Abstract: An electric motor for use with a power tool includes a rotor having a body, a stator having a plurality of electromagnetic coils surrounding the rotor, an output shaft coupled to the rotor for rotation with the rotor, and a plurality of magnets positioned within the body of the rotor. The motor also includes a mechanical magnet holder coupled to at least one of the rotor and the output shaft to engage each of the plurality of magnets. The mechanical magnet holder inhibits movement of the plurality of magnets out of the body of the rotor.

Abstract: A brushless direct current motor for a power tool. The motor includes a stator assembly including a stator core having stator laminations with an annular portion and inwardly extending stator teeth. The motor also includes a rotor assembly including a rotor core having rotor laminations and defining a central aperture that receives an output shaft. The rotor assembly also includes a rotor end cap on a first side of the rotor core having a bearing holder and defining a channel, wherein the channel is open on a side of the rotor end cap facing the rotor core. The motor further includes a bearing provided in the bearing holder that couples the rotor end cap to the output shaft and a position sensor board assembly provided in the channel of the rotor end cap and configured to provide position information of the rotor core to a motor controller.

Abstract: A power tool with a combined printed circuit board (PCB) that reduces internal wiring of the power tool and provides a large amount of air flow to internal components. In some instances, the combined PCB has a surfboard shape and includes a motor control unit and power switching elements (Field Effect Transistors or FETs). The combined surfboard PCB is located above the trigger, but below the motor and drive mechanism. In other instances, the combined PCB has a doughnut shape and is located coaxially with a motor shaft. The combined PCB may be positioned between a doughnut-shaped control PCB and the motor.

Abstract: A power tool with a combined printed circuit board (PCB) having a doughnut shape and located coaxially with a motor shaft. The combined PCB is secured to a heat sink on one end of the motor and a metal end piece is positioned on an opposite end of the motor. The metal end cap and heat sink are secured to one another via fasteners to provide a rigid coupling. A tabbed end piece is provided between the heat sink and the motor stator and is also secured into place via the fasteners. The tabbed end piece includes wire support tabs that provide strain relief to motor coil leads. The wire support tabs extend axially from circumferential locations of the tabbed end piece and include channels to guide the motor coil leads to solder contact points on the combined PCB.

Abstract: A power tool includes a housing, a battery connection portion supported by the housing, a drive mechanism configured to operate a working element, and a brushless DC motor positioned within the housing and connected to the drive mechanism. The motor includes a rotor, stator surrounding the motor, and an output shaft fixed to the rotor such that movement of the rotor is transmitted to the output shaft. The motor also includes a fan coupled to the output shaft to rotate with the output shaft and the rotor, and a brass bushing fixed to the output shaft to rotate with the rotor and the output shaft relative to the stator. The bushing includes a balancing feature.

Abstract: A power tool with a combined printed circuit board (PCB) having a doughnut shape and located coaxially with a motor shaft. The combined PCB is secured to a heat sink on one end of the motor and a metal end piece is positioned on an opposite end of the motor. The metal end cap and heat sink are secured to one another via fasteners to provide a rigid coupling. A tabbed end piece is provided between the heat sink and the motor stator and is also secured into place via the fasteners. The tabbed end piece includes wire support tabs that provide strain relief to motor coil leads. The wire support tabs extend axially from circumferential locations of the tabbed end piece and include channels to guide the motor coil leads to solder contact points on the combined PCB.

Abstract: A battery pack that is connectable to and supportable by a power tool (e.g., a hand-held power tool). The battery pack includes a top housing having a support member. The support member of the battery pack top housing is configured or operable to reinforce a support portion of the battery pack that is used to connect the battery pack to the power tool. By reinforcing the support portion of the battery pack, an interface between the battery pack and the power tool is able to withstand greater forces (e.g., from vibrations caused by the power tool).

Abstract: A brushless direct current motor for a power tool. The motor includes a stator assembly including a stator core having stator laminations with an annular portion and inwardly extending stator teeth. The motor also includes a rotor assembly including a rotor core having rotor laminations and defining a central aperture that receives an output shaft. The rotor assembly also includes a rotor end cap on a first side of the rotor core having a bearing holder and defining a channel, wherein the channel is open on a side of the rotor end cap facing the rotor core. The motor further includes a bearing provided in the bearing holder that couples the rotor end cap to the output shaft and a position sensor board assembly provided in the channel of the rotor end cap and configured to provide position information of the rotor core to a motor controller.

Abstract: A battery pack that is connectable to and supportable by a power tool (e.g., a hand-held power tool). The battery pack includes a top housing having a support member. The support member of the battery pack top housing is configured or operable to reinforce a support portion of the battery pack that is used to connect the battery pack to the power tool. By reinforcing the support portion of the battery pack, an interface between the battery pack and the power tool is able to withstand greater forces (e.g., from vibrations caused by the power tool).

Abstract: A brushless direct current motor for a power tool. The motor includes a stator assembly including a stator core having stator laminations with an annular portion and inwardly extending stator teeth. The motor also includes a rotor assembly including a rotor core having rotor laminations and defining a central aperture that receives an output shaft. The rotor assembly also includes a rotor end cap on a first side of the rotor core having a bearing holder and defining a channel, wherein the channel is open on a side of the rotor end cap facing the rotor core. The motor further includes a bearing provided in the bearing holder that couples the rotor end cap to the output shaft and a position sensor board assembly provided in the channel of the rotor end cap and configured to provide position information of the rotor core to a motor controller.

Abstract: An electrical combination, a motorized device system, a motor assembly, a battery pack, and operating methods. The combination may include an electrical device including a device housing, a load supported by the device housing, the load being operable to output at least about 1800 watts (W), and a device terminal electrically connected to the load; a battery pack including a pack housing, battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 20 volts, and a pack terminal electrically connectable to the device terminal to transfer current between the battery pack and the electrical device; and a controller operable to control the transfer of current.

Abstract: An electrical combination, a tool system, an electric motor, a battery pack, and operating and manufacturing methods. The tool may include a tool housing, a motor supported by the tool housing, the motor having a nominal outer diameter of up to about 80 millimeters (mm), the motor being operable to output at least about 2760 watts (W), and a tool terminal electrically connected to the motor; a battery pack including a pack housing defining a volume of the battery pack, the volume being up to about 5.2×106 cubic millimeters (mm3), battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 80 volts (V), and a pack terminal electrically connectable to the tool terminal to transfer current between the battery pack and the tool; and a controller operable to control the transfer of current.

Abstract: A battery pack that is connectable to and supportable by a power tool (e.g., a hand-held power tool). The battery pack includes a top housing having a support member. The support member of the battery pack top housing is configured or operable to reinforce a support portion of the battery pack that is used to connect the battery pack to the power tool. By reinforcing the support portion of the battery pack, an interface between the battery pack and the power tool is able to withstand greater forces (e.g., from vibrations caused by the power tool).

Abstract: A brushless electric motor includes a stator and a rotor. The stator includes a core defining a plurality of stator teeth, a first end cap proximate a first end of the core, a second end cap proximate a second end of the core, and a plurality of coils disposed on the respective stator teeth. The stator also includes a plurality of coil contact plates overmolded within one of the first end cap or the second end cap that short-circuit diagonally opposite coils on the stator.

Abstract: A power tool with a combined printed circuit board (PCB) that reduces internal wiring of the power tool and provides a large amount of air flow to internal components. In some instances, the combined PCB has a surfboard shape and includes a motor control unit and power switching elements (Field Effect Transistors or FETs). The combined surfboard PCB is located above the trigger, but below the motor and drive mechanism. In other instances, the combined PCB has a doughnut shape and is located coaxially with a motor shaft. The combined PCB may be positioned between a doughnut-shaped control PCB and the motor.

Abstract: A power tool with a combined printed circuit board (PCB) that reduces internal wiring of the power tool and provides a large amount of air flow to internal components. In some instances, the combined PCB has a surfboard shape and includes a motor control unit and power switching elements (Field Effect Transistors or FETs). The combined surfboard PCB is located above the trigger, but below the motor and drive mechanism. In other instances, the combined PCB has a doughnut shape and is located coaxially with a motor shaft. The combined PCB may be positioned between a doughnut-shaped control PCB and the motor.

Abstract: A power tool with a combined printed circuit board (PCB) that reduces internal wiring of the power tool and provides a large amount of air flow to internal components. In some instances, the combined PCB has a surfboard shape and includes a motor control unit and power switching elements (Field Effect Transistors or FETs). The combined surfboard PCB is located above the trigger, but below the motor and drive mechanism. In other instances, the combined PCB has a doughnut shape and is located coaxially with a motor shaft. The combined PCB may be positioned between a doughnut-shaped control PCB and the motor.

Abstract: A power tool with a combined printed circuit board (PCB) that reduces internal wiring of the power tool and provides a large amount of air flow to internal components. In some instances, the combined PCB has a surfboard shape and includes a motor control unit and power switching elements (Field Effect Transistors or FETs). The combined surfboard PCB is located above the trigger, but below the motor and drive mechanism. In other instances, the combined PCB has a doughnut shape and is located coaxially with a motor shaft. The combined PCB may be positioned between a doughnut-shaped control PCB and the motor.

Abstract: An electric motor includes first and second balancing members coupled to an output shaft for rotation with a rotor. The first and second balancing members substantially balance a mass of the rotor about a longitudinal axis of the output shaft to reduce vibrations of the electric motor during use. The first balancing member includes a brass bushing supported on the output shaft adjacent a first face of the body of the rotor. The brass bushing includes a hole drilled into an outer circumference of the brass bushing providing a first balancing feature of the electric motor. The second balancing member includes a fan supported on the output shaft adjacent a second face of the body of the rotor. The fan includes a plurality of fins extending from a first face of the fan and a second balancing feature of material removed from a second face of the fan.

Abstract: A power tool with a combined printed circuit board (PCB) having a doughnut shape and located coaxially with a motor shaft. The combined PCB is secured to a heat sink on one end of the motor and a metal end piece is positioned on an opposite end of the motor. The metal end cap and heat sink are secured to one another via fasteners to provide a rigid coupling. A tabbed end piece is provided between the heat sink and the motor stator and is also secured into place via the fasteners. The tabbed end piece includes wire support tabs that provide strain relief to motor coil leads. The wire support tabs extend axially from circumferential locations of the tabbed end piece and include channels to guide the motor coil leads to solder contact points on the combined PCB.