[0001] The present invention relates to apparatus for accurately positioning a work piece in relation to a working tool and maintaining a constant gauge thickness. Background of the Invention

[0002] The utilization of power tools such as cutting blades often requires various clamping devices and guiding devices for the accurate positioning of work pieces relative to the tools. These guiding devices are well known in the art and normally go by the way of miter gauges or the like.

[0003] Examples in the art of miter gauge type devices can be found in U.S. Patents 50384862 to Ducate, U.S. Patent 47413872 to Strong, U.S Patent 4628782 to Tark and U.S. Patent 53679332 to Jaksha.

[0004] All of the forgoing suffer from a number of disadvantages. They are often quite complex to operate and require a particular supporting infrastructure, for example the provision of Miter slots, for effective utilization.

[0005] Another example disadvantage is that, prior art feather-boards, while effective in dealing with flat boards, perform poorly with taller materials. This can occur as a result of the relative instability of a narrow common stock material being ripped on edge. A fence which is typically 4 inches tall, has the ability to guide the wood but as it is fed through, it is possible to inadvertently push the material above the fence height causing the panel to bind against the saw blade. This not only can damage the material being cut, but dramatically increases the probability of kickback and/or injury. To compound matters further, most miter slot feather-boards generally have a difficult time getting close enough to the table saw blade to push on thin materials. While there are a few that can reach up to the blade, the feathers are flexible enough that the slight pressure or tilt on the top of the panel easily deflects the fingers or finger of the feather-board. This can lead to disadvantageous results.

[0006] Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field. Summary of the Invention

[0007] The object of the present invention provide for an effective work piece positioning apparatus and method.

[0008] In accordance with a first aspect of the present invention, there is provided a system for workpiece placement in an environment, the system including: a first base plate adapted to receive a series of magnetic coupling devices activated upon the movement of an associated on-off switch to engage a magnetically active surface; and a resaw fence adapted to be interconnected with the first base plate and having a substantially planar surface in a perpendicular arrangement to the first base plate

[0009] The resaw fence preferably can include at least one recessed roller bearing located in a recess cavity in the surface thereof. Preferably, the roller bearing protudes slightly from the recess cavity to engage a workpiece in use. The resaw fence preferably can include a substantially planar surface designed to guide the workpiece when in use. Alternatively, the resaw fence preferably can include a convex surface formed from the intersection of two planes.

[0010] In one embodiment, the resaw fence preferably can include a planar surface having a first and second recessed roller bearing located therein. The first base plate preferably can include a series of slots to engage a miter slot connector tool for connecting to a miter table slot. The first base plate preferably can include a hinge arrangement inconnecting to the resaw fence. The first base plate preferably can include at least one aperture for the placement of a detachable magnetic coupling device .

[0011] In accordance with another aspect of the present invention, there is provided a workpiece positioning apparatus including: a first planar base having a series of apertures for the insertion of a magnetic coupling device for coupling the base in a fixed relationship with a magnetically attractive surface; a second base having a planar surface along which the workpiece is to move in use; and a mounting means for mounting the second base in a substantially perpendicular manner to the first planar base. [0012] In accordance with a further aspect of the present invention, there is provided a workpiece positioning apparatus including a first planar base having a series of apertures for the insertion of a magnetic coupling device for coupling the base in a fixed relationship with a magnetically attractive surface and a series of flexible feathers along a portion of the edge of the base. The apparatus can also include a second featherboard unit having a series of flexible feathers along an edge thereof and a detachable interconnect for interconnecting with the first planar base and a series of risers or spaces for holding the second featherboard unit in a predetermined relationship with the first planar base. Brief Description of the Drawings

[0013] Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0014] Fig. 1 illustrates two magnetic coupling devices and a spacer;

[0015] Fig. 2 illustrates a universal base and single roller resaw fence;

[0016] Fig. 3 illustrates a plan view of the universal base;

[0017] Fig. 4 illustrates a dual roller resaw fence;

[0018] Fig. 5 and Fig. 6 illustrate a single roller resaw fence in operation with a band saw;

[0019] Fig. 7 illustrates a single roller resaw fence in use with a sander;

[0020] Fig. 8 illustrates both a single and dual roller resaw fence in use;

[0021] Fig. 9 illustrates a first example featherboard; and

[0022] Fig. 10 illustrates a second example featherboard. Description of Preferred and other Embodiments

[0023] In the preferred embodiments there is provided a work piece positioning system. The work piece positioning system utilizes switchable permanent magnetic coupling devices activated upon the movement of an associated on-off switch mounted on a

Universal Base to provide for simple and effective work piece positioning. The Universal Base is, in turn, interconnected with a number of workpiece positioning devices, each of which are designed to position a workpiece that is to be worked on by a saw, sander or the like.

[0024] Turning initially to Fig. 1, the preferred embodiments rely upon a switchable permanent magnetic coupling devices activated upon the movement of an associated on-off switch such as that illustrated 1,2. The switchable magnetic coupling devices can be constructed as disclosed in U.S Patent 7012495 to Underwood et al, the contents of which are hereby incorporated by cross-reference. These devices are constructed from two planar permanent magnet devices and are activated by a turning a switch e.g. 4 which activates or deactivates the intensity of a magnetic field projecting primarily out of the base eg. 5. The magnetic field can thereby be utilized to attract the switching device to a magnetic attracting surface such as a planar cast iron metal work bench or the like. The switches can come in various sizes and powers e.g. 1,2. The magnetic switch 1 is operable between an on and off state by means of twisting a top lever 4. A spacer or adapter 3 can be provided for utilization with a smaller switch 2 so that it produces a body having the same circumferential profile as the larger magnetic coupling device 1.

[0025] As illustrated in Fig. 2, the magnetic coupling device is operable to be inserted into a universal base plate 10 which can be formed from injection moulded plastic. The universal base plate 10 is illustrated in plan view in Fig. 3 and includes at least two prongs 7, 8. As shown in Fig. 2, normally two magnetic coupling devices 11, 12 are utilised with the universal base plate 10. The magnetic coupling devices 11, 12 are utilised to hold the universal base plate in a firm static position during operations.

[0026] The Universal Base Plate 10 is designed to also engage with a Mitre slot via screws e.g. 20 which can engage with Miter slot hardware (not shown). In such cases of use, the magnetic coupling devices are detachable, and can be replaced with spacers e.g. 3. The switchable magnetic coupling devices can thereby be easily removed, replaced and moved.

[0027] Each end of the base plate 10 has a hinge mechanism 14, 15, attached thereto. The mechanisms are utilised for mounting a second operational device e.g. 17. Each mechanism can consist of a plate e.g. 18 on which is mounted a hinge 19. The hinge is tightened by tightening screw 20. The hinge 19 includes an access hole for a second screw e.g. 21 which is utilised to mount the second operational device e.g. 17. Each end of the base plate has a fine adjustment shim that allows for precision adjustment of the attachment (vertical piece) to a perfect 90 degrees relative to the base. This system also allows for minor angles +/- 2-3 degrees if desired by the user.

[0028] The second operational device can take many forms. An initial form is illustrated in Fig. 4 and comprises a resaw fence having two recessed roller bearings 41, 42. The roller bearings have a series of rollers thereon with the rollers minutely projecting out of their corresponding recess e.g. 43 so as to engage a work article e.g. 44 as it move along the surface of the fence 40. The article being firmly aligned in position due to the work support device positioning.

[0029] Alternative forms of resaw fences are possible. For example, turning now to Fig. 5, there is shown a universal base plate 10 with an alternative form of resaw fence 50. The resaw fence 50, in this case, having a single roller 51 and having a triangular surface profile. The arrangement 50 being ideal for utilising workpieces e.g. 53 in conjunction with band saw blade 54. Fig. 6 illustrates a further view of the arrangement of Fig. 5. The utilisation of the long fence 55 in conjunction with the resaw fence 50 provides for fine adjustment of the workpiece with set up being simple and fast. This allows a woodworker to compensate for blade drift and tilt due to the blade guide locations. The fine angle adjustment on both the dual roller and a single roller arrangement can compensate for blade angle misalignment or drift. This readily accounts for most bandsaw blade variations.

[0030] The Universal base and resaw fence provide a high level of flexibility in positioning of work pieces. For example, in Fig. 7 there is shown an alternative use of a resaw fence 73, utilised to position workpiece 72 against sander 71. Being able to stand material up and hold it with even width and pressure against a sanding disk is often important. When sanding curved features like rocker legs or arms, maintaining equal spacing from the bottom of the spindle to the top of the wood is often critical. Any pause can end up talcing too much off in a single spot and with coarse sanding, feeding repeatedly results in different thicknesses from top to bottom and along its length. Utilizing the resaw fence arrangement of Fig. 7 allows for a quick setting of the thickness desired per pass and allows for feeding at various speeds with the knowledge that the thickness across the height and length will be maintained. Rather than pushing against the spindle, it is possible to push against the bearings and have the shaper remove only the high spots. This adds a benefit to shaper sanders which typically damage a lot of material until the operator becomes proficient at using the sander.

[0031] As a further example of operational use, Fig. 8 illustrates the use of two Universal base plates in 80, 81, which are magnetically coupled to arm 86, each with their own resaw fences 83, 84, as guides for workpiece 85.

[0032] The Universal Base and associated attachments offer an innovative method to guide work material safely and accurately on power tools. For example, the roller attachments provide a means for holding tall upright work pieces firmly against a fence. Whether or not the magnetic coupling device capabilities of the universal base plate or the miter slot version are utilised, the advantage of having a ball bearing guide fence that can provide pressure along the entire height of the fence is significant. For example, when cutting a Tongue and Groove on a table saw, the firm pressure of the bearings allows for the ability to keep the cut very well centered. Furthermore, by utilizing a bearing contact surface the force require to guide the wood or material along the fence is minimized.

[0033] In prior art arrangements, typical feather-board fingers often scrape along the face surface thereby necessitating further sanding and increasing the friction observed by the operator. While the ball bearing surface is not designed to prevent kickback, by keeping the material firmly held in place and aligned to the blade, it is thought that the incidences of kickback are reduced.

[0034] The arrangements of the preferred embodiments can be used on both the in-feed and out-feed. Since the guides do not put any real pressure on the material being cut, it is possible to place them on the out-feed side of a table saw without binding the excess material against the blade. The dual roller arrangement of Fig. 4 merely keeps the cutoff material in line with where it is supposed to be. It is also possible to place them on the out-feed side of a table saw when making cuts that are not

"through cuts", or those that do not create a scrap piece of lumber that could become wedged against the blade. Eg: dado cuts, slots, molding head shaping, rabbet cuts etc. The dual roller arrangement of Fig. 4 keeps the cutoff material in line with where it is supposed to be.

[0035] The preferred embodiments are particularly advantageous in accurately guiding tall materials on a joiner table. As there are normally no provisions for a miter slot on a Joiner table, the prior art feather boards can not be utilized as a third or fourth hand in guiding material accurately. By utilizing multiple ball bearings and a height approaching that of the fence, boards that are being edge joined can finally be glued up without glue gaps due to wavering, movement or tilting of the board against the fence.

[0036] Use of this product on a joiner table can be done in a horizontal position such as that illustrated in Fig. 8, as well with both the infeed and outfeed table. This allows a board to be held in position and keeps it from tilting up and down which often causes "snipes" in the wood. The Dual Roller fence has features that allow a micro adjustment of the angle tilt of the bearings. This can accommodate a slight angle variation that may be desirable when putting an edge on lumber. Uses include wanting to flip boards front to back for even expansion or for a tighter glue seam on one side.

[0037] The Dual Roller or single roller fence guide will perform similarly as when used with a table saw or Joiner table. It is often important that the material being fed against a profile bit remain against the fence. Pushing with one hand on the face of the material while sliding it into the shaper with the other hand quite often causes dips in to the cutter that create uneven depths. Having to guide the material against the blade with one hand while sliding a long piece of material quite often means pausing while sliding the material to get a re-grip of the board further down to continue feeding. This often also causes unsightly burn marks in the material that needs either a second pass to remove more material or hand sanding a profile cut. By utilizing the dual roller or single roller guide on the in-feed and out-feed, moulding or other long board profile cuts becomes very consistent with feed speed consistency being the only variable the operator must control. [0038] Furthermore, as the preferred embodiments provide for a stable hand feeding environment, they provide the ability to adjust feeding speed when a wood or grain density changes. An individual feeding the wood in by hand can hear the pitch of the cutter change as he starts into a knot in the wood. This allows the user to automatically slow down the feed rate to avoid tear-out or chatter marks. The sound, resistance force, or feel of the wood as it is being fed into the blade provides a useful indicator of performance.

[0039] Further, other attachments for the universal base can be provided in accordance with ongoing demands.

[0040] An example of the extension of the universal base is illustrated in Fig. 9 and Fig. 10 which illustrate a featherboard arrangement which is stackable by means of spacers inserted between the featherboard units. Turning initially to Fig. 9, the featherboard arrangement 90 includes a base plate 91 on which two switchable permanent magnetic coupling devices are located 92, 93 in corresponding recesses. The arrangement 90 can be formed from injection moulded plastic and can include a number of resilient fingers e.g. 94 designed to engage the workpiece. Attached to the base plate 91 is a second featherboard unit 95. The unit 95 is offset from the unit 91 by means of risers 96, 97 and is held in place by means of screws 98, 99. The second featherboard unit 95 is slidable in a plane along slots 100, 101 so as to provide an adjustable extension or projection of fingers 102. Turning now to Fig. 10, the number of risers e.g. I l l, 112 can be increased and a larger screw utilized so as to increase the space between the two featherboard units 94, 95, thereby providing a different level of work piece feathering.

[0041] In review, the featherboard risers are able to be stacked to create a taller Featherboard, allowing for the use of a taller featherboard when resawing, Panel or edge work similar to other roller supports. This adds the flexibility of fingers to absorb thickness variations, rough lumber, and to help prevent kickback. The featherboards can be stacked to any height with added longer bolts. Common application would be with a secondary sub-fence attached to a table saw fence to hold the raised panel lumber against the taller sub-fence as securely as possible to avoid unwanted movement. Similar use can be to include tongue and groove forming, molding work with a molding head cutter, and dado work on an edge.

[0042] In review therefore, the Universal Base allows for installation on a table top or bench top tool via the use of either Miter Slot Hardware, or the magnetic coupling devices (of various sizes using the adaptors). The base is easily removed, placed and removed due to the use of switchable magnetic coupling devices and is not limited to miter slots as it is able to be placed anywhere on a cast iron table top for use when the miter slots are not in a position favorable to being used. This can be common when working with large pieces or wood, very small pieces and thin rips. Common use includes sander tables, shaper tables, drill press, band saw and spindle sanders.

[0043] The single bearing roller Resaw Fence is primarily designed for use with a Band Saw. However, it can be utilized on other apparatus and allows for attachment to the universal base via unique indexing pins and a threaded inserts system. The Fence uses ball bearings that allows for non-marring, friction free passing of wood pass the blade. In some embodiments, the surface of the fence has an angled Infeed and

Outfeed to allow for adjustment of the feed angle necessary when the blade and band saw exhibits Blade Drift, as is common. This is well suited for Infeed or Outfeed use when using a Joiner Planer, Table saw or shaper. For example, when standing a piece of wood on edge, such as edge joining, raised panel or when passing the wood over or past a blade as in the shaper. The low profile also allows for use on a fence holding down for consistency and safety. During such use, the operators hands do not need to get too close to the blade, and constant pressure creates less chatter, less score marks and burn marks.

[0044] The dual bearing roller resaw fence is similar to the single roller case except that it creates a situation where there is little or no pivot for greater consistency. This can hold the work piece with greater holding power when performing edge joining, raised panel, on table saws and joiner/planer, and can be placed directly over blade on joiner for Infeed and Outfeed simultaneously. It also holds wood securely against band saw fence when ripping or resawing. 5] The forgoing describes preferred forms of the present invention. Modifications, obvious to those skilled in the art can be made thereto without departing from the scope of the invention.