Abstract: A brushless motor is provided including a rotor rotating around a center axis and a stator including a stator core and stator teeth radially extending from the stator core forming stator slots therebetween. Each stator tooth includes a radial main body and a tooth tip extending substantially laterally from an end of the radial main body opposite the stator core, and stator windings are wound around the stator teeth. Winding retention wedges are axially received within the slots, each winding retention wedge comprising: a first portion received within gaps formed between tooth tips of adjacent stator teeth, and a second portion received at least partially between adjacent stator windings to apply a force substantially in a range of a radially-inward direction to a lateral direction to the adjacent stator windings.

Abstract: A power tool system includes a power tool having a tool housing and a load disposed in the tool housing. The tool housing includes a battery pack receptacle having a set of tool terminals. The power tool system includes a set of battery packs. Each battery pack includes a battery pack housing operably connectable to the battery pack receptacle through a battery pack interface disposed on the battery pack housing, a set of battery cells disposed in the battery pack housing, and a set of battery pack terminals electrically connectable to the set of tool terminals and electrically connected to the set of battery cells. Each battery pack in the set of battery packs has a same nominal voltage and defines a common interface and at least a portion of the set of battery packs defines a total volume in a range of approximately 150 cm3 to 1300 cm3.

Abstract: A battery pack may include a battery cell, a cradle, a board and a housing. The cradle may be coupled with the battery cell and may include one or more guide members extending from and integrally formed with a surface of the cradle. The board may be mounted to the cradle and may include a plurality of terminal contacts electrically connected with the battery cell. The one or more guide members may be adapted to guide a device into engagement with the terminal contacts. The housing may at least partially enclose the cradle and the battery cell and may include one or more guide apertures and a plurality of terminal apertures. The one or more guide members may protrude through the one or more guide apertures. Each of the terminal apertures may be aligned with a corresponding one of the plurality of contacts.

Abstract: A first battery pack that is switchable between a first configuration having a first rated output voltage that corresponds to a first power tool rated operating voltage such that the first battery pack enables operation of the first power tool, and a second configuration having a second rated output voltage that corresponds to a second power tool rated operating voltage such that the first battery pack enables operation of the second power tool.

Abstract: A dust collection system includes a sensor body, a selection circuit, a detection circuit, and a motor control circuit. The sensor body detachably encircles a cord supplying power to a power tool. The cord includes a neutral conductor and a hot conductor. The sensor body houses sensors that, in response to current flow through the cord, generate sensor signals. The selection circuit generates a positive output signal in response to the sensor signals and generates a negative output signal in response to the sensor signals. The detection circuit generates a current detection signal in response to a comparison of the positive and negative output signals with a threshold. The motor control circuit selectively turns on a motor of the dust collection system in response to the current detection signal.

Abstract: The present invention is directed to an airflow generation and particle dispersion arrangement for a power tool (e.g., an angle grinder). The arrangement includes a motor, an airflow generation assembly, and a particle dispersion assembly. The airflow generation assembly includes a fan driven by the motor. When engaged, the driven fan generates an airstream that is drawn through the power tool. The particle dispersion assembly includes a passive fan that is not driven by the motor, but instead is driven by the airstream. In operation, the passive fan generates centrifugal and mechanical forces sufficient to remove particles from intake air passing through the particle dispersion assembly.

Abstract: A reciprocating saw includes a carrier operable to cooperate with a motor to translate rotational movement of the motor into reciprocal linear actuation of a saw blade. A carrier is slidably disposed within the housing and includes a first portion adapted to receive a saw blade and a second portion having a slot therethrough. A rotatable element is fixed for rotation about an output shaft of the motor. A follower operably interconnects the carrier and the rotatable element wherein rotation of the rotatable element provides reciprocal linear motion of the carrier whereby the follower follows a reciprocal linear path within the slot.

Abstract: The present invention is directed toward a repositioning device for a tool such as miter saw. The device includes a tool platform rotationally coupled to a base platform via a reorientation mechanism. The tool platform supports the miter saw. The base platform connects directly to a workbench, or connects to a support assembly that supports the cutting tool on a supporting surface.

Abstract: A tool chuck includes a body supporting a plurality of jaws, and a sleeve that is operatively connected to the jaw. The sleeve may be rotated to open and close the jaws. The sleeve includes a radial inward facing surface with recesses that are covered by a metal insert. The metal insert provides a metal-to-metal interface for a lock feature.

Abstract: The present invention is directed toward a system for forming miter joints including a miter saw and an angle gauge. The miter saw includes a platform with a kerf slot and a pair of arcuate slots. Each arcuate slot includes an associated rail located on the underside of the platform. A fence is coupled to each of the rails such that the fence may be pivoted with respect to the platform. The angle measurement tool is a one-handed tool including spring loaded paddles that measure the angle between intersecting surfaces. The angle measurement tool connects to the miter saw to permit the transfer of the measured angle to the fences.

Abstract: A power tool includes a brushless DC motor housed inside a tool housing, an input unit, and a control unit. The motor includes a rotor, a stator, and at least one sensor positioned to sense a state of the rotational position of the rotor inside the stator. A control unit controls commutation of the motor through a series of power switches coupled to the power supply. The control unit receives a current sensor state from the sensor and a user-selected speed from the input unit and determines whether the motor has reversed direction using the user-selected speed and the current sensor state. The control unit disables commutation of the motor if the motor has reversed direction until a proper current sensor state is received from the sensor.

Abstract: A vibration dampening handle for a powered apparatus includes an elongate gripping member including a first end, a second end opposite the first end, a longitudinal axis extending through the first end and the second end, and a wall defining an inner bore and having an inner surface. The inner bore extends along the longitudinal axis at least partially through the gripping member, and opens on at least the first end of the gripping member. A weighted mass is disposed at the second end of the gripping member. An elongate elastic beam member is one of attached to and integral with the gripping member. The beam member extends along a region of the longitudinal axis and a portion of the beam member is disposed within the inner bore and is spaced apart from the inner surface. The beam member further includes a first end that extends beyond the first end of the gripping member and includes a fastening member adapted to connect the handle to the powered apparatus.

Abstract: A structure for a backing plate of an abrasive disk is disclosed. The structure includes layers of abrasive resin interspersed with layers of reinforcing fiberglass. The layers are generally disk shaped and cover certain radial intervals of the entire backing plate between the inner diameter and the outer diameter. For example, a radial stress profile plotting the stress along a radial line from inner to outer diameter can be determined. The amount and radial positioning of reinforcing layers (e.g., reinforcing fiberglass) may then be determined. An appropriate amount of reinforcing layers may then be placed within the radial intervals that experience the highest stress.

Abstract: A power tool, for example a hammer drill comprising: a housing; a handle having two ends, the first end being moveably mounted to the housing via a first mounting assembly, the second end being moveably mounted to the housing via a second mounting assembly; wherein the first mounting assembly comprises: a first part mounted on the housing and a second part mounted on the first end of the handle, one part comprising a sleeve, the other part comprising a rod mounted in an axially slideable manner in the sleeve to enable the first end of the handle to slide towards or away from the housing; and a biasing mechanism connected between the two parts which biases the first end of the handle away from the housing; wherein the second mounting assembly comprises: a third part mounted on the body and a fourth part mounted on the second end of the handle, one part comprising a support, the other part comprising a pin located in the support which is capable of being rotated in the support to enable the second end of the ha

Abstract: A side handle for a power tool comprising: a central bar; a tubular grip which is mounted on and surrounds the central bar via a vibration dampener; the vibration dampener comprising a spring having a central plate, which is mounted in a non moveable manner on the central bar, and a plurality of resiliently deformable arms attached to the plate and which extend away from the plate towards the grip, the ends of each of the arms being non moveably attached to the grip.

Abstract: A power tool including a motor, an input unit such as a variable-speed trigger switch, and a controller is provided. The controller controls the speed of the motor as a function of the input level indicated by the electrical signal from the input unit.

Abstract: A suction cup dust extractor for a drill having a housing; a drill collar attached to the housing, having a drill passage formed through it; an aperture located on the housing through which air can be sucked out by a suction device; a recess formed by the walls of the housing having an opening which, in use, locates against a work piece to create a chamber; at least one first air passage formed within the housing which enables air to pass from the drill passage to the aperture; at least one second air passage formed within the housing which enables air to pass from the recess to the aperture; and a manually operable valve mechanism mounted in the housing which is connected to the recess and which, when operated, allows air surrounding the housing to freely enter the recess when its opening is located against a work piece; characterized in that the housing further comprises a hand grip), the valve mechanism being mounted, at least in part, inside of the hand grip.

Abstract: A suction cup dust extractor for a drill having a housing; a drill collar attached to the housing, having a drill passage formed through it; a recess formed by the walls of the housing having an opening and which, in use, locates against a work piece to create a chamber; a single aperture located on the housing through which air can pass; at least one first air passage formed by the walls of the housing which connects between the drill and the aperture to enable air to pass from the drill passage to the aperture; and at least one second air passage formed within the housing which connects between the recess and the at least one first air passage and which enables air to pass from the recess to the aperture via a part of the at least one first air passage; characterized in that there is a dividing wall which forms both one of the walls of the recess and one of the walls of the first passage, the at least one second passage being an aperture formed through that wall.

Abstract: A suction cup dust extractor for a drill having a housing with a drill collar attached to the housing and having a drill passage formed through the housing. A recess formed by the walls of the housing has a planar opening and a seal is attached to the walls of the recess which surrounds the planar opening and which, in use, locates against a work piece to create an air tight seal between the housing and the work piece. The housing also has an aperture located thereon through which air can pass; at least one first air passage formed within the housing which enables air to pass from the drill passage to the aperture; and at least one second air passage formed within the housing which enables air to pass from the recess to the aperture; characterized in that the seal comprises a base which is attached to the walls of the recess and a flange which is attached to and extends from the base at an oblique angle to the plane of the opening.

Abstract: A suction cup dust extractor for a drill comprising: a housing; a drill collar attached to the housing, having a drill passage formed through it; a recess formed by the walls of the housing having an opening and which, in use, locates against a work piece to create a chamber; an single aperture located on the housing through which air can pass; at least one first air passage formed within the housing which enables air to pass from the drill passage to the aperture; and at least one second air passage formed within the housing which enables air to pass from the recess and the aperture; characterized in that the drill collar comprises a plurality of markers which are located around its periphery