IMPROVEMENTS TO POWER TOOL APPARATUS

Abstract

The invention relates to a power tool (2), a kit of parts, and method of controlling the operation of the same depending upon the configuration of use of the power tool (2) at an instant of time. The power tool (2) can, in one embodiment be a router power tool to perform work on a workpiece (32), and switching means (28, 42) allow the selective operation of the power tool (2) by controlling an electrical power source. First switching means (28) include a no Voltage release (NVR) function and means are provided to selectively disable the NVR function of the first switching means (28) when the power tool (2) is used in at least one predetermined configuration. Typically, this allows second switching means (42) which include a NVR function to be used to control the power to the tool (2). A fence body for use with a router is also disclosed.

Claims

1. A power tool, said power tool including a housing, a motor, a shaft to be moved by the operation of the motor, a toolholder connected to the shaft, a power source connectable to provide electrical power to operate the motor and first switching means to allow the user selective operation of the motor, said first switching means including a no Voltage release (NVR) function and wherein means are provided to selectively disable the NVR function of the first switching means when the power tool is used in at least one predetermined configuration.

2. Apparatus according to claim 1 wherein the said at least one predetermined configuration is for the power tool to be useable in conjunction with a second switching means which allows the selective operation of the power tool.

3. Apparatus according to claim 2 wherein when in said at least one predetermined configuration the apparatus is provided to be mounted on the underside of a worktable and in electrical connection with the said second switching means.

4. Apparatus according to claim 2 wherein the said second switching means is provided in electrical connection with, and positioned remotely from, the housing of the power tool in which the first switching means is provided.

5. Apparatus according to claim 2 wherein the said second switching means are located intermediate the power source and the first switching means.

6. Apparatus according to am claim 2 wherein the second switching means is provided as part of a switchbox mounted on, or positionable with respect to, a worktable or a surface on which a workpiece to be operated on by the power tool, is located.

7. Apparatus according to claim 6 wherein the mounting or position of the second switching means is selectable so as to be accessible by the user of the power tool when the power tool is in the said at least one predetermined configuration.

8. Apparatus according to claim 2 wherein the electrical connection for the second switching means is a cable connection between the second switching means and the motor within the housing of the power tool.

9. Apparatus according to claim 1 wherein the on/off function of the first switching means remains operable when the NVR function is disabled.

10. Apparatus according to claim 1 wherein the said means to disable the NVR function includes a trigger mounted on the power tool and a member which is selectively brought into contact with the trigger to disable the NVR function of the first switching means.

11. Apparatus according to claim 10 wherein the trigger is a microswitch located in the housing as part of the power supply control system for the operation of the power tool.

12. Apparatus according to claim 10 wherein said member is insertable from a position externally of the power tool housing through a port and into contact with the said trigger.

13. Apparatus according to claim 10 wherein the member is provided in the form of a button or other operating means to allow the said trigger to be moved to a position in which the NVR function of the first switching means is disabled.

14. Apparatus according to claim 10 wherein the said member and trigger are only operable to disable the NVR function of the first switching means when the power tool is positioned in the said at least one predetermined configuration and said second switching means are provided in electrical connection therewith.

15. Apparatus according to am claim 1 wherein the apparatus includes a detection means to determine when the power tool is in the said at least one predetermined configuration and only allow disabling of the NVR function of the first switching means when said at least one predetermined configuration is detected.

16. Apparatus according to claim 10 wherein the said member is only physically moveable so as to be capable of being used when the power tool is in the second configuration.

17. Apparatus according to claim 16 wherein the said member is located such that when the power tool is to be moved from the said at least one predetermined configuration, the said member has to be removed from the position in which the NVR function of the first switching means is disabled.

18. Apparatus according to claim 1 wherein the power tool is a router and the said at least one predetermined configuration is the router power tool mounted on the underside of the worktable or surface on which a workpiece is locatable.

19. (canceled)

20. Apparatus according to claim 1 wherein the said means for disabling the NVR function of the first switching means includes an actuating member permanently attached to the underside of a worktable.

21. Apparatus according to claim 20 wherein the user is required to remove the member from the router housing in order to be able to move the power tool from the underside of the worksurface and/or the member cannot be moved to a position to act to disable the NVR function when the power tool is in any configuration of use in which only the first switching means is used to operate the power tool.

22. Apparatus according to claim 2 wherein when the router power tool is in the said at least one predetermined configuration and the NVR function of the first switching means is disabled, only the second switching means is usable to switch the router power tool on and off and the second switching means has an NVR function.

23. Apparatus according to claim 1 wherein the apparatus includes a fence body which is selectively locatable via engagement means to a base of the power tool, said fence body including a fence plate and a guide plate and wherein the positions of both the guide plate and fence plate with respect to the fence body are selectively adjustable within a range of adjustment positions.

24-26. (canceled)

27. A kit of parts to allow a power tool to be used in at least first and second configurations and for switching means for the said power tool to be adapted with respect to the particular configuration in which the power tool is to be used at a particular time, said kit comprising a power tool including a housing, a motor for the selective operation to rotate a cutting head and first and second switching means and a power supply selectively provided to rotate the motor via operation of the first or second switching means, said second switching means located intermediate the source of the power supply and the first switching means and wherein a disabling assembly is provided to selectively allow at least one function of the first switching means to be selectively disabled when the second switching means is to be used to operate the said power tool.

28. A kit of parts according to claim 27 wherein the kit further includes a worktable and means to allow the power tool to be operated in a first configuration on the topside of the workpiece located on an upper surface of the worktable and a second configuration which the power tool is operated with respect to the lower side of the workpiece and the power tool is located on the underside of the worktable, said first switching means being used to operate the power tool in the first configuration and second switching means being used to operate the power tool in at least the second configuration and the disabling means are provided to only be capable of operation to disable a function of the first switching means when the power tool is in a second configuration.

29. A method for operating a power tool which is capable of being operated in at least two configurations and wherein, when the power tool is operated in a predetermined configuration, means are provided to be selectively used to disable a function of the first switching means of the power tool which are located on the power tool.

30. A method according to claim 29 wherein when the said function is disabled, the operation of the power tool and the provision of the disabled function is provided via a second switching means which are physically remote from the power tool but electrically connected to the power tool with the second switching means more conveniently useable by the operator when the power tool is in the predetermined configuration.

Description

SPECIFIC EMBODIMENTS OF THE INVENTION ARE NOW DESCRIBED WITH REFERENCE TO THE ACCOMPANYING DRAWINGS WHEREIN

[0043] FIG. 1 illustrates a power tool in accordance with one embodiment of the invention;

[0044] FIGS. 2a and b illustrate schematically, the router of FIG. 1, in first and second configuration positions for use; and

[0045] FIG. 3a-c illustrate the housing and control system for a router in accordance with FIGS. 1-2b, in accordance with one embodiment of the invention and illustrating the disablement of the NVR function.

[0046] FIGS. 4a-f illustrate a fence for selective use with the router as herein described in relation to FIGS. 1-3c, or with other routers.

[0047] Turning firstly to FIG. 1, there is illustrated a router power tool 2 in accordance with one embodiment of the invention.

[0048] The power tool includes a housing 4 in which is located a motor which is provided, when powered, to rotate a longitudinal shaft 6 which depends under and down from the housing as illustrated. At the free end of the longitudinal shaft, there is provided a tool holder 10 which allows the selective receipt of the cutting head 24. The particular type and dimensions of the cutting head can be selected by the user of the tool in order to allow a specific milling or routing operation to be performed and there is typically provided a means by which the tool holder can be moved between engaged and released positions. The gap 16 between the underside 18 of the housing, and a base 8 of the router power tool, can be adjusted via adjustment means provided on first and second legs 12, 20 which connect the base to the housing. This therefore allows the depth of the protrusion of the cutting head 24 through the aperture 22 and below the base 8 to be adjusted as indicated by arrow 14 and in turn, the depth of the channel formed in a workpiece into which the cutting head extends, to be adjusted.

[0049] FIG. 1 illustrates the router power tool in an orientation in which the cutting head protrudes below the base, but it should be appreciated and as subsequently explained, the router tool can be utilised having being moved through 180 degrees so that the cutting head protrudes above the base.

[0050] A power supply is provided to the motor in the housing via a cable 26 which typically allows a mains electricity supply to be provided to the router tool. Intermediate the power supply and the motor, there is provided on the housing, a first switching means 28 which allows the operator to perform an on and off control of the motor and hence the power tool operation. In addition, the switching means is provided with an NVR function which means that if the power supply to the router fails such as a result of a power cut or outage, then the NVR function automatically switches the power tool off. This therefore prevents the inadvertent operation of the router power tool should, for example, the power cut be short-lived, and the power be resumed without the operator being aware of that.

[0051] In FIG. 2a, the router power tool 2, is shown in a first configuration of use in conjunction with a worktable 30 which has an upper surface on which a workpiece 32 is positioned. The router power tool is provided on the top face 34 of the workpiece and the cutting head of the tool is positioned below the base 8 to a user selected extent such that when rotated by operation of the motor a channel to the required depth is formed along the upper surface of the workpiece. In this configuration of use, the operator can easily gain access to the first switching means 28 to switch the same on and off.

[0052] FIG. 2b illustrates the second and predetermined configuration of use of the power tool 2 in conjunction with the worktable and in this case, the router power tool has been reversed through 180 degrees so that the tool is located on the underside 36 of the worksurface typically by securing means which are provided to pass from the router tool to engagement means on the underside of the worksurface so as to securely locate the router in position and the cutting head protrudes through the aperture in the base and through an aperture in the worktable so as to access the underside 40 of the workpiece so that when the cutting head is operated and the power tool is switched on a channel is formed on the underside of the workpiece.

[0053] It will be appreciated that in the second configuration, access to the router power tool generally and in particular, to the first switching means 28, is more difficult to achieve, causes a risk of injury to the user when attempting to gain access to the first switching means and/or creates a potential electrical hazard.

[0054] Having recognised this problem, it is common for there to be provided a second switching means 42 which is located remotely from the housing of the power tool and may, in one embodiment, located on or positionable on the worktable 30 or can simply be positioned at a convenient location for the user when using the router power tool in the second configuration.

[0055] This second switching means 42, as with the first switching means 28, includes the NVR function and, as the second switching means 42 is located intermediate the power supply source via cable 26 and the cable 26 to provide the power to the router power tool, if a power outage occurs, then the NVR function of the first and second switching means will be triggered but more problematically, if the second switching means is simply turned off, this will cause the NVR function of the first switching means to be operated. and therefore, in order to be able to operate the router power tool thereafter when in the second configuration, the router power tool has to either be removed from the second configuration to allow access to be gained to the first switching means to reset the NVR function or alternatively, the user has to undertake the potentially hazardous task of getting access to the first switching means 28 to rest the NVR function whilst the power tool is in the second configuration. Neither of these options are acceptable and the need to do this generally negates the advantages of providing the second switching means.

[0056] In accordance with the invention, this problem is avoided by the provision of a selective disabling means which allows the NVR function of the first switching means to be selectively disabled and, furthermore, to only be disabled when the power tool is located in the second configuration.

[0057] As shown in FIG. 3b the interior of the housing includes control circuitry 44 typically provided on a printed circuit board 46 as indicated in FIG. 3b in which the cap of the housing has been removed for ease of illustration.

[0058] In accordance with the invention, there is provided a trigger 48 as part of the control means and, as illustrated in FIG. 3a in which the cap of the router housing is shown in position, the cap is provided with an aperture 38 which allows access to the trigger 48 (which is typically a microswitch) from externally of the router power tool.

[0059] This external access can be used, to receive therein, a member 50 which may be keyed or otherwise coded to be used with the particular router tool or the specific manufacturer. When the member 50 is successfully positioned into the aperture 38 the same can be used to activate the trigger 48 which, in turn, acts to disable the NVR function of the first switching means 28.

[0060] With the first switching means having the NVR function disabled, the same can still be used to provide conventional on and off functionality but, the NVR function will not operate. This therefore means that when the router power tool is in the second configuration on the underside of the worktable, and the said member 50, is in position, if there is a power outage or the second switching means 42 is used to switch the tool off in a normal operating mode, then the NVR function of the second switching means 42 will operate to automatically be activated but, as the NVR function of the first switching means 28 is disabled, no action will occur at the first switching means.

[0061] This therefore means that when the power is resumed to the power tool then the NVR function of the second switching means can be easily operated and accessed by the operator to allow the resumption of power to be provided to the power tool but there is no longer any need for the operator to try and gain access to reset the NVR function of the first switching means as this is unaffected when the said member is in position. Thus, the potentially hazardous and injurious requirements to gain access to the first switching means 28 when the power tool is in the second configuration is avoided.

[0062] In order to ensure that the advantages can be obtained, but without allowing the safety of the router power tool to be compromised in other uses, the member 50 which allows the disablement of the NVR function of the first switching means 28, is mounted with respect to the router and/or the worktable so that the member can only be extended into the aperture 38 in the housing to operate the trigger 48, when the router power tool is in the second configuration. Thus, if for example, the member 50 is located on a spiral carrier or a retractable cable then the extension of the member from the worktable is only to a sufficient extent so as to reach the trigger 48 when the router power tool is already located in the second configuration or is being moved thereto and not when the router power tool is in the first configuration or separated from the worktable. Thus, it can be ensured that the functionality of the NVR function on the first switching means is retained and cannot be disengaged in any other operating mode or configuration other than one or more predetermined configurations without the user having deliberately dismantled or acted against the safety instructions for use of the power tool.

[0063] In one embodiment, the said router apparatus is selectively useable in conjunction with a selectively attachable component typically know as a fence, and the router, such as that shown in FIG. 1 is selectively attachable to the fence at the base 8 which is located on the surface 54 of the fence body 52. A perspective view of the fence is shown in FIG. 4a, plan views are shown in FIGS. 4b and c, and an end and side view is shown in FIGS. 4d and e respectively.

[0064] The fence body 52 is provided with first and second opposing surfaces 54,56 and includes an aperture 58 through which the cutting head 10 and tool 24 of the router 2 pass to contact with the workpiece 32 so that it will be appreciated that the fence, in use of the apparatus, is located intermediate the router 2 and the workpiece 32 as illustrated schematically in FIG. 4f. The fence is provided with a plurality of guides which, in this embodiment, include a fence surface 60 which depends outwardly from the surface 56 and a guide plate 62 is also provided. The fence is slidably moveable as indicated by arrows 64,66 along the tracks 68,70 located adjacent the opposing edges of the fence and the guide plate 62 is slidably moveable along ridge portions 72 which, in this embodiment is located along a central longitudinal axis of the plate and which intersects the aperture through which the tool of the router passes. It will be appreciated that the location of the fence and the location of the guide plate, can be adjusted to suit the particular work operation which is to be performed. Typically, the fence is provided to be located against an edge 74 of the workpiece 32 on which the work operation is to be performed so as to locate the cutting tool of the router 2 with respect to a known location at a distance from the edge of the workpiece and the guide plate 62 is selectively located so as to adjust and set the circle radius and may be set, in one example to small, medium and large radii.

[0065] In the embodiment shown, the guide plate extends outwardly from both surfaces 54,56 of the fence body so as to be useable as a guide when the router tool 2 is located on the fence surface 54 or fence surface 56.

[0066] Typically, the selected position of the guide plate 62 is secured in a required position via a manual locking means such as a locking knob 76 and a wingnut 78. The ridge portion 72 includes a longitudinal location means such as a channel 80, into which a ruler of a type and shape typically used in woodworking, can be located so as to allow the ruler to be used as a scale for accurate adjustment of the guide plate 62 with respect to the position of the fence 60 and in turn, the router 2. The ruler can be held in a selected position by the tightening of securing means 84 onto the ruler.

[0067] The fence plate 60 includes location means 82 to allow the location therewith of antifriction, sacrificial and/or protective portions of material which, when located to the fence surface act as the external surface of the same which is to be positioned against the workpiece edge and which, if they become worn or damaged, can be removed and replaced with new portions. A securing knob 94 is provided to be manually tightened to secure the position of the fence plate 60 with respect to the fence body 52.

[0068] In order for the guide and fence plates to be effective, it is necessary for the location of the fence plate 60 with respect to the router apparatus 2 to be accurate and maintained during use and this is achieved by the provision of first and second mounting apertures 86 on the fence body 52 which, as shown, are formed of a keyhole shape and which pass between the surfaces 54, 56 of the body. The mounting apertures 86 are provided to receive therein male members 88 provided on the router base 8 which can be moved through into the wider portions of the mounting apertures 86 and then relative sliding movement between the base and the fence body as indicated by arrow 90 allow the locking of the router and fence body in position. Upstanding tabs 92 also secure against the edge of the router base 8 when the same is in the locked position and thereby retaining the base 8 in a secure position with the fence body 52 during use of the apparatus.