Abstract: A blade-height optimization indicator for a table saw determines based on the rotational position of one or more blade guards of the table saw as they are displaced by a workpiece being cut whether the blade-height of the table saw is optimized relative to the thickness of the workpiece and provides a visual GO/NO-GO indication depending on whether the blade-height is determined to be optimized.

Abstract: A fence assembly configured to guide a workpiece with respect to a blade of a saw device includes a fence that is supported by rails for sliding movement relative to a work surface. Opposed ends of the fence are supported on the rails via rail engagement members. The fence assembly includes a fence angle adjustment mechanism associated with a housing of one of the rail engagement members. The fence angle adjustment mechanism includes biasing elements working in conjunction with an adjustment screw to adjust the position of the fence with respect to parallelism to the blade.

Abstract: A fence assembly configured to guide a workpiece with respect to a blade of a saw device includes a fence that is supported by rails for sliding movement relative to a work surface. Opposed ends of the fence are supported on the rails via rail engagement members. The fence assembly includes a fence angle adjustment mechanism associated with a housing of one of the rail engagement members. The fence angle adjustment mechanism includes biasing elements working in conjunction with an adjustment screw to adjust the position of the fence with respect to parallelism to the blade.

Abstract: An object detection system in a saw includes an electrically conductive plate positioned at a predetermined distance from the implement, a detection circuit comprising a transformer, and a single cable connecting first terminal and second terminals of the transformer. The single cable includes a first conductor electrically connected to the first terminal of the winding and to the electrically conductive plate, a second conductor electrically connected to the implement, and an electrical insulator positioned between the first conductor and the second conductor.

Abstract: A table saw includes a working surface and a rail system. The rail system includes stationary rails mounted along the working surface, and extension rails. The rails each include matching guide surfaces extending along the longitudinal axis and configured to support and guide a rip fence. The rails have a common connection interface that in each case includes a connecting end and a supporting end, such that the extension rails are mountable with the stationary rails. When mounted, the guide surfaces of the extension rails extend the guide surfaces of the stationary rails. The connecting end in the common connection interface includes a connection mechanism configured to urge the connecting end together with the supporting end to form an internal connection, and to align the guide surfaces of the connected rails to as to be co-planar with each other.

Abstract: In one embodiment, a table saw assembly includes a motor assembly, an electrically conductive belt operably connected to the motor assembly, an arbor shaft operably connected to the belt, a drop arm assembly rotatably supporting the arbor shaft, and a first pulley rotatably supporting the belt, the first pulley including an inner bore and an outer surface, the first pulley configured to electrically isolate the inner bore from the outer surface.

Abstract: A method for detection of a fault in a sensing cable within a saw detects potential failures in a sensing cable that is part of an object detection system in the saw. The method includes generating a predetermined excitation signal transmitted through a first conductor and a second conductor in the sensing cable, detecting a return signal from the first conductor and the second conductor in the sensing cable in response to the predetermined excitation signal, identifying a signal-to-noise ratio (SNR) of the return signal, and generating an output indicating a fault in the sensing cable in response to the SNR of the return signal being below a predetermined value.

Abstract: A method of mounting a capacitive coupling plate to a power tool assembly including a drop arm assembly, an actuating device configured to transfer a force to the drop arm assembly, and a control system configured to control the actuating device includes connecting a capacitive coupling plate bracket formed from a non-conductive material to a drop arm frame of the drop arm assembly, and mounting the capacitive coupling plate to the capacitive coupling plate bracket.

Abstract: A power tool assembly includes a drop arm assembly rotatably supporting an arbor shaft and movable between a first drop arm position and a second drop arm position, an actuating device configured to transfer a force to the drop arm assembly when the drop arm assembly is at the first drop arm assembly position, a control system configured to control the actuating device to transfer the force to the drop arm assembly when an unsafe condition is sensed, a motor operably connected to the arbor shaft through a gear, and a gear housing which houses the gear, the gear housing formed from a non-conductive material.

Abstract: A table saw includes a working surface and a rail system. The rail system includes stationary rails mounted along the working surface, and extension rails. The rails each include matching guide surfaces extending along the longitudinal axis and configured to support and guide a rip fence. The rails have a common connection interface that in each case includes a connecting end and a supporting end, such that the extension rails are mountable with the stationary rails. When mounted, the guide surfaces of the extension rails extend the guide surfaces of the stationary rails. The connecting end in the common connection interface includes a connection mechanism configured to urge the connecting end together with the supporting end to form an internal connection, and to align the guide surfaces of the connected rails to as to be co-planar with each other.

Abstract: A method of resetting a drop arm assembly in a power tool assembly from a first drop arm assembly position whereat a portion of a shaping device mounted on the drop arm assembly does not extend above a workpiece support surface, includes removing a throat plate from a throat plate opening, moving at least a portion of a blade wrench downwardly through the throat plate opening, operably coupling the blade wrench with an arbor shaft of a drop arm assembly, releasing a first latch from engagement with a drop arm frame of the drop arm assembly after removing the throat plate, pulling the coupled blade wrench in an upwardly direction to a second drop arm assembly position whereat the portion of the shaping device extends above a workpiece support surface, and latching the drop arm assembly at the second drop arm assembly position with a second latch.

Abstract: An object detection system in a saw includes an electrically conductive plate positioned at a predetermined distance from the implement, a detection circuit comprising a transformer, and a single cable connecting first terminal and second terminals of the transformer. The single cable includes a first conductor electrically connected to the first terminal of the winding and to the electrically conductive plate, a second conductor electrically connected to the implement, and an electrical insulator positioned between the first conductor and the second conductor.

Abstract: A power tool assembly includes a drop arm assembly movable along a drop plane, an actuating device configured to transfer a force to the drop arm assembly to force the drop arm assembly along the drop plane, and a tool control unit assembly configured to control the power tool assembly, the tool control unit assembly including a printed circuit board (PCB) generally defining a PCB plane which is not perpendicular to the drop plane.

Abstract: An object detection system in a saw includes an electrically conductive plate positioned at a predetermined distance from the implement, a detection circuit comprising a transformer, and a single cable connecting first terminal and second terminals of the transformer. The single cable includes a first conductor electrically connected to the first terminal of the winding and to the electrically conductive plate, a second conductor electrically connected to the implement, and an electrical insulator positioned between the first conductor and the second conductor.

Abstract: A method for measuring brush wear in a motor of a saw includes generating, with a sensor connected to a brush in a motor of the saw, a first signal corresponding to a level of wear in the brush and identifying, with a controller, a level of wear for the brush with reference to the first signal. The method further includes generating, with the controller and a user interface device, an output requesting replacement of the brush in response to the identified level of wear exceeding a predetermined threshold.

Abstract: A method for operating an object detection system in a saw produces profiles for materials used in work pieces. The method includes operating a motor in the saw to move an implement and cut a work piece formed from a predetermined material, recording, a sensing signal produced in the object detection system during contact between the work piece and the implement, generating a detection profile for the material of the work piece based on the recorded sensing signal, storing, the detection profile in a memory in the saw, and operating the saw and the object detection system using the detection profile to distinguish between contact of the implement with a work piece formed from the predetermined material and contact of the implement with a portion of a body of an operator.

Abstract: A method for detection of proximity between an object and an implement in a table saw includes operating a motor in the table saw to move the implement, generating, with a capacitive sensor formed in a throat plate around the implement in the table saw, a capacitance signal during operation of the motor, identifying, with a controller operatively connected to the capacitive sensor, an object in proximity to the capacitive sensor in response to a change in a level of capacitance in the capacitance signal, and deactivating, with the controller, the motor in the table saw in response to the change in the capacitance signal indicating a capacitance level that exceeds a predetermined threshold corresponding to a body part of an operator.

Abstract: A power tool assembly includes a latch movable between a first latch position whereat the latch supports a drop arm assembly in a first drop arm assembly position, and a second latch position whereat the latch does not support the drop arm assembly position at the first drop arm assembly position, and an arbor lock movable between a first lock position whereat the arbor lock prevents movement of the drop arm assembly toward the second drop arm assembly position when the drop arm assembly is in the first drop arm assembly position, and a second lock position whereat the arbor lock does not prevent movement of the drop arm assembly toward the second drop arm assembly position when the drop arm assembly is in the first drop arm assembly position.

Abstract: A method of mounting a capacitive coupling plate to a power tool assembly including a drop arm assembly, an actuating device configured to transfer a force to the drop arm assembly, and a control system configured to control the actuating device includes connecting a capacitive coupling plate bracket formed from a non-conductive material to a drop arm frame of the drop arm assembly, and mounting the capacitive coupling plate to the capacitive coupling plate bracket.

Abstract: A power tool assembly includes a drop arm assembly movable along a drop path between a first drop arm assembly position whereat a shaping device portion supported by the drop arm assembly extends above a workpiece support surface and a second drop arm assembly position whereat the portion does not extend above the workpiece support surface, the drop arm assembly including a capacitive coupling plate bracket formed from a non-conductive material and connected to a drop arm frame, and a capacitive coupling plate mounted to the capacitive coupling plate bracket, an actuating device configured to transfer a force to the drop arm assembly when the drop arm assembly is at the first drop arm assembly position, and a control system operably connected to the capacitive coupling plate and configured to control the actuating device to transfer the force to the drop arm assembly when an unsafe condition is sensed.