Abstract: An improved method is provided for controlling a power tool having a rotary shaft. The method includes: disposing an inertial mass in a housing of the power tool, such that the inertial mass is freely rotatable about an axis of rotation which is axially aligned with the rotary shaft; monitoring rotational motion of the power tool in relation to the inertial mass during operation of the power tool; and activating a protective operation based on the rotational motion of the power tool in relation to the inertial mass.

Abstract: A battery pack with a housing and a plurality of cells disposed in the housing and electrically coupled to provide a storage capacity between about 2.17 and 2.67 ampere hours with an equivalent lithium content between about 6.5 and 8.0. The plurality of cells includes a first battery disposed in the housing and including a first plurality of cells connected in series and a second battery disposed in the housing and including a second plurality of cells connected in series, wherein the first battery and the second battery are operable in a storage mode and a use mode.

Abstract: A sensing mechanism (12) for detecting user contact with an active portion (26) of the power tool (10) is provided. In addition, a safety mechanism (14) for preventing prolonged user contact with the active portion (26) of a power tool (10) is provided. The safety mechanism (14) is configured to actuate upon receipt of a signal from the sensing mechanism (12). According to a first aspect, the safety mechanism (14) is arranged to rapidly displace the active portion (26) away from a user extremity. Alternatively, according to a second aspect, the safety mechanism (14) is arranged to rapidly urge an extremity of the user away from the active portion (26) of the power tool (10).

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 system to dissipate heat from the battery pack.

Abstract: A cordless welding machine includes first and second batteries being connected in parallel, a ground clamp connected to the first and second batteries, and a first welding electrode connected to the first and second batteries. The batteries providing a current output of at least about 40 amps.

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 system to dissipate heat from the battery pack.

Abstract: A worm-gear assembly including a worm screw having at least one groove and a wheel having a plurality of rotatable pins along its periphery for engaging the worm screw. The pins are able to rotate in a direction other than a direction of wheel rotation. At least one raceway is provided for contacting pins that are not engaged with the worm screw during operation of the assembly.

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 system to dissipate heat from the battery pack.

Abstract: A flashlight in accordance with an aspect of the invention includes an ID module for generating an ID signal indicative of a power mode of the flashlight. In an aspect, the flashlight mates with a removable battery pack that regulates at least one of an output voltage and output current in accordance with the ID signal. In an aspect, the flashlight includes a printed circuit board (PCB) on which the ID module is mounted. In an aspect, the flashlight includes a soft-start module and a bulb, wherein the soft start module increases power to the bulb at a controlled rate when the flashlight is turned on. In an aspect, the flashlight includes a lamp housing having a lens retained by a bezel. The lens includes an axially extending peripheral edge. In an aspect, the flashlight includes a main housing having a lamp housing. A mounting mechanism and mating features are adapted to selectively couple and decouple the main housing and the lamp housing.

Abstract: A battery pack for a cordless power tool and a cordless power tool and battery pack combination includes the battery pack having a retention member that pivotally engages a retention member of the power tool and a latch system in which one of the battery pack and power tool has a ball and the other of the power tool and battery pack has a latch that engages the ball. Spring biased actuators may be used to open the latch to enable insertion or release of the ball from the latch.

Abstract: A power tool accessory identification system includes a power tool which has a motor, an output spindle actuatable by the motor, and a tool holder connected to the spindle and configured to hold an accessory therein. The power tool includes an accessory reader to decoding an identification device on the accessory. In a method of controlling the power tool with an accessory operatively coupled thereto, the accessory is inserted in the tool and a communication interface between the accessory and tool is read. An accessory identification is decoded via an accessory reader of the tool. A tool setting for the power tool is accessed based on the decoded accessory identification.

Abstract: A method and apparatus for braking a motor has a braking circuit that intermittently shorts the windings of the motor to brake the motor. The braking circuit is powered by back EMF generated by the motor when power is disconnected from the motor.

Abstract: A cordless system has cordless system components that include a cordless device, such as a cordless power tool, a battery pack and a charger. The battery pack is mated with either the cordless device to provide power to operate the cordless device or to the charger to charge the battery cells in the battery pack. In an aspect, the cordless system has an identification and communication system by which the battery pack identifies and communicates information about the battery pack to the cordless device or to the charger to which the battery pack is mated. In an, the battery pack of the cordless system is capable of multiple modes, such as controlling the cordless device and controlling the charger. In an aspect, the battery pack validates the cordless device or charger to which it is mated.

Abstract: A cordless system has cordless system components that include a cordless device, such as a cordless power tool, a battery pack and a charger. The battery pack is mated with either the cordless device to provide power to operate the cordless device or to the charger to charge the battery cells in the battery pack. In an aspect, the cordless system has an identification and communication system by which the battery pack identifies and communicates information about the battery pack to the cordless device or to the charger to which the battery pack is mated. In an, the battery pack of the cordless system is capable of multiple modes, such as controlling the cordless device and controlling the charger.

Abstract: A cordless system has cordless system components that include a cordless device, such as a cordless power tool, a battery pack and a charger. The battery pack is mated with either the cordless device to provide power to operate the cordless device or to the charger to charge the battery cells in the battery pack. In an aspect, the cordless system has an identification and communication system by which the battery pack identifies and communicates information about the battery pack to the cordless device or to the charger to which the battery pack is mated. In an, the battery pack of the cordless system is capable of multiple modes, such as controlling the cordless device and controlling the charger.

Abstract: A cordless system has cordless system components that include a cordless device, such as a cordless power tool, a battery pack and a charger. The battery pack is mated with either the cordless device to provide power to operate the cordless device or to the charger to charge the battery cells in the battery pack. In an aspect, the cordless system has an identification and communication system by which the battery pack identifies and communicates information about the battery pack to the cordless device or to the charger to which the battery pack is mated. In an, the battery pack of the cordless system is capable of multiple modes, such as controlling the cordless device and controlling the charger.

Abstract: A shipping method including shipping specialized pallets from a factory to a distribution center, shipping specialized pallets from a distribution center to a customer, returning specialized pallets from the customer to the factory, and reusing the specialized pallets, wherein the specialized pallets separate batteries of battery packs during the shipping.

Abstract: A battery pack with a housing and a plurality of cells disposed in the housing and electrically coupled to provide a storage capacity between about 2.17 and 2.67 ampere hours with an equivalent lithium content between about 6.5 and 8.0. The plurality of cells includes a first battery disposed in the housing and including a first plurality of cells connected in series and a second battery disposed in the housing and including a second plurality of cells connected in series, wherein the first battery and the second battery are operable in a storage mode and a use mode.

Abstract: A battery monitoring device of a battery pack configured for powering a cordless power tool may include an integrated circuit connected to a microprocessor of the pack that is external to the integrated circuit, and which is connected to each of N battery cells of the pack. The integrated circuit may be configured to take, singly or sequentially, a sampled reading comprising one of an individual cell voltage or a total pack voltage for all cells in the pack. The sampled reading is filtered in the integrated circuit prior to being read by the microprocessor.

Abstract: A battery pack packaging system and method includes a kit box with a body, a first receptacle in the body operable to receive at least one of a cordless device and a charging device, a second receptacle in the body, and a battery container removably received by the second receptacle, the battery container configured to meet regulatory rules for shipping a battery pack with a cordless device or separately from a cordless device.