Abstract: The present invention provides a plunge-cut action circular saw having a double pivot hinge mechanism. Problems associated with this hinge mechanism, in particular axial end flow are reduced by urging a component of the hinge against a fixed component of the saw, such as a base plate component or the like. The urging force is applied by a resilient member, such as a spring washer.

Abstract: A cordless power tool system includes a power tool including with a motor disposed in the tool housing, and a variable speed circuit for controlling the speed of the motor. A power tool battery pack is electrically connectable to the power tool. The battery pack has an electric/electronic component connectable to the variable speed circuit. The variable speed circuit and/or the power tool are disabled if the variable speed circuit fails to detect the electric/electronic component.

Abstract: A cordless power tool has a housing which includes a mechanism to couple with a removable battery pack. The battery pack includes one or more battery cells as well as a vent system in the battery pack housing which enables fluid to move through the housing. A mechanism is associated with the battery pack to dissipate heat from the battery pack.

Abstract: An apparatus and method for forming a flat surface on a workpiece. The apparatus includes a cutterhead, having a plurality of cutting member, configured for forming a plurality of grooves in a workpiece. The cutterhead may be disposed generally at the interface of substantially parallel offset first and a second supports in order to form a plurality of grooves defining a datum or reference plane which may be implemented to orientate the workpiece for forming a flat surface. A plurality of ridges or the like structures defining grooves are included in the second support or as an attachment to the second support in order to support the workpiece from the material forming the interior surface of the grooves so that the workpiece may be orientated with respect to the datum plane. In an additional aspect, a second cutterhead may be included for removing or forming a flat surface which is parallel to the datum plane.

Abstract: An electric motor has a field assembly, such as a stator, for a dynamoelectric machine has field coils that are wound to a net shape. Lead wires are brought out from the ends of each field coil. The field coils are insulated with insulating sleeves or insulating slot liners. The field coils are assembled with stator core pieces, such as pole pieces and return path pieces, into the stator. The stator core pieces are formed prior to being assembled with the field coils. In an aspect of the invention, the pole pieces and return path pieces are separately formed and then assembled together with the field coils, which have also been separately formed.

Abstract: In accordance with the present invention, an improved battery pack is employed. The battery pack includes a housing with opposing walls, a plurality of cells disposed within the housing, at least two terminals electrically connected to the cells, a latching mechanism disposed on each opposing wall for latching the battery pack to a cordless device, each latching mechanism including a latch and a button disposed on the wall for moving the latch between unlatching and latching positions, the latching buttons being disposed along a first plane, the first plane being substantially vertical, wherein the number of cells disposed along the first plane is smaller than the number of cells disposed along a second plane substantially parallel to the first plane. The battery pack may also include a stacked cell disposed on the plurality of cells. The stacked cell may be disposed along the first plane. However, the stacked cell is not included in the number of cells disposed along the first plane.

Abstract: A power tool transmission is described in which an overload clutch mechanism is arranged to provide a relatively compact power tool. A torque adjustment dial is arranged between the visible portions of the motor housing and the gearbox, and the dial is coupled to a compression spring such that rotation of the dial cause the spring to be compressed or decompressed, thereby adjusting the torque at which the clutch overloads and ratchets. The compression spring is arranged at least partially between the motor and gearbox or gear train, in a space which conventional power tools do not utilized for this purpose. Thus, the dimensions of the power tool's transmission can be reduced with respect to conventional power tools. Furthermore, the space on the gearbox immediately behind a chuck can be used for another purpose other than accommodating the adjustment collar, as is the case with conventional power tools.

Abstract: A planing machine including a base, at least two support columns disposed on the base, and a carriage assembly carrying a cutterhead. The carriage assembly may be mounted on the support columns. At least one of the base and the carriage assembly is movable vertically towards the other of the base and the carriage assembly. The planing machine may have panel mounted on at least one of the base and the carriage assembly and extending between the carriage assembly and the base housing for preventing user contact with the cutterhead.

Abstract: A knuckle joint locking and release mechanism for a power tool having a locking mode where relative articulation between two body portions of the power tool is prevented and a release mode where relative articulation between the two body portions of the power tool is unhindered. The knuckle joint locking and release mechanism is biased into the locking mode but can be placed into the release mode by engaging an actuator pushbutton located on either side of the knuckle joint.

Abstract: A planer and thicknesser comprising a frame having a passageway that substantially extends through the frame. The planer and thicknesser further comprises an upper table having front and rear sections mounted on the frame, wherein a slot is located between the front and rear sections of the upper table, and a lower table moveably mounted within the passageway. The planer and thicknesser also comprises a cutting drum rotatably mounted within the frame such that a portion of the cutting drum projects upwardly through the slot and a portion of the cutting drum projects downwardly into the passage way. The planer and thicknesser also comprises a cover mounted above the upper table capable of being moved from a first position where it covers a portion of the cutting drum to a second position where it does not cover a portion of the cutting drum.

Abstract: A battery charger work light includes a housing defining an envelope and a charger circuit disposed in the housing. The charger circuit is operable to charge a rechargeable battery pack. A light is movably mounted to the housing. The light is movable between an extended position outside of the envelope and a storage position inside of the envelope.

Abstract: A charger including a power supply connectable to an outside power source, first and second battery power sources connected to the power supply for providing power to a battery pack, and a controller connected to the first and second battery power sources for controlling the first and second battery power sources. The first and second battery power sources are preferably connected in parallel to the battery.

Abstract: A control system is provided for use in a power tool. The control system includes: a rotational rate sensor having a resonating mass and a controller electrically connected to the rotational rate sensor. The rotational rate sensor detects lateral displacement of the resonating mass and generates a signal indicative of the detected lateral displacement, such that the lateral displacement is directly proportional to a rotational speed at which the power tool rotates about an axis of the rotary shaft. Based on the generated signal, the controller initiates a protective operation to avoid further undesirable rotation of the power tool. The controller may opt to reduce the torque applied to shaft to a non-zero value that enables the operator to regain control of the tool.

Abstract: The present invention is directed to a hand-held circular saw with an integrated dust collection system. Such saw may include an upper blade guard for protecting the user from a saw blade, the upper blade guard configured with a front region and a back region, the front region including a hollow channel to control the pathway of dust and debris and a dust collection system incorporated within the front region of the upper blade guard allowing dust and debris to be directed away from the user.

Abstract: A planer and thicknesser comprising a frame having a passageway that substantially extends through the frame. The planer and thicknesser further comprises an upper table having front and rear sections mounted on the frame, wherein a slot is located between the front and rear sections of the upper table, and a lower table moveably mounted within the passageway. The planer and thicknesser also comprises a cutting drum rotatably mounted within the frame such that a portion of the cutting drum projects upwardly through the slot and a portion of the cutting drum projects downwardly into the passage way. The planer and thicknesser also comprises a cover mounted above the upper table capable of being moved from a first position where it covers a portion of the cutting drum to a second position where it does not cover a portion of the cutting drum.

Abstract: An adjustable setsquare for a power tool guide rail is described. The setsquare comprises an attachment member, in the form of a bar, for locating into a channel on the guide rail. The cross section of the attachment means is generally V-shaped and arranged such that the setsquare can be removed and reattached to the guide rail with consistency, whereby the angular displacement between a reference surface of the setsquare and the intended line of cut to be made by a power tool disposed on the guide rail remains constant after each reattachment of the setsquare.

Abstract: A tool and method for winding and forming a field coil for field assembly, such as a stator, includes separable tool halves defining a winding cavity therebetween. The winding cavity receives magnet wire that is wound therein, such as by rotating the tool or a winding nozzle. The magnet wire generally conforms to the shape of the winding cavity such that when the tool halves are separated, a field coil having a net shape is produced. Once the magnet wire is sufficiently deposited within the winding cavity, wires of the coil may be bonded together either through a resistive heating process such as by passing an electrical current through the coil or through other heating or chemical bonding methods to thereby maintain the net shape of the field coil once it is removed from the tool.

Abstract: A dust collector for a power tool, such as a scroll saw, wherein the saw may include a base, a table supported by the base and a blade passing through a slot in the table. The dust collector may include a container defining an accumulation chamber and having an inlet port for collecting dust from the blade, a notch for receiving an assembly attached to the base and a locking device for removably attaching the container to the base. The dust collector may further include an outlet port for connecting a vacuum hose. The scroll saw may also include a removable storage drawer.