Abstract: An electronic module is provided including a circuit board defining a longitudinal axis and having a first surface and a second surface. A module housing is provided having a bottom surface and side walls extending from the bottom surface to form an open face through which the circuit board is received. Power switches configured as an inverter circuit to drive an electric motor are mounted on the second surface of the circuit board facing the bottom surface of the module housing, and a series of heat sinks are discretely mounted on the first surface of the circuit board facing the open face opposite the power switches. Potting material is disposed in the distance between the circuit board and the bottom surface of the module housing to cover the power switches. Thermal vias are disposed through the circuit board between corresponding ones of the heat sinks and the power switches.

Abstract: A power tool is provided including a housing; an electric motor disposed within the housing; a power terminal that receives electric power from a battery pack; a power switch circuit disposed between the power terminal and the electric motor; and a controller configured to control a switching operation of the power switch circuit to regulate power being supplied from the power terminal to the electric motor. The controller is configured to receive a temperature signal indicative of a temperature of the battery pack, determine if the temperature of the battery pack is below a lower temperature threshold, and operate the switching operation of the power switch circuit in a normal mode of operation if the temperature of the battery pack is greater than or equal to the low temperature threshold and in a cold mode of operation if the temperature of the battery pack is below the low temperature threshold.

Abstract: A power tool is provided including a gear case having a spindle, a motor case connected to a rear end of the gear case, a handle portion attached to a rear end of the motor case, and a motor housed inside the motor case. The motor includes a stator, a rotor rotationally arranged inside the stator, and a fan in rotational connection with the rotor. At least one air intake is arranged at least one of the motor case or the handle portion near the rear end of the motor case. A power module including power switches and a heat sink is housed in at least one of the motor case or the handle portion near the rear end of the motor case such that rotation of the fan causes air flow to enter through the air intake and flow near the heat sink and through the motor.

Abstract: An electronic module is provided for a power tool having an electric motor. The module includes a printed circuit board (PCB) having a first surface and a second surface; first set of power switches mounted on the first surface of the PCB; second set of power switches mounted on the PCB and electrically coupled to the first power switches forming an inverter bridge circuit for driving the electric motor; a first heat sink surface-mounted on the first surface of the PCB and having a planar main body disposed over the first power switches; a module housing arranged to receive the PCB therein; and a second heat sink secured to the module housing in thermal communication with the first heat sink to transfer heat from the first power switches.

Abstract: An electronic module is provided for a power tool having an electric motor. The electronic module includes a printed circuit board (PCB) being substantially disc-shaped; power switches mounted on the PCB forming an inverter bridge circuit for driving the electric motor; a controller mounted on the PCB and configured to control a switching operation of the power switches; positional sensors mounted on the PCB substantially equidistantly from a center of the PCB within the control portion and in communication with the controller to provide positional signals related to a rotational position of the electric motor to the controller; and a module housing arranged to receive the PCB therein. The module housing includes a planar portion in parallel to the PCB and openings disposed in the planar portion angularly around a center of the module housing to receive the positional sensors therein.

Abstract: A power tool is provided including a housing, an electric motor disposed within the housing, a power switch circuit disposed between a power supply and the electric motor, a main controller, and a redundant controller. The main controller is arranged to control a switching operation of the power switch circuit to regulate a speed of the motor, and is configured to monitor at least one of a speed or a rotational direction of the electric motor and deactivate the power switch circuit upon detection of fault condition associated the speed or the rotational direction of the electric motor. The redundant controller is configured to monitor at least one of the speed or the rotational direction of the electric motor independently from the main controller and deactivate the power switch circuit upon detection of fault condition associated the speed or the rotational direction of the electric motor.

Abstract: A power tool is provided including a housing; an electric motor disposed within the housing; a power terminal arranged to received electric power form a battery pack; a power switch circuit disposed between the power terminal and the electric motor; and a controller configured to control a switching operation of the power switch circuit to regulate power being supplied from the power terminal to the electric motor. The controller is configured to receive a temperature signal indicative of a temperature of the battery pack, determine if the temperature of the battery pack is below a lower temperature threshold, and operate the switching operation of the power switch circuit in a normal mode of operation if the temperature of the battery pack is greater than or equal to the low temperature threshold and in a cold mode of operation if the temperature of the battery pack is below the low temperature threshold.

Abstract: A power tool is provided including a tool housing and a brushless DC (BLDC) motor disposed within the tool housing. The motor includes a stator assembly and a rotor assembly having a rotor lamination stack mounted on a rotor shaft to rotate therewith. The power tool also includes a power module for driving the motor, which includes: a printed circuit board, power switches operatively connected to the motor disposed on a first surface of the printed circuit board, positional sensors disposed on a second surface of the printed circuit board around a periphery of a center portion of the printed circuit board, and a heat sink having a substantially planar surface facing the second surface of the printed circuit board and disposed between the motor and the printed circuit board. The heat sink includes a through-hole therein sized to axially expose the positional sensors in the direction of the motor.

Abstract: A power tool is provided including a gear case having a spindle, a motor case connected to a rear end of the gear case, a handle portion attached to a rear end of the motor case, and a motor housed inside the motor case. The motor includes a stator, a rotor rotationally arranged inside the stator, and a fan in rotational connection with the rotor. At least one air intake is arranged at least one of the motor case or the handle portion near the rear end of the motor case. A power module including power switches and a heat sink is housed in at least one of the motor case or the handle portion near the rear end of the motor case such that rotation of the fan causes air flow to enter through the air intake and flow near the heat sink and through the motor.