400 of the extendable track assembly 1000 can be moved relative to each other along the direction B, to move the cutting tool tray 400, and thus the cutting tool 600, along the desired angle to cut the workpiece 700 at the desired angle. The cutting tool tray assembly is able to move relative to the supporting frame assembly 200 along the direction B and along a third r&recffiiiilfisucltϊfiltSttϊi^cElting tool tray assembly 400 may be lowered and raised relative to the supporting frame assembly 200 and the workpiece 700.

[0054] Fig. 3 shows a cut-away perspective view of one exemplary embodiment of the pivot joint assembly 300. In particular, Fig. 3 shows how the pivot joint assembly 300 is attached to the first stationary component 1100 of the extendable track assembly 1000. As shown in Fig. 3, the pivot joint assembly 300 includes a first plate 320 and a second rotatable plate 330, where the relative rotational axis of the first and second plates 320 and 330 is the rotation axis 310. In various exemplary embodiments, the pivot joint assembly 300 uses internal ball bearings to allow the first and second plates 320 and 330 to freely rotate relative to each other. It should be appreciated that the pivot joint assembly can use any type of bearing, guide and/or support system to control and maintain the axis of rotation 310 and/or to support and/or stabilize the extendable track system 1000. It should be appreciated that such bearing, guide and/or support systems include ball bearings, plastic or ceramic bearings, bronze or other ferrous or non-ferrous bearing surfaces, or any other types of arrangements that adequately and appropriately control and maintain the axis of rotation 310 and/or to support and/or stabilize the extendable track system 1000.

[0055] In various exemplary embodiments, the first plate 320 is secured or attached to the bottom of the overhead frame 230, while the second plate 330 is attached to a stationary component 1100 of the extendable track assembly 1000. In various exemplary embodiments, so that the path of the cutting element of the cutting tool 600 will pass through a fixed spot on the work surface 210, the rotational axis 310 of the first and second plates 320 and 330 intersects the front surface of the back stop 211 of the work surface 210. The second plate 330 is attached to the extendable track assembly 1000 so that a cutting line of the cutting tool tray 1500 also intersects the rotational axis 310. As shown in Figs. 1-3, because the shown exemplary embodiment of the cutting tool tray 1500 centers the cutting tool 600, thus offsetting the cutting line to the left, the extendable track assembly 1000 is connected to the pivot joint assembly 300 at a corresponding off-center location.

[0056] It should be appreciated that the relative rotation between the first and second plates 320 and 330 can be accomplished by forming semi-circular channels in the opposing surfaces of the plates 320 and 330, where the channels are filled with the ball bearings and the plates 320 and 330 are rotatably mounted to each other. For example, a pin or other connector can be used to join the centers of the circular ball bearing channels to line up the axes of rotation of the plate 320 and 330 to establish the rotational axis 310.

[0057] It should also be appreciated that the pivot joint assembly 300 may be implemented using any other known or later-developed device or structure that allows the ^"ixteMaflfMlQK i&M?fW>tjf ©00 to rotate relative to the supporting frame assembly 200 such that the extendable track assembly 1000 can be connected to the overhead frame 230 while remaining easily alignable at a desired angle relative to the supporting frame structure 200. In various exemplary embodiments, the pivot joint assembly 300 comprises a turntable-type device or structure, but the joint may simply comprise a plate with a through hole rotating about a pin, a ball-and-joint assembly or any other known or later developed device, assembly structure or the like that allows the extendable track assembly 1000 to rotate about the rotational axis 310.

[0058] Fig. 4 is a perspective view of one exemplary embodiment of the extendable track assembly 1000 and one exemplary embodiment of the cutting tool tray assembly 400. Fig. 5 shows a front plan view of the exemplary embodiment of the extendable track assembly 1000 shown in Fig. 4 and one exemplary embodiment of the cutting tool tray assembly 400 shown in Fig. 4. This view more clearly shows the specific relationships between the components of the extendable track assembly 1000 and the cutting tool tray assembly 400. As shown in Figs. 4 and 5, the extendable track assembly 1000 contains a first stationary component 1100, a first sliding component 1200, a second sliding component 1300, a third sliding component 1400, and the cutting tool tray assembly 400. hi various exemplary embodiments, the first stationary component 1100 is attached to the pivot joint assembly 300, which allows the first stationary component 1100 to rotate around the axis 310 of the pivot joint assembly 300, but which prevents the first stationary component 1100 from moving laterally relative to that rotational axis 310.

[0059] The first sliding component 1200 is able to move laterally along the direction B relative to the first stationary component 1100 and thus relative to the pivot joint assembly 300 and the supporting frame assembly 200. The second sliding component 1300 is able to move laterally along the direction B relative to the first sliding component 1200 and thus relative to the pivot joint assembly 300 and the supporting frame assembly 200. The third sliding component 1400 is also able to move laterally along the direction B relative to the second sliding component 1300 and thus relative to the pivot joint assembly 300 and the supporting frame assembly 200. The cutting tool tray 400 is able to move more or less vertically along the direction C relative to the third sliding component 1400 and thus relative to the pivot joint assembly 300 and the supporting frame assembly 200. As discussed above, cutting tool tray assembly 400 typically has a saw or other cutting tool mounted on it.

[0060] It should be appreciated that the three movable components are exemplary only, and other exemplary embodiments of the extendable track assembly 1000 may have fewer or more movable components, depending on the length the extendable track assembly 1000 is αesi^ieStδl^teήβ€'I'ϊfep'feiiPiniple, if the extendable track assembly 1000 is designed to cut only molding, base stock and Hie like, it may need to extend only a few inches, and thus only two movable components may be sufficient. If the extendable track assembly 1000 is designed to cut rafters, joists, siding, clapboard, and the like, it will need to extend to about 12 to about 18 inches, and thus three or four movable components may be implemented, hi contrast, if the extendable track assembly 1000 is designed to cut very wide boards, plywood panels and the like, four, five or more movable components maybe needed. Regardless of the number of implemented movable components, the cutting tool assembly 400 will include the last movable component and the cutting tool tray 1500 will be movable connected to that last movable component.

[0061] It should be appreciated that, in various exemplary embodiments, the first stationary component 1100, the first sliding component 1200, the second sliding component 1300, the third sliding component 1400, and the cutting tool tray assembly 400 are connected together using linear slide bearings and linear shafts that restrict the path of movement of the components 1100-1400 and the cutting tool tray assembly 400 with respect to each other. Linear slide bearings are desirable because they allow the components 1100-1400 and the cutting tool tray assembly 400 to move relative to one another over substantial distances along the direction B, or the direction C, respectively, while maintaining the relative positions of the components 1100-1400 and the cutting tool tray assembly 400 relative to each other in orthogonal directions to a high precision and accuracy. A typical interface between two of the components 1100-1400 and/or the cutting tool tray assembly 400 includes two slide bearings, comprising two linear shafts connected to a first one of the components 1100-1400 and the cutting tool tray assembly 400, and two or more sets of linear bearings connected to a second one of the components 1100-1400 and the cutting tool tray assembly 400.

[0062] For example, if the user wanted to move the third sliding component 1400 laterally along the direction B with respect to the first stationary component 1100, that motion might be achieved by moving one or more of the first moveable component 1200, the second moveable component 1300, and/or the third moveable component 1400 relative to the first stationary component 1100 and thus relative to the pivot joint assembly 300 and the supporting frame assembly 200. As the components 1100-1400 are nested, the overall amount of relative displacement of the third moveable component 1400 with respect to the first stationary component 1100 and thus relative to the pivot joint assembly 300 and the supporting frame assembly 200 is greater than the provided amount of relative displacement between any of the individual components 1100-1400 of the extendable track assembly 1000.

[0063] It should also be appreciated that, in the extendable track assembly 1000, as ^"©BeilifMIMii^rllC^i'ΩϊtilSple linear bearings travel along each linear shaft. For example, at the track interface between the first stationary component 1100 and the first moveable component 1200, two or more linear bearings ride along each of the two linear shafts. The linear bearings mounted on each shaft must be in proper alignment with each other and with respect to the particular shaft they travel along. Additionally, the two shafts should be aligned in a way such that they are acceptably parallel with each other along the path of motion that the slide bearing creates. Furthermore, all of the linear bearings on the two linear shafts must be toleranced such that, along the path of motion, no single linear bearing interferes with the linear shaft the linear bearings travel along, along the entire length of the path of motion.

[0064] It should be appreciated that, in the exemplary embodiment shown in Figs. 4-11, the extendable track assembly 1000 contains three relatively rigid components. That is, the stationary component 1100, the second moveable component 1300 and the cutting tool tray assembly 400 are relatively rigid components. It should also be appreciated that the extendable track assembly 1000 contains two relatively adjustable components, the first and third moveable components 1200 and 1400, that may be flexible relative to the relatively rigid components 1100 and 1300 and the cutting tool tray 400. In various exemplary embodiments, the adjustable moveable components 1200 and/or 1400 contain both relatively rigid subcomponents as well as relatively elastically deformable sub-components.

[0065] In the illustrated exemplary embodiments, at least portions of the adjustable track components 1200 and/or 1400 elastically deform to adjust either the hole-to-hole distance or the center-to-center distance to match the other distance as the slide bearings travel along the linear shafts. The flexible sub-components in the first and third moveable components 1200 and 1400 effectively act as internal springs that allow either the hole-to- hole or center-to-center distance of the bearings to adjust to meet the dimensional requirements of the relatively rigid components 1100 and 1300 or the cutting tool tray 400.

[0066] In various other exemplary embodiments, a first sub-component and a second sub-component of each of the adjustable first and third moveable components 1200 and/or 1400 can be attached to each other so that these first and second sub-components can move or slide laterally relative to each other to adjust the hole-to-hole of the linear bearings or the center-to-center distance of the linear bearings of the linear shafts that are attached to the adjustable first or third moveable component 1200 or 1400 to match the center-to-center distance of the linear shafts or the hole-to-hole distance of the linear bearing that are attached to the relatively rigid first stationary component 1100 or second moveable component 1300.

[0067] hi still other exemplary embodiments, the adjustable third moveable component 1400 includes a hinge structure between its first sub-component and at least the pδrfiimrliflϊfsBeciQBidirpis-iiJδSiiponent to which the linear bearings or the linear shaft are attached. The hinge structure allows at least that portion of the second sub-component to rotate relative to the first sub-component to adjust the hole-to-hole distance of the linear bearings or the center-to-center distance of the linear bearings of the linear shafts that are attached to the adjustable first or third moveable component 1200 or 1400 to match the center-to-center distance of the linear shafts or the hole-to-hole distance of the linear bearing that are attached to the relatively rigid first stationary component 1100 or the second moveable component 1300.

[0068] In still other exemplary embodiments, two or more of these structures and/or adjusting mechanisms are incorporated into each of the adjustable first and/or third adjustable moveable components 1200 and/or 1400. Thus, the adjustable first moveable component 1200 may have an elastically deformable second sub-component that is attached to the first sub-component such that the first and second sub-components can move relative to one another laterally. Alternatively, the adjustable first moveable component 1200 can include first and second sub-components that are attached to each other so that they can move laterally relative to each other. Additionally, that second sub-component could be divided into two portions that are attached to each other using a hinge structure that is located between the first sub-component and the portion of the second sub-component that the linear bearings or the linear shaft are attached to.

[0069] Fig. 6 shows in greater detail one exemplary embodiment of the first stationary component 1100 shown in Figs. 4 and 5. As shown in Fig. 6, the first stationary component 1100 includes a top plate 1110, two side plates 1120 and 1130, and two sets of linear bearings 1122 and 1132. Because the first stationary component 1100 is rigid relative to the adjustable first moveable component 1200, the hole-to-hole distance between the two linear bearing sets 1122 and 1132 is relatively fixed.

[0070] Fig. 7 is a plan view showing in greater detail one exemplary embodiment of the adjustable first moveable component 1200 shown in Figs. 4 and S. The adjustable first moveable component 1200 contains a plate assembly 1210 comprising a relatively rigid subcomponent 1220 and a flexible sub-component 1230. As shown in Fig. 7, a first set of linear shafts 1222 is attached to the relatively rigid sub-component 1220, while a second set of linear shafts 1232 is attached to the flexible sub-component 1230. One or more fasteners 1240 attach the relatively rigid sub-component 1220 and the flexible sub-component 1230 together to form the plate assembly 1210. The upper linear shafts 1223 and 1233 of the first flexible component 1200 mate with the two sets of linear bearing 1122 and 1132, respectively, of the first stationary component 1100. IPiQf ® /M ' W^c^®- point along the first and second sets of linear shafts 1222 and 1232, the center-to-center distances between the upper linear shafts 1223 and 1233 can vary because, under at least mild stress, the flexible sub-component 1230 locally elastically deforms and/or the flexible sub-component 1230 slides or moves relative to the relatively rigid sub-component 1220 to at least partially adjust the center-to-center distance between the upper precision linear shafts 1223 and 1233 to match the hole-to-hole distance between the pairs of linear bearings 1123 and 1223 attached to the first relatively rigid component 1100. Thus, the center-to-center distances between the upper linear shafts 1223 and 1233 do not need to be constant over the usable length. Consequently, it is not necessary to place the upper linear shafts 1223 and 1233 such that the placement tolerances are extremely high, as is conventionally required when mounting the sets of linear shafts 1222 and 1232.

[0072] That is, because the first stationary component 1100 has a fixed hole-to-hole distance between each pair of linear bearings 1123 and 1133 formed between the sets of linear bearings 1122 and 1132, as the adjustable first moveable component 1200 travels along the direction B, the flexible sub-component 1230, by flexing and/or moving/sliding relative to the relatively rigid sub-component 1220, allows the center-to-center distance between corresponding portions of the linear shafts 1223 and 1233, as those travel past a given pair of linear bearings 1123 and 1133, to at least partially match the fixed hole-to-hole distance that is present between that pair of linear bearings 1123 and 1133.

[0073] Then, after those portions of the upper linear shafts 1223 and 1233 move away from that pair of linear bearings 1123 and 1133, at least the local portion of the flexible sub-component 1230 returns to a rest or unstressed position. Thus, the flexibility inherent in the flexible sub-component 1230 of the adjustable first moveable component 1200 allows for the tolerances used in positioning and aligning the linear bearings 1123 and 1133 on the first stationary component 1100 and the first and second sets of linear shafts 1222 and 1232 on the adjustable first moveable component 1200 to be significantly less than they would be in a device in which the components 1100 and 1200 were both fully rigid elements.

[0074] It should also be appreciated that the fastening subcomponents 1240 do not need to be rigid. In this particular exemplary embodiment, the fastening sub-components 1240 are padded by rubber washers that allow for even more built in elasticity at the location of these joints. In addition to the rubber washers, in various exemplary embodiments, additional rotational and translational flexibility of the relatively rigid sub-component 1220 relative to the relatively flexible sub-component 1230, is obtained by providing slots in one or both of the sub-components 1220 and 1230 and fastening them together so that the they remain able to move relative to one another. IWiI _/" ΪMOTlξNjo be appreciated that the dynamically adjusting nature of the adjustable first moveable component 1200 may also be used in alternate configuration, such as that of the adjustable third moveable component 1400. That is, it is possible to place the linear bearings, instead of the linear shafts, on the adjustable component. Furthermore, the path of motion is not necessarily restricted to a horizontal direction. There may be multiple ways to configure or align any such tracking system in a component assembly.

[0076] It should also be appreciated that the flexible sub-component 1230 does not necessarily need to be a unitary structure. Thus, instead of the flexible sub-component 1230 being a single elastically deformable element, the flexible sub-component 1230 can be implemented as a first member that is connected to the rigid sub-component 1220 by the fastening sub-components 1240 and a second member that is connected to the first member by one or more hinges or the like. In various exemplary embodiments, the one or more hinges can be implemented using a piano hinge that is approximately at least as long as the linear shaft 1232. Thus, instead of gaining its adjustable nature from the elastic behavior of the material used to form the flexible sub-component 1230, the at least one hinge or the like acts as a mechanical way of allowing the flexible sub-component 1230 to elastically deform.

[0077] Fig. 8 shows in greater detail one exemplary embodiment of the second moveable component 1300. The second moveable component 1300 contains a relatively rigid sub-component 1310, third and fourth sets of linear bearings 1322 and 1332, which are attached to the exterior of relatively rigid sub-component 1310, and two linear shafts 1324 and 1334, which are attached to the interior of the relatively rigid sub-component 1310. The exterior linear slide bearings 1323 and 1333 of the third and fourth sets of linear bearings 1322 and 1332 will mate with the lower linear shafts 1224 and 1234 of the first and second sets of linear shafts 1222 and 1232 attached to the adjustable first moveable component 1200. Additionally, as shown in Figs. 8 and 10, the lower linear shafts 1324 and 1334 mounted on the relatively rigid sub-component 1310 mate with the linear bearings 1425 and 1435 of the fifth and sixth sets of linear bearings 1424 and 1434 mounted on the adjustable third moveable component 1400.

[0078] It should be appreciated that the second moveable component 1300 maintains horizontal and vertical positions relative to the relatively rigid sub-component 1220. It should be noted that all of the relatively rigid sub-components are positioned on the left hand side of the components in the plan view shown in Fig. 5. This effectively creates a kind of "ground" position at the first stationary component 1100 including the set of linear bearings 1122. This ground position is then transferred down to the linear shaft 1222 and the rigid sub-component 1220, and is then transferred down through the second relatively rigid Sd set of linear bearings 1322 and the linear shaft 1324.

[0079] The second moveable component 1300 is thus grounded to the first stationary component 1100 by the slide bearings, including the linear bearings 1123 of the first set of linear bearings 1122 and the linear shaft 1223, the relatively rigid sub-component 1220, and the slide bearing including the linear shaft 1224 and the linear bearings 1323 of the third set of linear bearings 1322. The linear shaft 1324 and the linear bearings 1425 of the fifth set of linear bearings 1424 then acts as a ground point for the mating components in the saw tray assembly 400, including the adjustable third moveable component 1400 and the cutting tool tray 1500 mating with the set of linear bearings 1432 attached to the cutting tool tray assembly 400.

[0080] It should be appreciated that, while the left side linear bearings and flexible sub-components behave as ground structures for the sliding components, the right hand side of the components shown in the plan view of Fig. 5 serves as a floating guide. The right hand side linear bearings and flexible sub-components in this particular application are designed to adjust to meet the dimensional requirements of the rigid hole-to-hole or center-to-center distance as defined by the rigid mating components.

[0081] As outlined above, a hinge can be located between the first and second subcomponents 1220 and 1230 of the relatively flexible first moveable component 1200. In various exemplary embodiments, this hinge can be used to connect the first and second subcomponents 1220 and 1230 to each other. In various exemplary embodiments, this hinge can be used to attach separate portions of the sub-component 1230, while other structures or devices are used to connect together the first and second sub-components 1220 and 1230.

[0082] Fig. 9 and Fig. 10 are side and plan views of one exemplary embodiment of the cutting tool tray assembly 400 that includes the adjustable third moveable component 1400 and a cutting tool tray 1500. The adjustable third moveable component 1400 includes two rigid plate sub-components 1420 and 1430; four sets of linear bearings 1422, 1424, 1432, and 1434 ; a relatively rigid sub-component 1440; and a flexible sub-component 1450. The cutting tool tray 400 includes relatively rigid cutting tool tray 1500; two sets of linear shafts 1522 and 1532; and a stop 1524.

[0083] The relatively rigid sub-component 1440 is attached to the rigid plate subcomponent 1420. The rigid plate sub-component 1420 is also attached to two linear bearings 1423 of the set of linear bearings 1422. The flexible sub-component 1450 is attached to the rigid plate sub-component 1430, which is then attached to two linear bearings 1433 of the set of linear bearings 1432. The linear bearings 1423 of the set of linear bearings 1422 then mate with the linear shafts 1523 of the set of linear shafts 1522 that are attached to one side of the i$ϊfiΦ3|Mtaγ e'δilponent 1510. The set of linear side bearings 1422 mate with the set of linear shafts 1522. The linear bearings 1433 of the set of linear bearings 1432 mate with the linear shafts 1533 of the set of linear shafts 1532 that are attached to the other side of the relatively rigid cutting tool tray 1500. It should be appreciated that the adjustable third moveable component 1400 mates to both the second moveable component 1300 and the cutting tool tray 1500.

[0084] The flexible third moveable component 1400 is adjustable due to using two tray stabilizer guides, which include the relatively rigid sub-component 1440 and the flexible sub-component 1450. The relatively rigid sub-component 1440 is analogous to the relatively rigid sub-component 1220 and the flexible sub-component 1450 is an analogous to the flexible sub-component 1230 of the adjustable first moveable component 1200. This means that the relatively flexible sub-component 1450 is a more elastic and flexible element than is the relatively rigid sub-component 1440, allowing the two rigid plates 1420 and 1430, that are attached to adjust the two rigid plates 1420 and 1430, to move relative to each other as the linear bearings 1423 and 1433 of the sets of linear bearings 1422 and 1432 move along the linear shafts 1523 and 1533 of the set of linear shafts 1522 and 1532.

[0085] The above-outlined description of the extendable track assembly 1000 is directed to linear slide bearings and a novel method for reducing alignment tolerances. However, it should be appreciated that any other appropriate type of system that allow the moveable components 1200-1400 and/or the cutting tool tray assembly 400 to be moved relative to each other and/or the stationary component 1100, respectively, can be used in place of the linear slide bearings described above. Of course, even if the linear slide bearings are used, it should be appreciated that the novel system for reducing alignment tolerances does not need to be used, hi that case, it may not be necessary that the various components 1200- 1400 and the cutting tool assembly 400 use the specific structures outlined above so long as they can be readily moved relative to each other and the stationary component 1100. Thus, it should be appreciated that the drawer slides, cabinet slides, roller slides, tongue-and-groove slides, guide rods, magnetic bearings, air bearings, roller bearings and any other appropriate known or later developed device that appropriately and adequately provide lateral movement between the various components of the extendable track assembly 1000 could be used in place of the linear bearings outlined above.

[0086] Fig. 11 is a cut-away perspective view of one exemplary embodiment of the cutting tool tray assembly 400. As shown in Figs. 2, 4, 5 and 9-11, the cutting tool tray assembly 400 includes the rigid plate sub-components 1420 and 1430, a rod 410 extending between the rigid plate sub-components 1420 and 1430, first and second rollers 420 and 430 F^tM^lMM&P^i;®^!¹^;^ ^{410 and} fi^{rst and} second tension springs 440 and 450 wound around the rollers 420 and 430, respectively.

[0087] Each of the tension springs 440 and 450 provides an upward bias or force to the cutting tool tray 1500 and the cutting tool 600 carried on the cutting tool tray 1500. In various exemplary embodiments, each of the tension springs 440 and 450 has a different spring constant and thus provides a different amount of upward bias to the cutting tool tray 1500. Tension springs are used in some exemplary embodiments because they provide a generally constant force, regardless of the amount of the downward displacement of the cutting tool tray 1500 relative to the rigid plates 1420 and 1430. Thus, if the upward bias provided by the tension springs 440 and 450 substantially balances the weight of the cutting tool tray 1500 and cutting tool 600, once put in any position relative to the rigid plates 1420 and 1430, will tend to remain at that position.

[0088] Thus, as the operator uses the tool carrying device 100 to position the cutting tool 600 to cut the workpiece 700, it takes almost no effort for the operator to move the cutting tool tray 1500 toward the workpiece 700, or to move the cutting tool tray 1500 away from the workpiece after it is cut. That is, the tension springs 440 and 450 are designed to generally offset the weight of the cutting tool tray 1500 and the particular cutting tool 600 carried by the cutting tool tray 1500. Thus, the net upward or downward force on the cutting tool tray 1500 due to the upward force provided by the tension springs 440 and 450 and the downward force provided by gravity on the mass of the cutting tool tray 1500 and the particular cutting tool 600 is at least close to zero.

[0089] Thus, the operator, rather than having to overcome the weight of the cutting tool tray 1500 and the particular cutting tool 600, merely needs to provide a small amount of force to overcome the residual force. At the same time, because the tension springs 440 and 450 provide a constant upward force, rather than an increasing force, such as provided by a torsion spring, as the tension springs are increasingly displaced from their rest position, the operator does not need to provide additional downward force on the cutting tool tray 1500 as it moves from its rest position toward the workpiece 700 to be cut. Likewise, when the operator returns the cutting tool tray 1500 to its rest position away from the workpiece 700, the operator again only needs to overcome any residual force on the cutting tool tray 1500. Of course, it should be appreciated that, to begin moving the cutting tool tray 1500, the operator may also have to overcome any static friction in the extendable track assembly linking the cutting tool tray assembly 400 to the third moveable component 1400 of the extendable track assembly 1000.

[0090] In various exemplary embodiments, because the tool carrying device 100 is ^™ϋclesiyiSilS)ϋEQ.ⁱύ®tJ^fltϊ&βide variety of cutting tools 600, it is very likely that one user of the tool carrying device 100 could use a relatively small cutting tool 600, while another user of the same or a different tool carrying device 100 may use a very large cutting tool. Accordingly, to accommodate this wide range of cutting tools 600 that can be used with the tool carrying device 100, the tool carrying device 100 is typically, although not necessarily, provided with tension springs that have different spring constants, and thus provide differing amounts of upward bias to the tool carrying tray 1500. To identify the differing spring constants of the tension springs, the free ends 442 and 452 of the tension springs 440 and 450, respectively, can be provided with differing numbers of attachment holes 443 and 453.

[0091] As shown in Fig. 10, in various exemplary embodiments, a back wall 1510 of the cutting tool tray 1500 includes a corresponding set of attachment holes 1512 for each of the tension springs 440 and 450. In particular, in various exemplary embodiments, the set of attachment holes 1512 includes three different attachment holes. It should also be appreciated that various clamping devices or other tool hold down devices can be provided on the cutting tool tray 1500 to allow the cutting tool 600 to be securely held in place on the cutting tool tray 1500. The provided clarnp(s) and/or other structures should allow a wide variety of different types of cutting tools from a wide variety of manufacturers to be securely held to the cutting tool tray 1500.

[0092] In various exemplary embodiments, a tension spring that is designed to provide a small amount of upward force typically has a single mounting hole 442 or 452 that corresponds to the centermost mounting hole of the set of mounting holes 1512. A tension spring that is designed to provide a medium amount of upward force typically has a pair of mounting holes 442 or 452 that correspond to the outer mounting holes of the set of mounting holes 1512, while a tension spring that is designed to provide a large or high amount upward force will typically have three mounting holes 442 or 452 corresponding to the three mounting holes in the set of mounting holes 1512.

[0093] It should also be appreciated that these tension springs typically will be generally visibly distinguishable from each other, as the small force tension spring will tend to be smaller than the medium and large force tension springs, while the large force tension spring will tend to be bigger than the medium and small force tension springs. It should also be appreciated that, in various exemplary embodiments, the tool carrying device 100 is designed to allow the various tension springs to be easily detached from the cutting tool tray 1500, by removing easily-removable pins, which connect the tension springs 440 and 450 to the back wall 1510 by extending through the provided holes 442 or 452 and the corresponding ones of the holes 1512. fθ1EMi|,/ RiSMoSExemplary embodiments, the rod 410 can be detached from the rigid plate sub components 1420 and 1430, if necessary and/or desirable, to allow larger or smaller tension springs to be used in place of the currently installed set of tension springs. Thus, if a very light cutting tool 600 is placed on the cutting tool tray 1500, such that the small tension spring 440 would be sufficient to offset the weight of the cutting tool tray 1500 and the small cutting tool 600, if the small tension spring 440 is installed, it can be attached to the cutting tool tray 1500, and the other tension spring 450, whether small, medium or large, could be detached from the cutting tool tray 1500.

[0095] In contrast, if the installed tension springs 440 and 450 were both medium and/or large tension springs, one of the tension springs 440 and 450 could be removed from around the rod 410 and a small tension spring mounted on the rod 410 in its place. However, if a large cutting tool is placed on the cutting tool tray 1500, such that both of the installed tension springs 440 and 450 are sufficient to offset its weight and the weight of the cutting tool tray 1500, both of those tension springs 440 and 450 could be attached to the back wall 1510 of the cutting tool tray 1500. Otherwise, one or both of the unused tension springs could be removed from around the rod 410 and larger tension springs added to support the weight of the large cutting tool.

[0096] Operation of the tool carrying device 100 will now be described with respect to cutting a relatively long workpiece 700, such as a piece of siding, while the tool carrying device 100 is mounted on the work table of a scaffolding. In operation, the operator of the tool carrying device will typically place a mark or a line on the workpiece 700 to indicate the location and angle of the cut to be made on the workpiece 700.

[0097] Typically, when cutting siding, the angles the siding must be cut at are defined by the horizontal run of the siding relative to its vertical run. For example, a siding may have a 3 : 12 pitch, which indicates the siding needs to be cut so that for every three feet of vertical rise, for the siding work piece 700 there is twelve feet of horizontal run. This corresponds to a 75.96° cut. Accordingly, the operator marks a 75.96° line on the workpiece and/or indicates a location where the cut needs to start on the side of the workpiece that lies against the back edge 211 of the work surface 210.

[0098] Because the extendable track assembly 1000 of the tool carrying device 100 extends backwards behind the work surface 210, and because the extendable track assembly 1000 suspends the cutting tool tray 1500 back and away from the surface of the workpiece 700, the operator can easily place the workpiece 700 on the cutting surface 210 and can easily maneuver along the length of the tool carrying device 100 without running into the extendable track assembly 1000 and/or the carried cutting tool. In particular, the operator does not have ^<|δ,,mM€lfMttιe^>'\iδiMϊpseJ5ieiE00 past a cutting tool tray or cutting tool that limits how the workpiece 700 may be introduced into the tool carrying device 100 and aligned with the cutting tool 600. That is, the operator can easily place the workpiece 700 on the cutting surface 210 without having to maneuver the workpiece 700 around any portion of the extendable track assembly 1000 and/or the cutting tool tray 1500 or the cutting tool 600.

[0099] Once the operator has placed the marked-up workpiece 700 on the work surface 210, the operator lines up the mark at the end of the workpiece 700 that is adjacent to the backstop 211 with a mark that indicates the position of the rotational axis 310 along the length of the work surface 210, i.e., along the direction A. By placing this end of the cut to be made on the workpiece 700 at the location of the rotational axis 310, the operator knows that the cut line to be formed by the cutting tool 600 will necessarily go through this point, regardless of the position of the extendable track assembly 1000 relative to the support frame assembly 200, as the cut line of the tool 600 is aligned via the extendable track assembly 1000 with the rotational axis 310.

[0100] The operator then loosens the knob 510 of the front connection assembly 500 and moves the front connection 500, and thus the front end of the first moving component 1200 of the extendable track assembly 1000 laterally along the direction A until the cutting element of the cutting tool 600 carried by the extendable track assembly 1000 is properly aligned with the desired cut line to be made on the workpiece 700. In various exemplary embodiments, the overhead rail 240 can have marks, indentations, detents or other visible and/or physical indicia or marks provided on or formed in the overhead rail 240 corresponding to various desired cut angles. Accordingly, if the overhead rail 240 has a visible indicia and/or physical mark corresponding to the 3:12 pitch angle that the operator wishes to cut the workpiece 700 at, the operator can easily move the front connection assembly 500, and thus the extendable track assembly 1000 to that location. Otherwise, in various exemplary embodiments, the user can easily, visually line up the cutting element of the cutting tool 600 with the desired cut line provided on the workpiece 700.

[0101] In various other exemplary embodiments, one, two or more stop blocks can be provided on the overhead rail 240. The operator can place the stop blocks at desired positions along the overhead rail 240 where a number of cuts will be made. By using the stop blocks, the operator can quickly place the front connection assembly 500 at a known, highly accurate and/or precise location, whenever one of the repeated cuts needs to be made. This allows these repeated cuts to be done in a highly reproducible manner without having to manually re-align the cutting element of the cutting tool 600 with the desired cut line provided on the workpiece 700. ϋEPIf 13 ,/"Ii

user then tightens the knob 510 of the front connection assembly 500 to lock the front connection assembly 500, and thus the extendable track assembly 1000 at the desired angular location along the overhead rail 240. Because the tool carrying device 100 allows the cutting element of the cutting tool 600 to extend through the tool carrying tray 1500 in a relatively unobtrusive way, the area around the desired cut line can be seen and thus the cutting element of the cutting tool 600 aligned with the desired cut line. Because the extendable track assembly 1000 does not extend beyond the front edge of the work surface 210, it is easy for the operator to move along the length of the tool carrying device 100 so that the operator can accurately locate the cutting element of the cutting tool 600 with the desired cut line.

[0103] . Once the operator is ready to cut the workpiece 700, the operator turns on the cutting tool 600 and cuts the workpiece 700. In particular, depending on how long the operator wishes to cut the workpiece, the operator can grasp the cutting tool 600 mounted on the cutting tool tray 1500 and pull it toward him to extend the various sliding components 1200-1400 of the extendable track assembly 1000 to a point where the cutting element of the cutting tool 600 is ready to cut the outer edge of the workpiece 700. The operator then provides a small downward force to move the cutting tool tray 1500 and the cutting tool 600 downward toward the workpiece 700 so that the cutting element of the cutting tool 600 can cut the workpiece 700. Generally, the operator will move the cutting tool tray 1500 down until the cutting element of the cutting tool 600 extends to below the bottom surface of the workpiece 700, such as when it contacts the cutting table surface 210. The user or operator then pushes the cutting tool 600, and thus the cutting tool tray 1500 and the various moving elements of the extendable track assembly 1000, back towards the back stop 211 of the work surface 210 to cut the workpiece 700. Once the user has completely cut through the workpiece 700, the user provides a small amount of upward force on the tool 600, and thus the cutting tool tray 1500, to return the cutting tool tray 1500 to its raised, rest position.

[0104] Of course, it should be appreciated that the operator can cut the workpiece 700 by immediately lowering the tool tray 1500, and thus the cutting tool 600 toward the far edge of the workpiece 700. The operator can then draw the cutting tool 600, and thus the cutting tool tray 1500 and the various moveable components of the extendable track assembly 1000, towards the outer edge of the workpiece 700 to cut the workpiece 700. Once the operator has cut the workpiece 700, the operator again provides a small amount of force to raise the cutting tool 600, and thus the cutting tool tray 1500, out of the way of the workpiece 700, so the cutting element of the cutting tool 600 does not have to pass back though the cut it just made in the workpiece 700. Rather, after the operator easily raises the cutting tool 600 ^*g:nd|iiέ)i;;$g$%g«-tσ^]|;|ray "p5$Q to their rest position, the user can easily push the cutting tool 600, and thus the cutting tool tray 1500 and the other components of the extendable track assembly 1000, back along the direction B to return them to their rest position.

[0105] The workpiece 700 is now cut at the desired angle and can be readily and immediately installed by the operator, without the operator having to leave the confines of the scaffolding or wait for a co-worker to hand up the appropriately cut workpiece 700. Because, in various exemplary embodiments, the extendable track assembly 1000 typically does not extend beyond the front edge of the work surface 210, and, even if does so extend, extends only a modest amount, the tool carrying device 100 is quite suitable to be used on a scaffolding. It should also be appreciated that, in various exemplary embodiments, the extendable track assembly 1000, when placed at one extreme end of the overhead rail 240, allows the extendable track assembly 1000 to be substantially, if not entirely, stored underneath the overhead surface 230. When placed in this storage and/or travel position, it is less likely to be damaged and it is generally secured while being transported.

[0106] It should be appreciated that, to keep the nested tracks 1100-1400 of the extendable track assembly from moving around while the tool carrying device 100 is being transported, a spring-loaded catch pin or the like can be used to lock down the tracks 1100- 1400 in place. It should also be appreciated that the tool carrying device 100 can be easily moved to, set up at, and/or removed from a particular work or job site. The tool carrying device 100 can be easily taken up to and installed on a scaffolding and/or taken down from the scaffolding, because it can be disabled into easy-to-handle parts. That is, in various exemplary embodiments, the extendable track assembly 1000 can be easily removed from the overhead rail 240 and the overhead surface 230 to move the tool carrying device 100 onto or off of a scaffolding, to transport it around a worksite or between worksites or to place it into a storage locker. The tool carrying device 100 can thus be easily, securely stored overnight during a multi-day job.

[0107] While this invention has been described in conjunction with the exemplary embodiments outlined above, various alternatives, modifications, variations, improvements and/or substantial equivalents, whether known or that are or may be presently foreseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit or scope of the invention. Therefore, the invention is intended to embrace all known or earlier developed alternatives, modifications, variations, improvements and/or substantial equivalents.

Claims

1. A method for cutting a workpiece along a desired cutting line, comprising: positioning a workpiece within a working space of a tool carrying device, the tool carrying device comprising: a support structure having a first element extending along a first direction, a pivot device that connects the support structure and an extendable track assembly, the extendable track assembly displaceable along the first element along the first direction, the extendable track assembly having at least one component that is displaceable along a linear path of motion relative to the pivot device, and a tool carrying component of the extendable track assembly that carries a tool having a cutting element, the tool carrying component displaceable to and from the workpiece relative to the first element; adjusting a location of the extendable track assembly along the first element to place the extendable track assembly at a desired angle relative to the workpiece such that, at the adjusted location, the cutting element of the tool carried by the tool carrying component of the extendable track assembly is substantially aligned to the desired cutting line of the workpiece; moving at least the tool carrying component of the extendable track assembly into a cutting position relative to the workpiece, and then along the linear path of motion, such that the cutting element of the tool moves along the path of motion to cut the workpiece along the desired cutting line; and moving at least the tool carrying component away from the cutting position relative to the workpiece.

2. The method of claim 1, further comprising removing the cut workpiece from the working space after moving at least the tool carrying component away from the cutting position relative to the workpiece.

3. The method of claim 1 , wherein: the tool carrying device includes a working surface, and positioning the workpiece within the working space of the tool carrying device, the tool carrying device comprises placing the workpiece on the working surface.

4. The method of claim 1 , further comprising securing the extendable track assembly at the adjusted location of the extendable track assembly along the first element

5. The method of claim 1 , wherein: the first element is an overhead rail and the tool carrying device includes a i01,aϊi|||||tf<||n,Λ§»iaiJ|i!i|tgi'i§i>|'βtween a gripping position where the clamp securely grips the overhead rail and a loosened position where the clamp can be moved along the rail along the first direction, the extendable track assembly is rotatably connected to the clamp, and adjusting a location of the extendable track assembly along the first element to place the extendable track assembly at a desired angle relative to the workpiece comprises placing the clamp in the loosened position and moving the clamp and the rotatably connected extendable track assembly along the overhead rail along the first direction.

6. The method of claim 5, further comprising securing the extendable track assembly at the adjusted location of the extendable track assembly along the first element

7. The method of claim 6, wherein securing the extendable track assembly at the adjusted location of the extendable track assembly along the first element comprises placing the clamp in the gripping position.

8. The method of claim 1 , wherein: the extendable track assembly includes at least one stationary component, at least one extendable component and the tool carrying component; and moving at least the tool carrying component of the extendable track assembly into the cutting position relative to the workpiece, and then along the linear path of motion, such that the cutting element of the tool moves along the path of motion to cut the workpiece along the desired cutting line comprises: moving at least one of the at least one extendable component and the tool carrying component along the path of motion away from the pivot device to a first position; moving at least the tool carrying component relative to the at least one extendable component toward the workpiece to the cutting position such that the cutting element of the tool can engage the workpiece, and moving at least one of the at least one extendable component and the tool carrying component, while in the cutting position, along the path of motion toward the pivot device, such that the cutting element of the tool engages the workpiece as the at least one of the at least one extendable component and the tool carrying component move along the path of motion toward the pivot device.

9. The method of claim 8 , wherein: moving at least the tool carrying component away from the cutting position relative to the workpiece comprises moving at least the tool carrying component relative to the at least one extendable component away from the workpiece such that the cutting element ff-t]*ftibi:iaflς!rfg'ig||#pτ,'ii|he workpiece.

10. The method of claim 1 , wherein adjusting the location of the extendable track assembly along the first element to place the extendable track assembly at the desired angle relative to the workpiece comprises adjusting the location of the extendable track assembly along the first element to place the extendable track assembly at the desired angle relative to the workpiece such that the extendable track assembly is maintained at the adjusted location of the extendable track assembly along the first element.

11. The method of claim 1 , wherein: the first element is an overhead rail and the tool carrying device includes a connection assembly that can be adjusted between a first position where a position of the connection assembly relative to the overhead rail along the first direction cannot be altered substantially and a second position where a position of the connection assembly relative to the overhead rail along the first direction can be substantially freely adjusted, the extendable track assembly is rotatably connected to the connection assembly, and adjusting a location of the extendable track assembly along the first element to place the extendable track assembly at the desired angle relative to the workpiece comprises: placing the connection assembly in the second position; moving the connection assembly and the rotatably connected extendable track assembly along the overhead rail along the first direction so that the extendable track assembly is at the desired angle relative to the workpiece; and placing the connection assembly in the first position.

12. The method of claim 11, wherein the connection assembly comprises at least one of a clamp assembly, a locking assembly that includes at least one of a locking pin, a hole engaging element and a detent engaging element, and thread engaging assembly.

13. A tool carrying device that carries a cutting tool usable to cut a workpiece placed within a working space of the tool carrying device along a desired cut line, the tool carrying device comprising: a support structure having a first element extending along a first direction, a pivot device connected between the support structure and an extendable track assembly such that the extendable track assembly is rotatable relative to the support structure, the extendable track assembly connected to the first element, and displaceable along the first element along the first direction, the extendable track assembly having at least one component that is displaceable along a linear path of motion relative to the pivot device, and a tool carrying component of the extendable track assembly that carries the Slaving a cutting element, the tool carrying component displaceable to and from the workpiece relative to the first element.

14. The tool carrying device of claim 13, further comprising a working surface, wherein the support structure is connected to the working surface.

15. The tool carrying device of claim 14, wherein the extendable track assembly, when in a retracted state, does not extend beyond a front edge of the working surface.

16. The tool carrying device of claim 15, wherein the extendable track assembly, when in an extended state, places the cutting element of the cutting tool at least 12 inches beyond a back edge of the working surface.

17. The tool carrying device of claim 13, wherein the extendable track assembly comprises: a stationary component connected to the pivot device, the stationary component rotatable relative to the support structure; a first movable component that is movably connected to the stationary component and is rotatably connected to the first element of the support structure; a last movable component that is directly or indirectly movably connected to the first movable component and the tool carrying component, wherein the tool carrying component is movably connected to the last movable component.

18. The tool carrying device of claim 17, further comprising a clamp, wherein: the first element is an overhead rail and the clamp can be adjusted between a gripping position where the clamp securely grips the overhead rail and a loosened position where the clamp can be moved along the rail along the first direction; and the first movable component is rotatably connected to the overhead rail by being rotatably connected to the clamp.