Abstract: An armature for an electric motor has a lamination stack on a shaft with a commutator mounted on one end of the shaft. Magnet wires wound in slots in the lamination stack, the commutator and armature shaft are at least partially encapsulated in thermoset. The commutator has a commutator ring divided into a plurality of segments with slots between the segments that are filled with a second plastic when the commutator is made by molding a core of the second plastic, such as phenolic, in the commutator ring before the commutator ring is mounted on the armature shaft. Prior to molding the thermoset, the commutator ring is sealed. The seal prevents the thermoset from flowing into the slots between the commutator ring segments or over the commutator ring.

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 flexible sensor is disposed in a power tool. The flexible sensor has an electrical resistance that varies based on a radius of curvature of the flexible sensor. A trigger partially disposed in the power tool, operates to apply a bending force at an engagement point on the flexible sensor to bend the flexible sensor and alter the radius of curvature. A controller outputs an electrical signal to the power tool based on the electrical resistance to control a function of the power tool.

Abstract: A flux switching electric motor (102) is disclosed. The motor comprises a rotor (104), a stator (106), field windings (124, 126) and armature windings (128, 130). #A microcontroller (134) controls supply of electrical current to the field and armature windings. A rotor position sensor includes a divider for (i) receiving an input signal dependent upon the rate of change of current in at least one field winding, (ii) receiving an input signal dependent upon the voltage across at least one armature winding, current through which causes at least part of the current in the field winding, and (iii) providing the microcontroller (134) with a control signal which is dependent upon the ratio of the input signals received by the divider.

Abstract: A power tool has an electric motor with field windings. Each field winding includes two coils. When the motor is first energized, the two coils of each field winding are connected in series, reducing in-rush current. Upon expiration of a soft start period, the two coils of each field winding are connected in parallel. In another aspect, the field windings that are connected in series with a separate start winding when the motor is first energized. Upon expiration of the soft start period, the start winding is bypassed. In another aspect, the field windings are connected in series with a start impedance when the motor is first energized and a time delay relay having a set of delay contacts coupled across the start impedance energized. Upon expiration of the soft start period, the time delay contacts close, bypassing the start impedance. In an aspect, the motor is a universal motor.