Abstract: A power tool system includes a power tool having a tool housing. The tool housing includes a battery pack receptacle having a set of tool terminals. A brushless motor includes an output shaft operably coupled to drive a tool element, a stator having an outer diameter of approximately 60 mm to approximately 80 mm, and a stack length of approximately 75% to approximately 125% of the outer diameter of the stator. A controller is operably connected to the set of tool terminals and to the brushless motor to control power delivery to the brushless motor. A battery pack includes a battery pack housing connectable to the battery pack receptacle on the tool housing and a set of battery cells. The set of battery cells includes at least 15 battery cells each having a nominal voltage of approximately 3.6V and an impedance of approximately ?13 m?. A set of battery pack terminals is connectable to the set of tool terminals.

Abstract: An electric lawn apparatus is provided including a frame having an upper body and a lower support body, two drive motors, a mow deck supporting multiple deck motors, and a battery. The apparatus further includes a motor control panel having one or more control modules that control the drive motors and the deck motors and a regenerative energy control module; and a regenerative energy absorbing module that is physically decoupled from the motor control panel and is activated by the regenerative energy control module when the voltage from the battery exceeds a voltage threshold.

Abstract: An electric lawn apparatus is provided including a frame, an operator seat mounted on an upper body, two drive motors secured two side plates for driving two rear tires, a mow deck secured below a lower support body of the frame that supports at least one deck motor driving a mow blade, a footrest platform secured to the lower support body of the frame, and a motor control panel located between the mow deck and the footrest platform. The motor control panel includes a plate that supports multiple control modules and controls a supply of electric power to the drive motors and the deck motor.

Abstract: A control module for a high power motor includes a mounting frame made up of thermally-conductive material including a bottom wall and four side walls; a circuit board disposed within the side walls of the mounting frame; power switches configured as an inverter circuit oriented in two arrays mounted on opposite surfaces of the circuit board; an auxiliary circuit board extending substantially perpendicularly from the circuit board; capacitors mounted on the auxiliary circuit board with a long axis thereof extending parallel to the circuit board and away from the power switches; and connectors mounted between an edge of the circuit board and distal ends of the capacitors.

Abstract: A drill system including a drill and a secondary computing device. The drill includes a housing, a controller, a wireless transceiver, a motor, and a chuck. The motor, the controller and the wireless transceiver are housed in the housing. The chuck is selectively driven by the motor. The secondary computing device includes a wireless transceiver which allows wireless communication between the drill and the secondary computing device. The secondary computing device further includes a user interface configured to allow an operator to change operating parameters of the drill. The operating parameters are configured to be automatically reset.

Abstract: A drill system including a drill and a secondary computing device. The drill includes a housing, a controller, a wireless transceiver, a motor, and a chuck. The motor, the controller and the wireless transceiver are housed in the housing. The chuck is selectively driven by the motor. The secondary computing device includes a wireless transceiver which allows wireless communication between the drill and the secondary computing device. The secondary computing device further includes a user interface configured to allow an operator to change operating parameters of the drill. The operating parameters are configured to be automatically reset.

Abstract: A system is provided with a set of removable battery packs and a set of power tools each including a motor, a controller, and a battery receiving portion. For each power tool, the controller is configured to identify a type of battery pack coupled to the battery receiving portion and set a conduction band associated with phases of the motor or an advance angle by which phases of the motor are shifted based on the identified type of the battery pack.

Abstract: A system is provided with a set of removable battery packs and a set of power tools each including a motor, a controller, and a battery receiving portion. For each power tool, the controller is configured to identify a type of battery pack coupled to the battery receiving portion and limit a maximum amount of electric current drawn from the battery pack by the motor based on the identified type of the battery pack. The greater a ratio of an impedance of the motor to an impedance of the battery pack, the less the controller limits the maximum amount of electric current drawn from the battery pack such that for a given battery pack of the set of removable battery packs, the lower the impedance of the motor, the more current the motor draws from the given battery pack.

Abstract: A power tool is provided an electric motor, a nosecone assembly having a metal body, a terminal block that couples to a removable battery pack, and an electronic power module that regulates supply of electric current from the battery pack to the motor. A discharge wire is coupled to the terminal block on a first end and to the metal body of the nosecone assembly on a second end to provide a discharge path from the nosecone directly to the battery pack bypassing the electronic power module.

Abstract: An electronic module for controlling a motor includes a module housing including a bottom surface, walls, and an open face, a printed circuit board (PCB) arranged along a plane within the module housing; a plurality of power terminals; and a plurality of power switches mounted on the PCB to switchably connect a supply of electric power from a power source to the plurality of power terminals. The plurality of power switches includes first portions projecting outside the module housing through one of the walls along a direction substantially parallel to the plane for coupling to a plurality of wires couplable to the motor, and second portions extending substantially perpendicularly to the plane and electrically contacting the PCB.

Abstract: A power tool system includes a power tool having a tool housing. The tool housing includes a battery pack receptacle having a set of tool terminals. A brushless motor includes an output shaft operably coupled to drive a tool element, a stator having an outer diameter of approximately 60 mm to approximately 80 mm, and a stack length of approximately 75% to approximately 125% of the outer diameter of the stator. A controller is operably connected to the set of tool terminals and to the brushless motor to control power delivery to the brushless motor. A battery pack includes a battery pack housing connectable to the battery pack receptacle on the tool housing and a set of battery cells. The set of battery cells includes at least 15 battery cells each having a nominal voltage of approximately 3.6V and an impedance of approximately ?13 m?. A set of battery pack terminals is connectable to the set of tool terminals.

Abstract: A system is provided with a set of removable battery packs and a set of power tools each including a motor, a controller, and a battery receiving portion. For each power tool, the controller is configured to identify a type of battery pack coupled to the battery receiving portion and limit a maximum amount of electric current drawn from the battery pack by the motor based on the identified type of the battery pack. The greater a ratio of an impedance of the motor to an impedance of the battery pack, the less the controller limits the maximum amount of electric current drawn from the battery pack such that for a given battery pack of the set of removable battery packs, the lower the impedance of the motor, the more current the motor draws from the given battery pack.

Abstract: A drill system including a drill and a secondary computing device. The drill includes a housing, a controller, a wireless transceiver, a motor, and a chuck. The motor, the controller and the wireless transceiver are housed in the housing. The chuck is selectively driven by the motor. The secondary computing device includes a wireless transceiver which allows wireless communication between the drill and the secondary computing device. The secondary computing device further includes a user interface configured to allow an operator to change operating parameters of the drill. The operating parameters are configured to be automatically reset.

Abstract: A drill system is provided. The drill system includes a drill driver and a secondary computing device. One or more descriptors for a fastening application is entered into the secondary computing device and is being received by a controller residing in the power tool. The descriptors are indicative of a fastening application to be performed by the power tool and are received via a wireless data link from the secondary computing device located remotely from the power tool. A parameter of the drill driver is changed in response to the input of the descriptor in the secondary computing device.

Abstract: A hand-held power tool is configured to receive an input indicative of a clutch setting for an electronic clutch from the tool operator, where the clutch setting is selectable from a drill mode, an automated drive mode and one or more user-defined drive modes. Each of the user-defined drive modes specifies a different value of torque at which to interrupt transmission of torque to the output spindle. In an automated drive mode, the controller interrupt torque to the output spindle in an automated manner when a fastener being driven reaches a desired stopping position. In a selected one of the user-defined drive modes, the controller sets a value of a maximum current threshold in accordance with the selected one of the user-defined drive modes and interrupts torque to the output spindle when current measures exceeding the maximum current threshold.

Abstract: A method is provided for setting a fastener in a workpiece. The method includes: monitoring a parameter of the power tool during operation of the power tool, where the parameter is indicative of the placement of a fastener being driven by the power tool in relation to the workpiece; detecting, a change in the parameter, where the detected change in the parameter indicates that the power tool became disengaged with the fastener; modifying operation of the power tool in response to the detected change in the parameter; subsequently detecting a second change in the parameter; and interrupting transmission of torque to the output spindle in response the detected second change in the parameter, thereby properly setting the placement of the fastener in relation to the workpiece.

Abstract: A method is provided for controlling operation of a power tool, such as a drill driver. The method begins with one or more descriptors for a fastening application being received by a controller residing in the power tool, where the descriptors are indicative of a fastening application to be performed by the power tool and are received via a wireless data link from a computing device located remotely from the power tool. The descriptors are translated into a threshold value used by a fastener setting algorithm and the threshold value is stored in a data store of the power tool. During a subsequent fastening operation performed using the tool, an operating parameter of the power tool is monitored and evaluated in accordance with the fastener setting algorithm, including the updated threshold value. Example operating parameters include current delivered to the motor and speed of the motor.

Abstract: A method is provided for controlling operation of a power tool, such as a drill driver. The method begins with one or more descriptors for a fastening application being received by a controller residing in the power tool, where the descriptors are indicative of a fastening application to be performed by the power tool and are received via a wireless data link from a computing device located remotely from the power tool. The descriptors are translated into a threshold value used by a fastener setting algorithm and the threshold value is stored in a data store of the power tool. During a subsequent fastening operation performed using the tool, an operating parameter of the power tool is monitored and evaluated in accordance with the fastener setting algorithm, including the updated threshold value. Example operating parameters include current delivered to the motor and speed of the motor.

Abstract: A method is provided for setting a fastener in a workpiece. The method includes: monitoring a parameter of the power tool during operation of the power tool, where the parameter is indicative of the placement of a fastener being driven by the power tool in relation to the workpiece; detecting, a change in the parameter, where the detected change in the parameter indicates that the power tool became disengaged with the fastener; modifying operation of the power tool in response to the detected change in the parameter; subsequently detecting a second change in the parameter; and interrupting transmission of torque to the output spindle in response the detected second change in the parameter, thereby properly setting the placement of the fastener in relation to the workpiece.

Abstract: An improved technique is presented for detecting when a fastener driven by a drill driver has reaches a desired stopping position. The improved techniques generally includes: sampling periodically current delivered to the electric motor; storing a sequence of current measures most recently sampled; and determining a slope for the sequence of current measures by way of linear regression. Transmission of torque to the output spindle can be interrupted based in part on the slope of the current measures.