Patents by Inventor Carl B. Westerby
Carl B. Westerby has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20240097542Abstract: A method of manufacturing a brushless electric motor including providing a stator that includes a core defining a plurality of stator teeth, positioning a rotor within the stator, coupling a stator end cap to an end of the core, winding a plurality of coils on the plurality of stator teeth, and overmolding a plurality of coil contact plates within the stator end cap. The coil contact plates short-circuit diagonally opposite coils on the stator.Type: ApplicationFiled: November 28, 2023Publication date: March 21, 2024Inventors: Andrew T. Beyerl, Keith Boulanger, Matthew R. Bailey, Carl B. Westerby
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Patent number: 11881750Abstract: A motor assembly for use with a power tool includes a motor housing, a brushless electric motor disposed at least partially in the motor housing, and a PCB assembly coupled to the motor housing. The PCB assembly includes a heat sink, a power PCB coupled to a first side of the heat sink, and a position sensor PCB coupled to a second side of the heat sink opposite the first side and in facing relationship with the motor.Type: GrantFiled: August 24, 2021Date of Patent: January 23, 2024Assignee: MILWAUKEE ELECTRIC TOOL CORPORATIONInventors: Andrew T. Beyerl, Keith Boulanger, Matthew R. Bailey, Carl B. Westerby
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Publication number: 20230421078Abstract: A power tool includes a three-phase DC motor, a power switching network, a power source, and an electronic processor. A first phase of the motor is connected between a first low side electronic switch and a power source electronic switch, and connected to the power source via a first high side electronic switch in parallel with a diode. The electronic processor is configured to receive an indication to stop the motor during operation of the motor and activate the first low side electronic switch and a second low side electronic switch for a first predetermined time responsive to receiving the indication such that a back-electromagnetic force generated by the motor is stored in the first phase. The electronic processor is configured to deactivate the second low side electronic switch after the first predetermined time such that a first regenerative current is provided to the power source via the diode.Type: ApplicationFiled: July 3, 2023Publication date: December 28, 2023Inventors: Carl B. Westerby, Timothy R. Obermann, Alex Huber
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Patent number: 11695352Abstract: A power tool includes a three-phase DC motor, a power switching network, a power source, and an electronic processor. A first phase of the motor is connected between a first low side electronic switch and a power source electronic switch, and connected to the power source via a first high side electronic switch in parallel with a diode. The electronic processor is configured to receive an indication to stop the motor during operation of the motor and activate the first low side electronic switch and a second low side electronic switch for a first predetermined time responsive to receiving the indication such that a back-electromagnetic force generated by the motor is stored in the first phase. The electronic processor is configured to deactivate the second low side electronic switch after the first predetermined time such that a first regenerative current is provided to the power source via the diode.Type: GrantFiled: July 12, 2021Date of Patent: July 4, 2023Assignee: Milwaukee Electric Tool CorporationInventors: Carl B. Westerby, Timothy R. Obermann, Alex Huber
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Publication number: 20230060846Abstract: Systems and methods for reporting usage of a power tool. The power tool comprises a pair of jaws configured to crimp a workpiece, a piston cylinder configured to actuate at least one of the pair of jaws, and a sensor configured to sense operating characteristics associated with a crimping application. An electronic processor connected to the sensor. The electronic processor is configured to receive, from the sensor, one or more characteristic signals, determine, based on the one or more characteristic signals, a first operating characteristic of the power tool, and determine, based on the one or more characteristic signals, a second operating characteristic of the power tool. The electronic processor is configured to determine the crimping application of the power tool based on the first operating characteristic and the second operating characteristic and generate a report indicating the crimping application performed by the power tool.Type: ApplicationFiled: August 11, 2022Publication date: March 2, 2023Inventors: Carl B. Westerby, Jonathan E. Abbott, Corey J. Dickert
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Publication number: 20230021235Abstract: 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.Type: ApplicationFiled: August 26, 2022Publication date: January 19, 2023Inventors: Samuel Sheeks, Keith Boulanger, Andrew T. Beyerl, Timothy R. Obermann, Carl B. Westerby, Matthew J. Mergener, Cameron R. Schulz, Kyle C. Fassbender, Matthew R. Polakowski
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Publication number: 20220407274Abstract: Systems and methods for evaluating a crimping application. A power tool includes a pair of jaws configured to crimp a workpiece, a piston cylinder configured to actuate at least one of the pair of jaws, and a pressure sensor configured to provide pressure signals associated with a crimping application. The power tool also includes an electronic processor connected to the pressure sensor. The electronic processor is configured to monitor, while performing the crimping application, a pressure applied by the piston cylinder, construct a pressure curve indicative of a change in the pressure applied during the crimping application, process the pressure curve into a vector indicative of one or more features, evaluate the crimping application based on the vector, and provide an output indicative of the evaluation.Type: ApplicationFiled: June 21, 2022Publication date: December 22, 2022Inventors: Timothy J. Radtke, Carl B. Westerby, Jonathan E. Abbott, Corey J. Dickert
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Patent number: 11476527Abstract: 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.Type: GrantFiled: July 25, 2018Date of Patent: October 18, 2022Assignee: MILWAUKEE ELECTRIC TOOL CORPORATIONInventors: Samuel Sheeks, Keith Boulanger, Andrew T. Beyerl, Timothy R. Obermann, Carl B. Westerby, Matthew J. Mergener, Cameron R. Schulz, Kyle C. Fassbender, Matthew R. Polakowski
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Patent number: 11462794Abstract: 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.Type: GrantFiled: January 24, 2020Date of Patent: October 4, 2022Assignee: MILWAUKEE ELECTRIC TOOL CORPORATIONInventors: Samuel Sheeks, Keith Boulanger, Andrew T. Beyerl, Timothy R. Obermann, Carl B. Westerby, Matthew J. Mergener, Cameron R. Schulz, Kyle C. Fassbender, Matthew R. Polakowski
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Publication number: 20220137147Abstract: A device, such as a power tool, configured to receive a battery pack that is operable to determine a type of battery pack that is attached to the device. When the battery pack is connected to the device, the device is configured to determine an impedance of the battery pack. Based on the determined impedance of the battery pack, the device is capable of detecting the particular type of battery pack that has been attached. In some embodiments, the device is configured to be controlled based on the type of battery pack that has been detected by the device.Type: ApplicationFiled: October 27, 2021Publication date: May 5, 2022Inventors: Carl B. Westerby, Griffin M. Steffy, Alex R. Kuhls, Jonathan E. Abbott, Alexander T. Huber, Gareth Mueckl, Douglas R. Fieldbinder
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Publication number: 20210384809Abstract: A motor assembly for use with a power tool includes a motor housing, a brushless electric motor disposed at least partially in the motor housing, and a PCB assembly coupled to the motor housing. The PCB assembly includes a heat sink, a power PCB coupled to a first side of the heat sink, and a position sensor PCB coupled to a second side of the heat sink opposite the first side and in facing relationship with the motor.Type: ApplicationFiled: August 24, 2021Publication date: December 9, 2021Inventors: Andrew T. Beyerl, Keith Boulanger, Matthew R. Bailey, Carl B. Westerby
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Publication number: 20210344289Abstract: A power tool includes a three-phase DC motor, a power switching network, a power source, and an electronic processor. A first phase of the motor is connected between a first low side electronic switch and a power source electronic switch, and connected to the power source via a first high side electronic switch in parallel with a diode. The electronic processor is configured to receive an indication to stop the motor during operation of the motor and activate the first low side electronic switch and a second low side electronic switch for a first predetermined time responsive to receiving the indication such that a back-electromagnetic force generated by the motor is stored in the first phase. The electronic processor is configured to deactivate the second low side electronic switch after the first predetermined time such that a first regenerative current is provided to the power source via the diode.Type: ApplicationFiled: July 12, 2021Publication date: November 4, 2021Inventors: Carl B. Westerby, Timothy R. Obermann, Alex Huber
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Publication number: 20210310231Abstract: A sewer cleaning machine includes a frame and a drum rotatably supported by the frame. The drum defines an opening. The sewer cleaning machine also includes a cable supported within the drum and is operable to enter and exit the drum through the opening. The cable includes a plurality of tags spaced along a length of the cable. The sewer cleaning machine further includes a reader module positioned adjacent the opening. The reader module is operable to identify each of the plurality of tags as the plurality of tags passes the reader module and communicate to a user a distance the cable is payed out of the drum based on the plurality of tags.Type: ApplicationFiled: April 7, 2021Publication date: October 7, 2021Inventors: Alex R. Kuhls, Luke J. Skinner, Carl B. Westerby
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Patent number: 11114927Abstract: 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.Type: GrantFiled: November 11, 2020Date of Patent: September 7, 2021Assignee: MILWAUKEE ELECTRIC TOOL CORPORATIONInventors: Andrew T. Beyerl, Keith Boulanger, Matthew R. Bailey, Carl B. Westerby
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Patent number: 11075594Abstract: A power tool includes a three-phase DC motor, a power switching network, a power source, and an electronic processor. A first phase of the motor is connected between a first low side electronic switch and a power source electronic switch, and connected to the power source via a first high side electronic switch in parallel with a diode. The electronic processor is configured to receive an indication to stop the motor during operation of the motor and activate the first low side electronic switch and a second low side electronic switch for a first predetermined time responsive to receiving the indication such that a back-electromagnetic force generated by the motor is stored in the first phase. The electronic processor is configured to deactivate the second low side electronic switch after the first predetermined time such that a first regenerative current is provided to the power source via the diode.Type: GrantFiled: June 9, 2020Date of Patent: July 27, 2021Assignee: Milwaukee Electric Tool CorporationInventors: Carl B. Westerby, Timothy R. Obermann, Alex Huber
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Publication number: 20210067018Abstract: 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.Type: ApplicationFiled: November 11, 2020Publication date: March 4, 2021Inventors: Andrew T. Beyerl, Keith Boulanger, Matthew R. Bailey, Carl B. Westerby
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Patent number: 10848042Abstract: 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.Type: GrantFiled: February 12, 2018Date of Patent: November 24, 2020Assignee: Milwaukee Electric Tool CorporationInventors: Andrew T. Beyerl, Keith Boulanger, Matthew R. Bailey, Carl B. Westerby
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Publication number: 20200304043Abstract: A power tool includes a three-phase DC motor, a power switching network, a power source, and an electronic processor. A first phase of the motor is connected between a first low side electronic switch and a power source electronic switch, and connected to the power source via a first high side electronic switch in parallel with a diode. The electronic processor is configured to receive an indication to stop the motor during operation of the motor and activate the first low side electronic switch and a second low side electronic switch for a first predetermined time responsive to receiving the indication such that a back-electromagnetic force generated by the motor is stored in the first phase. The electronic processor is configured to deactivate the second low side electronic switch after the first predetermined time such that a first regenerative current is provided to the power source via the diode.Type: ApplicationFiled: June 9, 2020Publication date: September 24, 2020Inventors: Carl B. Westerby, Timothy R. Obermann, Alex Huber
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Patent number: 10720860Abstract: A power tool including a three-phase DC motor, a power switching network, a power source, and an electronic processor. A first phase of the motor is connected between a first high side electronic switch and a first low side electronic switch, and between a second high side electronic switch and a second low side electronic switch. The first high side electronic switch is parallel to the second high side electronic switch, and the first low side electronic switch is parallel to the second low side electronic switch. The electronic processor receives an indication to stop the motor, and deactivates the first high side electronic switch and the first low side electronic switch, and activates the second high side electronic switch and the second low side electronic switch such that the back-electromagnetic force generated by the motor is connected in a second polarity relative to the power source.Type: GrantFiled: January 3, 2019Date of Patent: July 21, 2020Assignee: MILWAUKEE ELECTRIC TOOL CORPORATIONInventors: Carl B. Westerby, Timothy R. Obermann, Alex Huber
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Publication number: 20200162007Abstract: 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.Type: ApplicationFiled: January 24, 2020Publication date: May 21, 2020Inventors: Samuel Sheeks, Keith Boulanger, Andrew T. Beyerl, Timothy R. Obermann, Carl B. Westerby, Matthew J. Mergener, Cameron R. Schulz, Kyle C. Fassbender, Matthew R. Polakowski