POWER TOOL

Abstract

A power tool (1) includes an electric motor (2) as a drive source and a start switch (20; 61) that starts the electric motor (2) and is lockable in an ON position in a lock-ON state. An electromagnetic actuator (30; 40; 50; 60) pushes out or pulls in an actuation pin (30a; 40a; 50a; 60a) with respect to a body of the electromagnetic actuator (30; 40; 50; 60) in response to cutting off of a supply of electrical current to the power tool (1). The pushed-out or pulled-in actuation pin, directly or indirectly, disengages the start switch (20; 61) from the lock-ON state and/or prevents the start switch (20; 61) from being shifted into the lock-ON state.

Claims

1. A power tool comprising: an electric motor as a drive source, a start switch configured to start the electric motor, the start switch being movable between an OFF position and an ON position and being engageable or latchable in a lock-ON state, and an electromagnetic actuator configured to advance an actuation pin out of a body of the electromagnetic actuator in response to interruption of a supply of electric current to the power tool, wherein: the start switch and the actuation pin are arranged such that, when the supply of electric current to the power tool is interrupted and the actuation pin is advanced, the advanced actuation pin, directly or indirectly, (i) causes the start switch to be disengaged or latched from the lock-ON state and/or (ii) prevents the start switch from being engaged or latched in the lock-ON state.

2. The power tool according to claim 1, wherein: the start switch is supported by a support-pedestal part of a main-body housing such that it is slidable between the ON position and the OFF position, the start switch is supported in the ON position such that it is tiltable or pivotable between the lock-ON state and a lock-OFF position, and in the ON position, the start switch is tiltable or pivotable to the lock-ON state and is configured to be held at the lock-ON state by engagement of a lock part of the start switch with a portion of the support-pedestal part.

3. The power tool according to claim 1, further comprising: an intermediate lever operably interposed between the start switch and the electromagnetic actuator, wherein the intermediate lever is configured to be tilted or pivoted by the advancing movement of the actuation pin of the electromagnetic actuator to disengage or unlatch the start switch from the lock-ON state and/or to prevent the start switch from engaging or latching in the lock-ON state.

4. A power tool comprising: an electric motor as a drive source, a start switch configured to start the electric motor, the start switch being movable between an OFF position and an ON position and being engageable or latchable in a lock-ON state, and an electromagnetic actuator configured to retract an actuation pin into a body of the electromagnetic actuator in response to interruption of a supply of electric current to the power tool, wherein: the start switch and the actuation pin are arranged such that, when the supply of electric current to the power tool is interrupted and the actuation pin is retracted, the retracted actuation pin, directly or indirectly, (i) causes the start switch to be disengaged or latched from the lock-ON state and/or (ii) prevents the start switch from being engaged or latched in the lock-ON state.

5. The power tool according to claim 4, wherein: the start switch is supported by a support-pedestal part of a main-body housing such that it is slidable between the ON position and the OFF position, the start switch is supported in the ON position such that it is tiltable or pivotable between the lock-ON state and a lock-OFF position, and in the ON position, the start switch is tiltable or pivotable to the lock-ON state and is configured to be held at the lock-ON state by engagement a lock part of the start switch with a portion of the support-pedestal part.

6. The power tool according to claim 4, further comprising: an intermediate lever operably interposed between the start switch and the electromagnetic actuator, wherein the intermediate lever is configured to be tilted or pivoted by the retracting movement of the actuation pin of the electromagnetic actuator to disengage or unlatch the start switch from the lock-ON state and/or to prevent the start switch from engaging or latching in the lock-ON state.

7. The power tool according to claim 4, wherein the actuation pin of the electromagnetic actuator is arranged to directly contact and push the start switch in the lock-ON state when actuation pin advances.

8. A power tool comprising: an electromagnetic actuator configured to shift from a first configuration when the power tool and the electromagnetic actuator are connected to a source of electric current to a second configuration when the power tool and the electromagnetic actuator are not connected to the source of electric current; and an electric motor selectively connectable to the source of electric current by a start switch, the start switch being movable between an OFF position and an ON position and being latchable in a lock-ON state, wherein the start switch is configured to move from the lock ON state to the OFF position when the electromagnetic actuator shifts from the first configuration to the second configuration.

9. The power tool according to claim 8, further comprising: a lever having a first end at the actuation pin and a second end at the start switch, wherein shifting of the electromagnetic actuator from the first configuration to the second configuration pivots the lever.

10. The power tool according to claim 8, wherein: the electromagnetic actuator comprises an actuation pin shiftable from an advanced position to a retracted position and the first configuration of the electromagnetic actuator comprises the electromagnetic actuator with the actuation pin in the advanced position.

11. The power tool according to claim 10, wherein the start switch is configured such that: the start switch has an end, moving the start switch from the OFF position to the ON position shifts the end in a longitudinal direction of the power tool and moving the start switch from the ON position to the lock-ON state shifts the end of the start switch in a direction different than the longitudinal direction of the power tool.

12. The power tool according to claim 11, wherein the direction different than the longitudinal direction comprises a radial direction of a substantially cylindrical housing of the power tool.

13. The power tool according to claim 12, wherein the start switch is spring-biased toward the OFF position.

14. The power tool according to claim 8, wherein: the electromagnetic actuator comprises an actuation pin shiftable from an advanced position to a retracted position and the first configuration of the electromagnetic actuator comprises the electromagnetic actuator with the actuation pin in the retracted position.

15. The power tool according to claim 14, wherein the start switch is configured such that: the start switch has an end, moving the start switch from the OFF position to the ON position shifts the end in a longitudinal direction of the power tool and moving the start switch from the ON position to the lock-ON state shifts the end of the start switch in a direction different than the longitudinal direction of the power tool.

16. The power tool according to claim 15, wherein the direction different than the longitudinal direction comprises a radial direction of a substantially cylindrical housing of the power tool.

17. The power tool according to claim 16, wherein the start switch is spring-biased toward the OFF position.

18. The power tool according to claim 8, wherein: the start switch is supported by a main-body housing such that it pivotable between the ON position and the OFF position, and when the start switch is pivoted to the ON position, it is holdable in the lock-ON state by a tip part of a pivotable lock-ON lever abutting on a longitudinal end portion of the start switch.

19. The power tool according to claim 18, wherein: the lock-ON lever is pivotably supported by a rear-part case of the power tool that is connected to the main-body housing, the electromagnetic actuator is disposed and held on the lock-ON lever so as to move integrally therewith, and the lock-ON lever is spring-biased towards a lock-OFF position.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 is an overall-oblique view of a power tool according to a first embodiment of the present disclosure.

[0016] FIG. 2 is a cross-sectional auxiliary view taken along line (II)-(II) in FIG. 1 and is a transverse cross-sectional view of the power tool according to the first embodiment. This figure shows the state in which a start switch is in an OFF position prior to the supply of electric current and shows the state in which an actuation pin of an electromagnetic actuator is pushed out (advanced).

[0017] FIG. 3 is a transverse cross-sectional view of the vicinity of the start switch. This figure shows the state in which the actuation pin of the electromagnetic actuator is pulled in (retracted) due to the supply of electric current to the electromagnetic actuator and shows the state in which the start switch is still in the OFF position.

[0018] FIG. 4 is another transverse cross-sectional view of the vicinity of the start switch. This figure shows the state in which the actuation pin of the electromagnetic actuator has been pulled in due to the supply of electric current and shows a lock-ON state in which the start switch has been locked at (in) an ON position.

[0019] FIG. 5 is another transverse cross-sectional view of the vicinity of the start switch. This figure shows the state in which the actuation pin of the electromagnetic actuator has been pushed out due to the supply of electric current being cut off and shows the state immediately after the lock-ON state of the start switch has been released or disabled.

[0020] FIG. 6 is a longitudinal-cross-sectional view of a front portion of the power tool according to a second embodiment. This figure shows the lock-ON state of the start switch.

[0021] FIG. 7 is a cross-sectional auxiliary view taken along line (VII)-(VII) in FIG. 6. This figure shows the state in which the actuation pin of the electromagnetic actuator has been pushed out due to the supply of electric current.

[0022] FIG. 8 is another longitudinal-cross-sectional view of the front portion of a power tool according to the second embodiment. This figure shows the state immediately after the lock-ON state of the start switch has been released or disabled.

[0023] FIG. 9 is a cross-sectional auxiliary view taken along line (IX)-(IX) in FIG. 8. This figure shows the state in which the actuation pin of the electromagnetic actuator has been pulled in due to the supply of electric current being cut off.

[0024] FIG. 10 is another longitudinal-cross-sectional view of the front portion of the power tool according to the second embodiment. This figure shows the state in which the lock-ON state has been released or disabled and the start switch has returned to the OFF position.

[0025] FIG. 11 is a cross-sectional auxiliary view taken along line (XI)-(XI) in FIG. 10. This figure shows the state in which the actuation pin of the electromagnetic actuator has been pulled in, the same as in FIG. 9.

[0026] FIG. 12 is a transverse cross-sectional view of a power tool according to a third embodiment. This figure shows the start switch in the lock-ON state and shows the state in which the actuation pin of the electromagnetic actuator has been pulled in due to the supply of electric current.

[0027] FIG. 13 is another transverse cross-sectional view of the power tool according to the third embodiment. This figure shows the state in which the actuation pin of the electromagnetic actuator has been pushed out due to the supply of electric current being cut off and shows the state in which the release of the lock-ON state of the start switch is in progress.

[0028] FIG. 14 is an overall-longitudinal-cross-sectional view of a power tool according to a fourth embodiment. This figure shows a lock-OFF state in which the start switch is locked at an OFF position by a lock-OFF lever. This figure shows the state in which the actuation pin of the electromagnetic actuator has been pulled in due to the supply of electric current.

[0029] FIG. 15 is another overall-longitudinal-cross-sectional view of the power tool according to the fourth embodiment. This figure shows the lock-ON state in which the lock-OFF lever has been pivoted out of contact with the main housing and a lock-ON lever has been operated (pivoted) to lock the start switch at (in) its ON position (i.e. in the lock-ON state).

[0030] FIG. 16 is another overall-oblique view of the power tool according to the fourth embodiment. This figure shows the state immediately after the actuation pin of the electromagnetic actuator has been pushed out due to the supply of electric current being cut off.

[0031] FIG. 17 is another overall-oblique view of the power tool according to the fourth embodiment. This figure shows the lock-OFF state in which the lock-ON state has been released and the start switch is locked at the OFF position by the lock-OFF lever being pivoted back into contact with the main housing. This figure differs from FIG. 14 in that it shows the state in which the supply of electric current has been cut off and the actuation pin of the electromagnetic actuator is pushed out.

DETAILED DESCRIPTION

[0032] Next, embodiments of the present disclosure will be explained with reference to FIGS. 1 to 17, in which a disc grinder will be utilized as one representative, non-limiting example of a power tool 1 according to the present teachings. FIGS. 1-5 show a power tool 1 according to a first embodiment. In the first exemplary power tool 1, an electric motor 2, which serves as a drive source, is built into (mounted or disposed within) a main-body housing 3. The main-body housing 3 has a substantially cylindrical shape of a size that is easy to grip by a user. The user grips the main-body housing 3 and is positioned (stands) rearward (the right side in FIG. 1 and FIG. 2) of the power tool 1. Hereinbelow, the front, rear, left, and right directions of members, structural elements, and the like are denoted with reference to a user holding the power tool 1 in a normal operating state.

[0033] A rear-part case 4 is joined to a rear part of the main-body housing 3. A switch main body (power switch) 5 is housed in the rear-part case 4. A power-supply cord 6 for supplying electric power (current) is routed through the rear part of the rear-part case 4. An alternating electric current in the range of 100-240 volts (mains electricity) is supplied via the power-supply cord 6.

[0034] A cooling fan 18 is attached to an output shaft 2a of the electric motor 2. Upon starting the electric motor 2, the cooling fan 18 rotates together with the electric motor 2, thereby drawing outside air into the main-body housing 3 and cooling the electric motor 2. The rear side of the cooling fan 18 is covered by a baffle plate 19, which is attached at the side of the cooling fan 18 facing the main-body housing 3. Because the rear side of the cooling fan 18 is covered by the baffle plate 19, a cooling draft that flows from the rear side toward the front side of the main-body housing 3 as the cooling fan 18 rotates is efficiently generated.

[0035] A gear-head case 11 of a gear-head part 10 is joined to a front part of the main-body housing 3. A drive-side bevel gear 12 is attached to the output shaft 2a of the electric motor 2. The bevel gear 12 meshes with a follower-side bevel gear 13. The follower-side bevel gear 13 is joined to a spindle 14. The spindle 14 is supported such that it is rotatable relative to the gear-head case 11 around an axis line orthogonal to the output shaft 2a of the electric motor 2. A lower part of the spindle 14 protrudes downward from a lower surface of the gear-head case 11.

[0036] A circular grinding wheel 15 (one representative, non-limiting example of a tool accessory that may be driven by the spindle 14) is attached to the lower part of the spindle 14 that protrudes from the lower surface of the gear-head case 11. The grinding wheel 15 is attached to the spindle 14 such that the grinding wheel 15 is interposed between an inner flange 16 and an outer flange 17. A grinding-wheel cover 7 covers a substantially semicircular area of the rear side of the grinding wheel 15. The grinding-wheel cover 7 prevents the dispersion of dust, chips or the like towards the user (i.e. in the rearward direction).

[0037] A start switch 20 is disposed on a left-side surface of the front part of the main-body housing 3. The start switch 20 is configured to slide in the forward-rearward direction and is provided along a flat support-pedestal part 3a on a left-side part of the main-body housing 3. When the start switch 20 is slid toward the front side, e.g., by a fingertip (e.g., a thumb) of the hand that grips the main-body housing 3, the electric motor 2 starts and the grinding wheel 15 rotates. When the start switch 20 is slid toward the rear side, the electric motor 2 stops and consequently the grinding wheel 15 stops.

[0038] A lock part (latch) 20a and an arm part 20b are integrally provided on the start switch 20. The left-side, outer surface of the start switch 20 is designed as a pressing (pressable) part 20c, which extends in the leftward direction in an arc shape, and is configured to be pressed by a user's finger (e.g., thumb). A jagged, slip-preventing part is formed on the outer surface of the pressing part 20c that is pressed by the user's finger. The lock part 20a protrudes in the rightward direction (i.e. towards the interior of the main-body housing 3) from the front end of the pressing part 20c.

[0039] The arm part 20b protrudes toward the interior of the main-body housing 3 through an insertion window 3b, which is provided in (penetrates through) the support-pedestal part 3a of the main-body housing 3. The arm part 20b is coupled to a front part of a connecting rod (intermediate lever) 21. A rear part of the connecting rod 21 is coupled to a switch frame 23 via a tension spring 22. The switch frame 23 is disposed around leftward and rearward portions of the switch main body 5 and is supported so as to be movable in the forward-rearward direction of the power tool 1. When the start switch 20 is slid forward toward the ON position, the switch frame 23 is displaced (pulled) forward by the connecting rod 21 and the tension spring 22, thereby pressing forward (inward) an actuation button 5a of the switch main body 5 and turning ON the switch main body 5. When the switch main body 5 turns ON, the electric motor 2 starts.

[0040] When the start switch 20 returns rearward to its OFF position, the switch frame 23 is displaced rearward by the connecting rod 21, thereby releasing the actuation button 5a of the switch main body 5 and turning OFF the switch main body 5. When the switch main body 5 turns OFF, the electric motor 2 stops. Because the tension spring 22 is interposed between the connecting rod 21 and the switch frame 23, the biasing force of the tension spring 22 is continuously applied, via the switch frame 23, to the actuation button 5a of the switch main body 5 and therefore, a large pushing force is not directly applied to the actuation button 5a and the switch main body 5.

[0041] The actuation button 5a of the switch main body 5 is spring-biased toward its OFF side (the protruding side, i.e. rearward). Consequently, the direction of the sliding (the ON operation) of the start switch 20 toward the front side is opposite of the direction of the biasing force of the tension spring 22 and the spring-biasing force of the actuation button 5a. Conversely, when the pressing force on (sliding of) the start switch 20 toward the front side is released, the start switch 20 returns rearward to its OFF position owing to the biasing force of the tension spring 22 and the spring-biasing force of the actuation button 5a. FIG. 1 and FIG. 2 show the state in which the start switch 20 has returned to the OFF position.

[0042] The start switch 20 can be locked at (in) the ON position on the front side in a lock-ON state. That is, after the start switch 20 has been slid by a fingertip to the ON position on the front side so that the lock part 20a is laterally adjacent to the support-pedestal part 3a, if the tip side of the start switch 20 (i.e. the lock part 20a) is then pushed radially inward (in the right direction) with respect to the substantially-cylindrical main-body housing 3, then the lock part 20a will catch (latch) on a front-end part of the support-pedestal part 3a, i.e. the lock part 20a engages or latches on the front-end part of the support-pedestal part 3a. In this caught (engaged) state, the biasing force of the tension spring 22 acts on the start switch 20 via the connecting rod 21, thereby holding the start switch 20 in this position, i.e. in the lock-ON state. The lock-ON state, in which the lock part 20a is caught by (engaged with) the front-end part of the support-pedestal part 3a, can be released (disengaged or unlatched) manually by the user, for example, by pressing the rear side of the start switch 20 towards the housing 3 (i.e. radially inward with respect to the cylindrical housing 3 or in the direction of the right arrow shown in FIG. 4) with his or her fingertip.

[0043] The power tool 1 of the present embodiment also includes a mechanism for automatically releasing, disabling and/or preventing the lock-ON state of the start switch 20 when the supply of electric power is cut off (interrupted). As shown in FIGS. 2-5, an electromagnetic actuator 30 is built into (disposed on) the front side of the support-pedestal part 3a of the main-body housing 3. In the present embodiment, the electromagnetic actuator 30 is designed such that, when it is supplied with electric current, an actuation pin 30a is pulled (retracted) into a body of the actuator 30 by a magnetic force, as shown in FIGS. 3 and 4. Conversely, when the electric power is cut off (interrupted) and the magnetic field is thus dissipated, the actuation pin 30a is actuated (moved) in a pushing out (advancing) direction by a spring force of a return spring that biases the actuation pin 30a towards the pushed out (advanced) position. Therefore, the return spring causes the actuation pin 30a to advance or move so that it protrudes out of the body of the actuator 30, as shown in FIGS. 2 and 5. Electric power is supplied to the electromagnetic actuator 30 via the power-supply cord 6, the same as for the electric motor 2. Electric current (power) at a proper voltage is supplied to the electromagnetic actuator 30 when the 100-240 V mains electricity is supplied via the power-supply cord 6. If the power-supply cord 6 is pulled out of the power-supply outlet (either intentionally or accidentally), then the supply of electric power to the power tool 1 is cut off (interrupted) and consequently the supply of electric current to the electromagnetic actuator 30 is also cut off (interrupted).

[0044] Thus, when the supply of electric current to the electromagnetic actuator 30 is cut off, the actuation pin 30a is pushed out (moved to its advanced position), as shown in FIGS. 2 and 5. When the actuation pin 30a is pushed out, the front-end part of the support-pedestal part 3a is closed up or blocked by the actuation pin 30a. Consequently, when the actuation pin 30a has been pushed out, although the start switch 20 can still be slid to the ON position, the lock part 20a thereof cannot be caught by (latch on) or engage the front-end part of the support-pedestal part 3a due to the presence (blocking effect) of the actuation pin 30a.

[0045] In contrast, as shown in FIG. 3, when the power-supply cord 6 is connected to the power-supply outlet and electric power is supplied to the electric motor 2, electric current is simultaneously supplied to the electromagnetic actuator 30, thereby causing the actuation pin 30a to be pulled (retracted) into the body of the electromagnetic actuator 30 and opening (unblocking) the front-end part of the support-pedestal part 3a. In order words, when the actuation pin 30a retracts inwardly towards the center of the main-body housing 3 and thereby the front-end part of the support-pedestal part 3a is opened (unblocked), the lock part 20a of the start switch 20 is once again capable of being caught by (latched on or engaged with) the front-end part of the support-pedestal part 3a.

[0046] Consequently, as shown in FIG. 4, when the start switch 20 is slid forward to the ON position and then the front part of the start switch 20 is pressed inward (rightward) toward the center (interior) of the housing 3, the lock part 20a can be caught by (latched on) or engage with the front-end part of the support-pedestal part 3a. Thereafter, the state in which the lock part 20a is caught by (latched on) the support-pedestal part 3a is maintained by the biasing force of the tension spring 22 that pulls on (tensions) the start switch 20 via the connecting rod 21. By maintaining the condition in which the lock part 20a of the start switch 20 is caught by (latched on) the front-end part of the support-pedestal part 3a, the start switch 20 is (remains) locked at (in) the ON position (in the lock-ON state). By locking the start switch 20 at (in) the ON position, there is no longer a need for the user to continuously press, using his or her fingertip, the start switch 20 towards the ON position side during a power tool operation. Therefore, grinding work or the like can be performed comfortably for a long time, thereby improving the work efficiency and ergonomics of the power tool 1.

[0047] If the supply of electric power to the power tool 1 is cut off while the start switch 20 is engaged in the lock-ON state, for example, by the power-supply cord 6 mistakenly being pulled out of the power-supply outlet or by the occurrence of a power failure, then the supply of electric power to the electromagnetic actuator 30 is also cut off, which causes the actuation pin 30a to be actuated (advanced) in the pushed out (ejection) direction. As shown in FIG. 5, when the actuation pin 30a of the electromagnetic actuator 30 is pushed out (advanced), the lock part 20a of the start switch 20 is pressed (pushed outward) by the actuation pin 30a and thereby separates (disengages or unlatches) from the front-end part of the support-pedestal part 3a. This separation causes the start switch 20 to return (slide) rearward (to the OFF position side) owing principally to the biasing force of the tension spring 22, and thereby causes the switch main body 5 to turn OFF.

[0048] Thus, if the supply of electric power is cut off in the lock-ON state of the start switch 20, then the lock-ON state is automatically released (disabled) and the switch main body 5 turns off. Consequently, when the supply of electric power subsequently returns (resumes), the electric motor 2 does not automatically start in a manner that would be contrary to the intention of the user, because the start switch 20 was previously moved back to its OFF position. After the supply of electric power resumes and the user once again turns ON the start switch 20, then the electric motor 2 will start and the user can perform work using the power tool 1. In addition, because the actuation pin 30a of the electromagnetic actuator 30 is actuated (moved) to the pulled-in side by the resumption of the supply of electric power, the user can perform work without having to hold the start switch 20 for as long as the start switch 20 remains in the lock-ON state.

[0049] According to the embodiment explained above, if the supply of electric power to the power tool 1 is cut off, then the actuation pin 30a of the electromagnetic actuator 30 is actuated (advanced) to the pushed out side and the lock-ON state of the start switch 20 is forcibly released (disengaged or unlatched). As a result, when the supply of electric power returns (resumes), the electric motor 2 will not automatically start in an unintended manner, thereby preventing an inadvertent startup of the power tool 1. The embodiment described above is configured such that the lock-ON state of the start switch 20 is released (disengaged) by the electromagnetic actuator 30 and thus this release (disengagement) is not in the actuation control of the electric motor, as in the known example described above in the background section. Therefore, the controller that controls the actuation of the electric motor can be simplified and made more compact, thereby enabling a reduction of size and cost of the power tool 1.

[0050] In addition, after the work ends, the start switch 20 is switched to the OFF side, thereby stopping the electric motor 2. If the power-supply cord 6 is subsequently pulled out of the power-supply outlet, then the actuation pin 30a of the electromagnetic actuator 30 will be held in the state that it is pushed out (i.e. it is maintained in the pushed out or advanced position). Consequently, when the power tool 1 is not in use (e.g., when in storage), the lock-ON operation is prevented from being mistakenly performed even if, for example, some other structural element or a person interferes with (e.g., accidentally slides) the start switch 20 to its ON position. In this manner, an inadvertent start up is reliably prevented when the power tool 1 is subsequently reconnected to a supply of electric power, e.g., when the power cord 6 is plugged into an electric outlet (mains power) again.

[0051] In the embodiment as explained above, various modifications are possible. The first embodiment described above illustrates a configuration in which the lock part 20a of the start switch 20 is directly pressed by the actuation pin 30a of the electromagnetic actuator 30, thereby releasing the lock-ON state of the start switch 20. However, as shown in FIGS. 6-11, for example, a second embodiment may be utilized in which an intermediate lever 41 is operably interposed between an actuation pin 40a and the lock part 20a so that the lock part 20a is indirectly pressed towards the released side. In the following explanation of such a modification, members and structural elements not requiring modification are assigned the same reference numbers, and redundant explanations thereof are therefore omitted.

[0052] In the second embodiment, as shown in FIG. 7, the intermediate lever 41 is provided such that it is capable of tilting or pivoting, about a pivot (fulcrum) 42, along the inner side of the support-pedestal part 3a of the main-body housing 3. More specifically, in this second embodiment, the intermediate lever 41 is supported such that it is capable of tilting or pivoting about the pivot 42 at substantially its center in the longitudinal direction of the intermediate lever 41. As shown in FIG. 7, an electromagnetic actuator 40 is disposed on one side of an upper end of the pivot 42. A compression spring 43 is interposed between the upper end of the intermediate lever 41 and the main-body housing 3 on the side of the intermediate lever 41 opposite the electromagnetic actuator 40. The intermediate lever 41 is biased about the pivot 42 by the compression spring 43 in a counterclockwise direction as shown in FIG. 7.

[0053] In the second embodiment, the electromagnetic actuator 40 includes an actuation pin 40a that actuates (moves) reversely (in an opposite direction) to the movement direction of the actuation pin 30a of the electromagnetic actuator 30 of the first embodiment. That is, in the second embodiment, when electric current is supplied to the electromagnetic actuator 40, the actuation pin 40a is pushed out (advanced) by an electromagnetic force. When the actuation pin 40a is pushed out (advanced out of the body of the actuator 40), the intermediate lever 41 tilts (pivots) about the pivot 42 in the clockwise direction, as shown in FIG. 7. The operation of tilting (pivoting) in the clockwise direction goes against the biasing force of the compression spring 43 and thus the compression spring 43 is compressed by the intermediate lever 41 in the pushed out (advanced) position of the actuation pin 40a.

[0054] When the intermediate lever 41 is tilted in the clockwise direction in FIG. 7, an engaging (contacting or pressing) part 41a, which is provided on a lower end of the intermediate lever 41, is displaced in the right direction (according to the directional arrows shown in FIG. 7, which is leftward from the perspective of a person viewing FIG. 7). i.e. in the clockwise direction, away from the end part of the support-pedestal part 3a of the main-body housing 3. When the engaging part 41a is spaced apart from the end part of the support-pedestal part 3a, the lock part 20a can be caught by (latched on) the end part of the support-pedestal part 3a, which means that the start switch 20 can be moved (pivoted) into the lock-ON position.

[0055] If the supply of electric power to the power tool 1 is subsequently cut off such that the supply of electric current to the electromagnetic actuator 40 is also cut off, then the actuation pin 40a is actuated (moved) to the pulled-in side (that is, it retracts), as shown in FIG. 9, owing to the absence of a magnetic force acting on the actuation pin 40a and the biasing force of the compression spring 43. In other words, the actuation pin 40a is pulled (pushed) into the body of the actuator 40, because the upper end of the intermediate lever 41 is pressed towards the electromagnetic actuator 40 by the biasing force of the compression spring 43. As a result, the intermediate lever 41 tilts (pivots) about the pivot 42 in the illustrated counterclockwise direction as can be understood by comparing the tilting postures of the intermediate lever 41 in FIGS. 7 and 9.

[0056] When the intermediate lever 41 is tilted or pivoted in the counterclockwise direction as shown in FIG. 9, the lower side of the engaging part 41a (that is, the lower or down side as shown in FIG. 9) is displaced in the counterclockwise direction and approaches (moves towards) the end part of the support-pedestal part 3a. Consequently, the lock part 20a of the start switch 20 is pressed (pushed out), by the engaging part 41a, towards the lock-ON-released side (leftward according to the directional arrows in FIG. 9). As shown in FIG. 8 and FIG. 9, when the engaging part 41a of the intermediate lever 41 presses (pushes out) the lock part 20a, the lock part 20a of the start switch 20 separates (disengages or unlatches) from the end part of the support-pedestal part 3a, and thus the lock-ON state is released (disabled). When the lock-ON state is released, the start switch 20 returns to the OFF position, as shown in FIG. 10 and FIG. 11, owing to the biasing force of the tension spring 22 acting via the connecting rod 21.

[0057] The second embodiment thus also has a configuration in which, when the supply of electric power is cut off, the lock-ON state of the start switch 20 is released (disabled) by the movement of the actuation pin 40a of the electromagnetic actuator 40. Therefore, the controller for motor control can be simplified and made more compact as compared with the configuration in which the lock-ON state is electrically released in the actuation control of the electric motor, as in the above-described known example.

[0058] In addition, when the power-supply cord 6 is pulled out of the power-supply outlet after usage of the power tool 1 has concluded, the actuation pin 40a of the electromagnetic actuator 40 will be held in the pushed out (advanced) state (i.e. it is maintained in the pushed out or advanced position). Therefore, the engaging part 41a of the intermediate lever 41 remains at the front side of the end part of the support-pedestal part 3a. Consequently, the start switch 20 cannot be pushed into the lock-ON position due to the blocking effect of the engaging part 41a. It follows from this that, even if, for example, some other structure or a person interferes with (accidentally slides) the start switch 20 to its ON position while the power tool 1 is not being used to process a workpiece, the start switch 20 can not be placed (intentionally or unintentionally) into the lock-ON state. Therefore, the power tool 1 will not inadvertently start when the power tool 1 is subsequently re-connected to a supply of power, i.e. when the cord 6 is plugged into a power-supply outlet again.

[0059] FIG. 12 and FIG. 13 show the power tool 1 according to a third embodiment. In the third embodiment, the support for an intermediate lever 51 and an electromagnetic actuator 50 differs from that of the second embodiment. The third embodiment utilizes an electromagnetic actuator of the same type as that of the first embodiment, that is, a type in which an actuation pin 50a is pushed out (advanced) when the supply of electric current is cut off. In addition, in the third embodiment, the intermediate lever 51 is also supported such that it is capable of pivoting (tilting) about a pivot 52. But, in the third embodiment, the pivot 52 is located at one end (the lower end in FIGS. 12 and 13) of the intermediate lever 51 in the longitudinal direction, rather than in the middle of the intermediate lever (41). An engaging (contacting) part 51a is provided on the intermediate lever 51 at an intermediate, e.g., substantially central, position between the longitudinal ends of the intermediate lever 51.

[0060] The electromagnetic actuator 50 is disposed on one side of the upper end portion of the intermediate lever 51. When the actuation pin 50a of the electromagnetic actuator 50 is pulled in (retracted into the body of the actuator 50) by supplying electric current to the electromagnetic actuator 50, the intermediate lever 51 is tilted (pivoted) about the pivot 52 in the counterclockwise direction, as shown in FIG. 12, owing to the biasing force of a not-shown compression spring (similar to the compression spring 43 of the second embodiment). Consequently, as shown in FIG. 12, the engaging part 51a is displaced (pivoted) in the counterclockwise direction with respect to the pivot 52 away from the end part of the support-pedestal part 3a. It follows that, while electric power is being supplied to the power tool 1 and thus to the actuator 50, the lock part 20a can be caught by (latched on) the end part of the support-pedestal part 3a, and therefore the start switch 20 can be pushed into the lock-ON position (the lock-ON state is enabled).

[0061] On the other hand, when the supply of electric power to the power tool 1 is cut off (interrupted) and thus the supply of electric current to the electromagnetic actuator 50 is also cut off (interrupted), the actuation pin 50a of the electromagnetic actuator 50 is pushed out (is advanced out of the body of the actuator 50), as shown in FIG. 13. When the actuation pin 50a is pushed out, the upper part of the intermediate lever 51 is pressed thereby, and the intermediate lever 51 tilts (pivots) about the pivot 52 in the clockwise direction, as shown in FIG. 13. Consequently, the engaging (contacting) part 51a of the intermediate lever 51 is displaced (pivoted) to a position at which it is adjacent to (contacts and presses) the front side of the front-end part of the support-pedestal part 3a, whereby the lock part 20a of the start switch 20 is pressed (pushed) out of the locked ON position and the lock-ON state of the start switch 20 is released (disabled).

[0062] In addition, because the engaging part 51a of the intermediate lever 51 is positioned (located) at the front side of the front-end part of the support-pedestal part 3a when the supply of electric power is cut off, the lock part 20a of the start switch 20 cannot be caught by (latched on) the front-end part of the support-pedestal part 3a. Consequently, when the supply of electric power is cut off, the start switch 20 cannot be placed in the lock-ON position (state) due to the blocking effect of the engaging part 51a.

[0063] According to the third embodiment, a configuration is again adopted in which the lock-ON state of the start switch 20 is released (disabled) by the electromagnetic actuator (50), and therefore the controller for motor control can be simplified and made more compact as compared with the above-described known configuration in which the lock-ON state is electronically released in the actuation control of the electric motor.

[0064] In addition, according to the third embodiment as well, when the supply of electric power is cut off (interrupted), the start switch 20 cannot be pushed into the lock-ON position. Therefore, even if some other member (structure) or a person interferes with (accidentally pushes) the start switch 20 when the power tool 1 is not being used for workpiece processing (e.g., during storage), the start switch 20 can not be put (intentionally or unintentionally) into the lock-ON state. Consequently, the power tool 1 will not inadvertently start when the supply of electric power is subsequently connected to the power tool 1 again.

[0065] FIGS. 14-17 show the power tool 1 according to a fourth embodiment. The power tool 1 of the fourth embodiment comprises, as the switch that starts and stops the electric motor 2, a large-lever-type start switch 61 that differs from the sliding-type start switch 20 of the first to third embodiments. Members and structural elements that are the same as those in the first to third embodiments are assigned the same reference numbers, and redundant explanations thereof are therefore omitted.

[0066] The start switch 61 has an elongated lever shape and may be referred to as a paddle switch. The start switch 61 is disposed such that it extends from the lower surface of the front part of the main-body housing 3 to the rear part of the lower surface of the rear-part case 4. The start switch 61 is supported such that it is capable of tilting (pivoting) up and down (according to the directional arrows shown in FIG. 14), wherein the front-end part is engaged (joined or hinged) with the main-body housing 3 and serves as a fulcrum (pivot point). A front-side-grip part 61a and a rear-side-grip part 61b are provided on the start switch 61. The user can start the electric motor 2 by pulling on (squeezing) either the front-side-grip part 61a or the rear-side-grip part 61b. That is, when the user grasps (holds) the main-body housing 3, the electric motor 2 can be started by pulling on (squeezing) the front-side-grip part 61a. On the other hand, when the user grasps (holds) the rear-part case 4, the electric motor 2 can be started by pulling on (squeezing) the rear-side-grip part 61b, which makes the power tool 1 easier to operate in a variety of grasping positions.

[0067] A lock-OFF lever 62 is provided on the start switch 61 between the front-side-grip part 61a and the rear-side-grip part 61b. The function of the lock-OFF lever 62 is to lock the start switch 61 at (in) its OFF position in order to prevent the start switch 61 from being turned ON inadvertently. The lock-OFF lever 62 is supported such that it is capable of tilting (pivoting) frontward and rearward (clockwise and counterclockwise) about a pivot 62a. The lock-OFF lever 62 is biased toward a standing or vertical position (a lock-OFF position), as is shown in FIG. 14, by a not-shown return spring. As shown in FIG. 14, when the lock-OFF lever 62 is stood up (i.e., is generally perpendicular to a longitudinal axis of the power tool main body housing 3), an upper part thereof contacts a contact part 3c of the main-body housing 3. Consequently, the start switch 61 cannot be pulled (squeezed) towards the upper side (the ON side), as shown in FIG. 14. On the other hand, when the lock-OFF lever 62 is tipped (rotated) in the counterclockwise direction against the spring biasing force as shown in FIG. 15, the upper part of the lock-OFF lever 62 is displaced (rotated) in the downward direction. As a result, the start switch 61 can now be pulled (squeezed upward) towards the ON side.

[0068] The switch main body 5 is located within the main-body housing 3 upward of the rear-side-grip part 61b. The switch main body 5 turns ON when the rear-side-grip part 61b of the start switch 61 presses (pushes upward) the actuation button 5a into the switch main body 5. A lock-ON lever 63 is provided at (adjacent) the rear side of the start switch 61. The lock-ON lever 63 is supported by the rear-part case 4 so that the lock-ON lever 63 is capable of tilting (pivoting) upward and downward (i.e. clockwise and counterclockwise) about a pivot 63a. The lock-ON lever 63 is biased towards the lock-ON-released side (the clockwise direction in FIGS. 14-17) by a compression spring 64.

[0069] A lock part 63b is provided integrally with the lock-ON lever 63. The lock part 63b extends upward from the vicinity of the pivot 63a. An electromagnetic actuator 60 is supported along (held by) the lock part 63b. Therefore, the electromagnetic actuator 60 displaces (pivots) integrally with the lock-ON lever 63. The fourth embodiment utilizes an actuator of the type in which an actuation pin 60a is pulled in (retracted) by the supply of electric current, the same as in the first embodiment. Therefore, when the supply of electric current is cut off (interrupted), the actuation pin 60a is pushed out (advanced out of the body of the actuator 60). In FIG. 14, when the power-supply cord 6 is connected to a power-supply outlet (mains power) and thereby electric power is supplied to the power tool 1, electric current is supplied to the electromagnetic actuator 60 and thus the actuation pin 60a is pulled into the body of the electromagnetic actuator 60.

[0070] When electric power is being supplied, as shown in FIG. 15, the lock-OFF state can be released (disabled) by tipping (pivoting) the lock-OFF lever 62 in the counterclockwise direction against the spring biasing force that is continuously applied by the not-shown return spring by using the fingertip of the hand that grasps the main body housing 3 or the rear part of the case 4. If the start switch 61 is then pulled upward (squeezed toward the interior of the housing 3) while maintaining the lock-OFF-released state, then the actuation button 5a of the switch main body 5 is pressed by the rear-side-grip part 61b and thereby the switch main body 5 turns ON. When the switch main body 5 turns ON, the electric motor 2 starts and the grinding wheel 15 rotates.

[0071] When the start switch 61 is pulled in (the ON state of the switch main body 5) and the lock-ON lever 63 is subsequently pushed in against the compression spring 64, then the lock part 63b and the electromagnetic actuator 60 integrally displace (pivot) upward and forward (i.e. counterclockwise) about the pivot 63a and along an arcuate path. At this time, the actuation pin 60a of the electromagnetic actuator 60 displaces (moves) towards the pulled-in (lower) side of the start switch 61 (in particular, towards an engaging (contact) part 61c). By then engaging (abutting) the tip of the counterclockwise-pivoted lock part 63b with (on) the lower surface of the raised (upward tilted) engaging part 61c provided on a rear-end portion of the start switch 61, the start switch 61 is prevented (blocked) from returning (pivoting clockwise) towards its OFF position. In this respect, the engaging (contact) part 61c may be formed as a lip or flange at the end of the rear-side-grip part 61b of the start switch 61 that is designed to catch or latch the upper (terminal) end of the lock part 63b. Therefore, the start switch 61 is held in the lock-ON state by the abutment of the lock part 63b on the engaging (contact) part 61c while the actuation pin 60a is pulled into the body of the electromechanical actuator 60, as shown in FIG. 15.

[0072] In other words, by engaging (abutting) the forward-pivoted lock part 63b with (on) the upward-tilted engaging part 61c from below, the lock-ON state results in which the start switch 61 is locked at the ON position and it is prevented (blocked) from returning (pivoting downward or clockwise) towards its OFF position. In addition, by engaging (abutting) the lock part 63b with (on) the engaging part 61c from below, the lock-ON lever 63 is prevented or blocked from pivoting in the clockwise direction according to FIGS. 14-17, and the lock-ON lever 63 is held in the pushed-in position (lock-ON position).

[0073] To manually release the lock-ON state, the user's grip may be strengthened (i.e. the start switch 61 is squeezed upward towards the housing 3) so that the start switch 61 is displaced slightly upward; thereby, the engaging part 61c is retracted upward and away from the lock part 63b. When the engaging part 61c is slightly retracted (pulled) upward away so as to be spaced apart or separated from the lock part 63b (and the actuation pin 60a is in its retracted position), the lock-ON lever 63 will automatically pivot in the clockwise direction past the raised engaging part 61c owing to the biasing force of the compression spring 64. Therefore, the lock-ON lever 63 will return to its lock-ON-released position, which is shown in FIG. 14. Subsequently, if the grip on the start switch 61 is released (i.e. the start switch 61 is no longer squeezed), then the actuation button 5a projects (advances) outward (downward in FIGS. 14-17) from the switch main body 5, which turns OFF and thereby stops the electric motor 2.

[0074] If the supply of electric power is cut off (interrupted) in the lock-ON state set by the counterclockwise-pivoted lock-ON lever 63, then the supply of electric current to the electromagnetic actuator 60 is cut off (interrupted). As shown in FIG. 16, the actuation pin 60a is pushed out by the cut off (interruption) of the supply of electric current to the electromagnetic actuator 60. When the actuation pin 60a is pushed out, the engaging part 61c is pushed slightly upward by the actuation pin 60a. Because the advancing actuation pin 60a presses upward and the engaging part 61c retracts (pivots counterclockwise), the lock part 63b disengages (separates) from the engaging part 61c. When the lock part 63b thus no longer contacts (disengages or separates from) the engaging part 61c, the lock-ON lever 63 automatically pivots in the clockwise direction owing to the biasing force of the compression spring 64 in the same manner as in the case of the manual release discussed above. For example, the terminal end of the actuation pin 60a may contact an edge of the engaging part 61c at an angle such that the actuation pin 60a slides off and away from the engaging part 61c owing to the biasing force of the compression spring 64. Therefore, the lock-ON lever 63 returns to the lock-ON-released position shown in FIG. 17.

[0075] According to the power tool 1 of the fourth embodiment as explained above, a configuration is again adopted in which the lock-ON state of the start switch (61) is released (disabled) by the electromagnetic actuator (60), and therefore the controller for motor control can be simplified and made more compact than in the above-described known configuration in which, the lock-ON state is electrically released in the actuation control of the electric motor.

[0076] In addition, according to the fourth embodiment as well, when the supply of electric power is cut off, the actuation pin 60a of the electromagnetic actuator 60 is pushed out. Consequently, even if the start switch 61 is mistakenly pulled (squeezed) and the lock-ON lever 63 is pressed in, the start switch 61 is prevented or blocked from locking in the ON position (i.e. the lock-ON state is disabled), and therefore the power tool 1 will not inadvertently start when it is connected to a supply of electric power again.

[0077] Each embodiment as explained above can be supplemented with additional modifications. For example, by using an electromagnetic actuator in which the direction of the actuation (movement) of the actuation pin is the reverse of that in the first embodiment, it is possible to adopt a configuration in which the lock part 20a of the start switch 20 directly engages with (latches) the actuation pin of the electromagnetic actuator in order to lock the start switch 20 in the ON position, i.e. the lock part 20a engages/contacts the actuation pin instead of the front-end part of the support-pedestal part 3a. In such an embodiment, if the supply of electric current to the electromagnetic actuator is cut off, then the actuation pin is pulled in (retracted) and the engagement (latching) of the lock part 20a with the actuation pin is released, whereby the lock-ON state of the start switch 20 is released (disabled).

[0078] In addition, power tools are illustrated in which an AC power supply (mains power) serves as the power supply, but the present disclosure can likewise be adapted to power tools in which a rechargeable battery pack is used as the power supply. The present techniques are particularly advantageous in the situation in which the charge of the rechargeable battery runs out while the power tool is operating in the lock-ON state. If the start switch is not moved out of the ON position (e.g., by an electromagnetic actuator according to the present disclosure), the power tool will start operating, possibly detrimentally to the user, as soon as a recharged battery pack is mounted on the power tool. Such a power tool optionally can be designed such that the electromagnetic actuator is actuated to disable the lock-ON state when the remaining charge of the battery pack falls below a predetermined threshold, to reduce the likelihood that the rechargeable battery will reach an over-discharged state that could permanently damage the rechargeable battery.

[0079] Furthermore, although a disc grinder was illustrated as the power tool 1, the same functions and effects also can be obtained with other power tools, such as cutting machines (e.g., reciprocating saws), screwdrivers, polishers, sanders, etc., by using an electromagnetic actuator as described above to automatically release (disable) a lock-ON mechanism when the supply of electric power is cut off (interrupted).

[0080] Each of the electromagnetic actuators 30, 40, 50, 60 disclosed herein may be embodied as an electromechanical solenoid having an electromagnetically-inductive coif wound around a movable steel or iron pin (actuation pin), which may also be called a plunger or armature. The coil is shaped such that the pin moves either in or out of the center of the coil in response to energization of (supply of electric current to) the coil. A return spring biases the pin in a direction opposite of the direction that the magnetic field generated by the coil pulls the pin when the coil is energized. Therefore, in the absence of the magnetic field (i.e. when the current to the coil is interrupted), the pin will move in the direction of the biasing force of the return spring.

[0081] Representative, non-limiting examples of the present invention were described above in detail with reference to the attached drawings. This detailed description is merely intended to teach a person of skill in the art further details for practicing preferred aspects of the present teachings and is not intended to limit the scope of the invention. Furthermore, each of the additional features and teachings disclosed above may be utilized separately or in conjunction with other features and teachings to provide improved power tools.

[0082] Moreover, combinations of features and steps disclosed in the above detailed description may not be necessary to practice the invention in the broadest sense, and are instead taught merely to particularly describe representative examples of the invention. Furthermore, various features of the above-described representative examples, as well as the various independent and dependent claims below, may be combined in ways that are not specifically and explicitly enumerated in order to provide additional useful embodiments of the present teachings.

[0083] All features disclosed in the description and/or the claims are intended to be disclosed separately and independently from each other for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter, independent of the compositions of the features in the embodiments and/or the claims. In addition, all value ranges or indications of groups of entities are intended to disclose every possible intermediate value or intermediate entity for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter.

EXPLANATION OF THE REFERENCE NUMBERS

[0084] 1 Power tool (disc grinder) [0085] 2 Electric motor [0086] 2a Output shaft [0087] 3 Main-body housing [0088] 3a Support-pedestal part [0089] 3b Insertion-window part [0090] 3c Contact part [0091] 4 Rear-part case [0092] 5 Switch main body [0093] 5a Actuation button [0094] 6 Power-supply cord [0095] 7 Grinding-wheel cover [0096] 10 Gear-head part [0097] 11 Gear-head case [0098] 12 Bevel gear (drive side) [0099] 13 Bevel gear (follower side) [0100] 14 Spindle [0101] 15 Grinding wheel [0102] 18 Cooling fan [0103] 19 Baffle plate [0104] 20 Start switch [0105] 20a Lock part [0106] 20b Arm part [0107] 20c Pressing part [0108] 21 Intermediate lever [0109] 22 Tension spring [0110] 23 Switch frame [0111] 30 Electromagnetic actuator (first embodiment) [0112] 30a Actuation pin [0113] 40 Electromagnetic actuator (second embodiment) [0114] 40a Actuation pin [0115] 41 Intermediate lever [0116] 41a Engaging part [0117] 42 Pivot [0118] 43 Compression spring [0119] 50 Electromagnetic actuator (third embodiment) [0120] 50a Actuation pin [0121] 51 Intermediate lever [0122] 51a Engaging part [0123] 52 Pivot [0124] 60 Electromagnetic actuator (fourth embodiment) [0125] 60a Actuation pin [0126] 61 Start switch [0127] 61a Front-side-grip part [0128] 61b Rear-side-grip part [0129] 61c Engaging part [0130] 62 Lock-OFF lever [0131] 62a Pivot [0132] 63 Lock-ON lever [0133] 63a Pivot [0134] 63b Lock part [0135] 64 Compression spring