Abstract: A stator assembly for a brushless DC motor includes a stator core including stator poles and an outer surface, at least one magnet wire wound on the poles forming stator windings, and a bus bar including a non-conductive mount arranged on the outer surface and conductive terminals. Each conductive terminal includes: a main portion mounted on the non-conductive mount substantially parallel to the longitudinal axis of the motor, a tang portion folded over the main portion from a first longitudinal end of the main portion, and a connection tab at a second longitudinal end of the main portion. At least a contact portion of the at least one magnet wire is wrapped around the tang portion and fused to make an electric connection to the conductive terminal, and the connection tab makes electric contact with a wire supplying electric power to the motor.

Abstract: A power tool battery pack enclosure is configured to be retrofittedly coupled to battery pack receptacles of a plurality of power tools, each battery pack receptacle configured to removably receive a plurality of power tool battery packs. The enclosure includes a first clamshell member and a second clamshell member configured to be coupled around at least a portion of an exterior surface of each battery pack receptacle. Each of the first and second clamshell members have a top wall portion configured to be received over the exterior surface of the battery pack receptacle and a sidewall portion that extends downward from the top wall portion over at least a portion of the battery pack housing when the battery pack is received in the battery pack receptacle.

Abstract: The present disclosure is directed to a cordless power tool vibration isolation system. A solution to negative impacts of vibration on a removable battery pack caused by operation of a cordless power tool. Isolating the battery pack from the power tool reduces wear and tear on the battery pack including the pack housing, the pack terminals and internal pack components. A battery pack interface of the power tool including a discrete interface housing that mates with the battery pack and a vibration isolation element that separates and isolates the combination of the discrete interface housing and the battery pack from the power tool and the power tool's associated motor induced vibrations.

Abstract: A construction laser level including a housing, a laser mount disposed in the housing and at least one laser generator on the laser mount. The laser mount includes a plurality of heat dissipating fins.

Abstract: A laser beam generating device includes a housing a first laser diode which generates a visible first output beam which projects outside of the housing onto a surface and a second laser diode which generates a visible second output beam which projects outside of the housing onto the surface. The laser beam generating device has a first mode in which the first laser diode and the second laser diode are both on. In the first mode, the first laser diode is operated at a first duty cycle the second laser diode is operated at a second duty cycle. The first duty cycle and the second duty cycle are staggered.

Abstract: A power tool chuck includes a body with a central bore extending along an axis and configured to receive a tool bit, a plurality of angled passageways, and a plurality of jaws received in the passageways and moveable between an axially forward and radially inward clamping position and an axially rearward and radially outward retracted position. At least one jaw has a rear end lying in a first plane transverse to the axis. A first key drive member coupled to a tail portion of the body is configured to be engaged by a second key drive member on a power tool output shaft to non-rotationally couple the body to the output shaft. The first key drive has a forward end lying in a second plane transverse to the axis. The second plane is axially forward of the first plane when the jaws are in the retracted position.

Abstract: A wet-dry vacuum device assembly comprises a housing and a motor-fan assembly mounted in the housing. The motor-fan assembly is arranged to generate an air flow along an airflow path between a dirty air inlet and a clean air exhaust. The wet-dry vacuum device comprises a tank positioned along the airflow path and arranged to capture liquid entrained in the dirty air flow. The wet-dry vacuum device further comprises a removable pump accessory mountable to the housing. The removable pump accessory comprises pump and a fluid inlet in fluid communication with the tank and the pump. A fluid outlet is in fluid communication with the pump and connectable to an exterior hose. The pump is arranged to move captured liquid in the tank from the fluid inlet to the fluid outlet.

Abstract: A brushless direct-current (BLDC) motor is provided. The motor includes a stator including a stator core and windings; a rotor shaft disposed within the stator and extending along a longitudinal axis; and a rotor including a rotor core fixedly mounted on the rotor shaft and at least one permanent magnet mounted on an outer surface of the rotor core. A sleeve is provided including a substantially cylindrical body mounted on the at least one permanent magnet and a flange that engages a first axial end of the at least one permanent magnet to constrain the at least one permanent magnet radially and along a first axial direction. Further, a fan is mounted on the rotor shaft and engaging a second axial end of the at least one permanent magnet to constrain the at least one permanent magnet along a second axial direction.

Abstract: An electronic module for a power tool having an electric motor is provided including a printed circuit board (PCB), an inverter bridge circuit, a first conductive track disposed on the PCB and coupled to the power source, a second conductive track disposed on the PCB and coupled to the inverter bridge circuit, and a fuse strap provided between the first conductive track and the second conductive track. The fuse strap includes a main body spaced apart from the PCB, a first mounting portion mounted on the first conductive track via a first solder joint, and a second mounting portion mounted on the second conductive track via a second solder joint.

Abstract: Systems, methods, and computer software are disclosed where sensor data is received from sensors operatively connected to a powered device. Based on the sensor data, an inventory of detectable items proximate the powered device is generated. The inventory of detectable items is compared to an expected inventory of detectable items that are expected to be proximate the powered device. An alert is generated at a client device when the inventory of detectable items does not match the expected inventory of detectable items.

Abstract: A side handle for a power tool is provided including a main gripping body; a rod extending through the main gripping body and having a threaded end extending through a frontal end of the main gripping body; and a knob mounted on an end of the rod opposite the threaded end and being rotatable relative to the main gripping body. The frontal end of the main gripping body includes a keying feature operable to engage a portion of the power tool to prevent rotation of the main gripping body relative to the power tool while the knob is rotated to fasten the threaded end of the rod to a threaded opening of the power tool.

Abstract: An impact power tool includes a transmission output shaft, a rotary impact assembly with a cam shaft, hammer, and anvil, and a tool output shaft rotatable with the anvil. A coupler removably couples the cam shaft to the transmission output shaft. When torque on the tool output shaft is less than or equal to a first threshold, the transmission output shaft, cam shaft, hammer, and anvil rotate together to transmit torque to the tool output shaft. When torque on the tool output shaft is above the first threshold, the hammer moves along the cam shaft away from the anvil by a first distance and applies rotary impacts to the anvil. When the hammer moves along the cam shaft away from the anvil by a second distance greater than the first distance, the coupler decouples the transmission output shaft from the cam shaft, interrupting torque transmission to the tool output shaft.

Abstract: A chalk reel includes a housing defining a chalk chamber and an opening from the chalk chamber; a spool positioned within the chalk chamber; and a line wound on the spool and extending through the opening, the line having a width of dimension X. The spool comprises an axial hub and a sidewall. The sidewall comprises a plurality of apertures extending through the sidewall from a first face distal from the axial hub to a second face proximal to the axial hub. Each of the plurality of apertures having a maximum width of dimension Y. The dimension Y is less than or approximately equal to twice the dimension X.

Abstract: A motor is provided including: a stator including a stator core, stator windings, and an end insulator; a rotor rotatably received within the stator; and stator terminals supported by the routing insulator and extending away from the stator. Each stator terminal includes a main body having a curved portion, a tang portion folded over the main body and receiving a portion of a magnet wire therein to make an electrical connection with at least one of the stator windings, and a terminal pin projecting axially away from the stator core. The stator core has a maximum diameter of less than or equal to approximately 34 mm defining an outer envelope of the stator, and the stator terminals are fully contained within the outer envelope.

Abstract: A power tool is provided including a motor having an axial length of smaller than or equal to 65 mm and an outer diameter of smaller than or equal to 63 mm. The electric motor is configured to produce a maximum power output of greater than or equal to 2800 watts when the battery pack coupled to the battery receiver has a nominal voltage output of smaller than or equal to 60 volts and a rated capacity of approximately 9 ampere-hours (A.h.). Further, the motor drives an output spindle so as to maintain an output rotational speed of greater than 3,500 rotations-per-minute (RPM) within a torque range of 30 inch-lbs to 45 inch-lbs and exhibit a drop in the output rotational speed that is less than or equal to approximately 11.5% as the torque increases from 30 inch-lbs to 45 inch-lbs.

Abstract: A cordless aw is provided with regenerative braking means that increases the number of repeated cuttings the saw is able to perform (x) per full discharge cycle of the battery pack, as compared to the number of repeated cuttings achievable by the same saw not employing a regenerative braking means (y) per full discharge cycle of the battery pack, such that x/y is approximately at least one of the following: i) 1.1 when cutting a Pressure-Treated (PT) lumber workpiece having a cross-sectional size of approximately 89 mm×89 mm±2 mm, ii) 1.15 when cutting a Spruce Pine Fir (SPF) lumber workpiece having a cross-sectional size of approximately 38 mm×89 mm±2 mm, or iii) 1.25 when cutting Medium Density Fiberboard (MDF) workpiece having a thickness of approximately 19 mm±1 mm and a width of approximately 76 mm±2 mm.

Abstract: A power tool includes a housing, a motor disposed in the housing, an output spindle extending outward from the housing and configured to be rotationally driven by the motor, a keyed chuck coupled to the output spindle for rotation with the output spindle, and a chuck key holder configured to releasably retain a chuck key with a first shaft with a key disposed thereon for operating the chuck, and a second shaft coupled to the first end portion of the first shaft generally perpendicular to the first shaft, the second shaft including a lever portion. The chuck key holder includes a first recess configured to receive the first shaft and a second recess with a sheath configured to receive the second shaft with the lever portion exposed from the sheath.