Operator interactive control of speed and torque in machine tools
This is a continuation application of Ser. No. 07/702,505, filed May 20, 1991, now abandoned. 
    
    
     FIELD OF USE 
     Machine tools are provided with power transmission means in which the ratio of motor output shaft speed and torque to tool speed and torque can be changed. 
     BACKGROUND OF INVENTION 
     Electrical service furnishes 240 volts single phase alternating current to virtually all customers of power utilities in the United States. The relative inexpensiveness and widespread availability of such service has caused manufacturers to equip their machinery to utilize such current in power requirements up to about three horsepower, and also to manufacture products which utilize such current. The motors most commonly used with alternating current are characterized by near constant operating speed and low starting torque when compared to motors which utilize polyphase or direct current. Where a greater range of speed and torque control is required than is possible with single phase alternating current motors, motor driven generators or rectifiers may be used to supply direct current to a machine drive motor from single phase alternating current service. 
     The method and means of this invention increases the range of continuously variable tool speed and torque control from that heretofore available to operate machine tools from single phase alternating current by additively coupling interactive machine operator manual control of mechanical regulation of speed and torque to that of electrical control using direct current motor drive, to effect reduction or elimination of machine down time needed for performing a series of machine operations requiring differing tool speeds and torques. 
     SUMMARY OF THE INVENTION 
     Alternating current rectification, pole reversal switching, and voltage control in conjunction with interactive manual control of biasing of a variable diameter drive belt sheave provides a capability to a machine tool furnished with single phase alternating current to perform a greater range of machining operations than is possible with conventional machine drives using similar current and of similar motor ratings, without requiring down-time for changing drive belt or gear engagement necessary to complete the range of operations. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a right side elevational view, oriented with respect to a machine operator, of an embodiment of a portion of a drill press machine tool of this invention; 
     FIG. 2 is a left side elevational view of the embodiment of FIG. 1; 
     FIG. 3 is a top plan view of the embodiment of FIG. 1. 
    
    
     DESCRIPTION OF THE INVENTION 
     Referring to the drawings, FIGS. 1 and 2 shown drill press 10 in truncated elevational views with base standard deleted for convenience of illustration. A drill press is selected as an example of one type of machine tool embodying the method and means of this invention, with the application of the invention to other kinds of machine tools being apparent to persons skilled in the art, and such applications are included in the scope of invention described and claimed. 
     Post 11 extends vertically from a base standard, not shown, carrying elevationally adjustable work table 12 clamped thereon, and in addition carrying horizontally extending cabinet 13 housing the mechanisms for driving and for elevationally biasing drill chuck 14 and affixed drill bit 15. Multiply grooved, stepped diameter sheave 16 is fixed on a shaft, concealed from view, which carries chuck 14. Lever 17 is rotatively biased manually by a machine operator to operable raise and lower drill bit 15. Power transmission V-belt 18 is engaged with sheave 16 for rotatively driving chuck 14 and drill bit 15. Clamp bracket 19 is disposed on the opposite side of post 11 from that of cabinet 13, being bolted to the cabinet to tightly secure the assembly on post 11. The foregoing disclosure describes prior art and comprises no part of this invention. 
     Bracket 20 is frictionally clamped on post 11 for supporting arm 21. Adjustable, threaded rod 22 is threadedly engaged with the far reach of arm 22 for carrying control box 25. Within control box 25 are housed a rectifier for single phase alternating current, preferably a full wave rectifier, a voltage controller, a terminal reversing switch, and an on-off switch, all concealed from view. Control box 25 equipped as described can be purchased, for example, from Minarik Electric Company, Glendale, Calif. 
     Toggle switch levers 26, 27, and dial 28 are shown projecting from the front of control box 25, for controlling, respectively, voltage, on-off, and current reversing functions. Electrical lead 30 depending from control box 25 supplies single phase alternating current to drill press 10 through control box 25. Electrical lead 31 provides rectified current from control box 25 to junction box 33 on direct current motor 35. Motor 35 may be any suitably constructed motor, a preferred embodiment being a permanent magnet motor as manufactured, for example, by Leeson Electric Motor Corporation, Grafton, Wisc. 
     Motor 35 is fixedly mounted on hinge plate 37 for being arcuately moved together with the hinge plate around hinge connector 38, with hinge connector being disposed pivotally connecting fixed mounting plate 39 with hinge plate 37. Bolts 40 secure mounting plate 39 to cabinet 13. Hinge rod 42 is connected to the far reach of plate 37, enabling plate 37 to be manually biased around hinge connector 38 for altering the distance between sheave 16 mounted on cabinet 13 and sheave 50 mounted on motor shaft 36. Rod 42 as shown is is axially rotative and operably and outwardly movable in ball joint 43 mounted on hinge plate 37 so that handle portion 41 of rod 40 can be disengaged from notches 46 in bar 47 and the rod pushed, or raised and swung outwardly to increase the length of the lever arm before being pushed, to rotate hinge plate 37 about hinge connector 38 and lengthen the distance from sheave 16 to sheave 50. Bar 47 is adjustably mounted on the side of cabinet 13 by being engaged in slotted feet 60 for longitudinal movement to accommodate stretch in V-belt 18 which occurs from use. Three notches 46 conform to the positions of handle portion 41 of rod 40 corresponding to engagement of V-belt 18 in each of the three grooves in stepped diameter sheave 16. Adjusting screw 61 is threaded through tapped lug 62 on cabinet 13 to provide an adjustable stop against which bar 47 abuts under tension of V-belt 18 urging rod 42 and bar 47, with which handle portion 41 of rod 42 engages, toward the front of drill press 10. 
     Variable diameter sheave 50 is fixedly mounted on output shaft 36 of motor 35. Sheave 50 comprises lower flange 53 fixed on shaft 36, and upper flange 54 splined to be axially movable on shaft 36. Upper flange 54 is downwardly biased by compression spring 55 toward lower flange 53, with spring 53 disposed with its upper end extremity abutting head 56 at the top of shaft 36, and with the lower extremity of the axially extended spiral configuration of the spring contacting the outer peripheral extremity of upper flange 54 of sheave 50. Compression in spring 53 acts in opposition to tension in V-belt 18 in changing the pitch diameter of sheave 50, with tension decreasing the pitch diameter of sheave 50 and spring compression increasing it. Biasing of rod 40 in a direction which moves hinge plate 37 rearward and away from clamp bracket 19 increases tension in V-belt 18 and forces flange 54 of sheave 50 upward against the urging of spring 53 thereby decreasing the pitch diameter of sheave 50. In response to such manual biasing of rod 40 by a machine operator during drilling operations, the rotational speed of a tool such as drill bit 15 decreases and torque increases. Many drilling operation for bit diameters up to approximately one inch are best performed in steel stock at speeds of from about 50 to 85 revolutions per minute, with lower speeds being desirable for use with hole cutters. For use with taps, both lower speeds and repeated reversal of rotational direction are required. With drill press 10, all operations can be performed without requiring machine down-time for changing drive belt 18 on its sheaves. Rather, reduction in rotating speed and increase in torque beyond that available from motor control alone is provided by operator biasing of rod 40 in suitable manner, with tap use being made convenient and fast by use of reversing switch 27 to repeatedly reverse rotational direction of a tap drive. Myriad other situations in operating a drill press will present themselves in which one embodiment of invention described enables machining operations to proceed without requiring repositioning of drive belt or gears as otherwise would be required. 
     Adaptation of the disclosed invention to machine tools other than drill presses will be apparent to persons skilled in the art, such as, for example, to a milling machine, and such adaptation is included within the scope of the disclosure and claims of this specification. Other arrangements for tensioning drive belt 18 will be apparent, such as, for example, by use of belt tensioning idler sheave or pulley, which acts respectively, against the outer face or inner face of V-belt 18 between sheaves 16 an 50 for operably varying the pitch diameter of sheave 50. Means such as rod 40 for operating a belt tensioner may be mounted on either side of a machine tool such as drill press 10 for the convenience of a machine operator.