Abstract: A power tool having multiple wireless communication states and a method of wirelessly communicating by a power tool. The power tool includes a motor, a battery pack interface that selectively receives a battery pack, a backup power source, and a wireless communication controller coupled to the backup power source and the battery pack interface. The wireless communication controller operates in a connectable state when coupled to a battery pack and transmits tool operational data to the external device and receives tool configuration data from the external device. The wireless communication controller operates in an advertisement state when the wireless communication controller is coupled to and powered by the backup power source. In the advertisement state, the wireless communication controller is configured to transmit the unique tool identifier. The external device may also display an indication of the communication state of the power tool.

Abstract: A power tool and method of detecting impacts of a power tool that includes a motor driving a hammer to impact an anvil. A motor control unit is configured to determine a motor characteristic indicative of a speed of the motor. When the motor characteristic indicates that the speed of the motor is below a speed threshold, the motor control unit employs an acceleration-based technique to detect a first impact based on a change in motor acceleration and generate a first impact indication in response to detecting the first impact. When the motor characteristic indicates that the speed is above the speed threshold, the motor control unit employs a time-based technique to detect a second impact based on an elapsed time and generates a second impact indication in response to detecting the second impact.

Abstract: A rotary power tool includes a housing having a motor housing portion and a handle portion extending therefrom. An electric motor is positioned within the motor housing portion. The rotary power tool further includes a trigger switch configured to activate and deactivate the motor. The rotary power tool further includes a non-contact speed selector switch positioned in the housing. The non-contact speed selector switch is configured to adjust a rotational speed of the motor. The non-contact speed selector switch is separate from the trigger switch.

Abstract: A programmable power tool and method and systems of programming a power tool using wireless communication. An external device having a processor and a transceiver establishes a communication link with the power tool. The external device receives, with the transceiver, a first mode profile stored on the power tool. The first mode profile is defined by a profile type and a first value associated with a parameter for executing the profile type. The external device displays a control screen including the profile type and the parameter at the first value, and receives a user input. The external device generates, in response to the user input, a second mode profile by modifying the parameter to be at a second value. The external device transmits, with the transceiver, the second mode profile to the power tool.

Abstract: A power tool having multiple wireless communication states and a method of wirelessly communicating by a power tool. The power tool includes a motor, a battery pack interface that selectively receives a battery pack, a backup power source, and a wireless communication controller coupled to the backup power source and the battery pack interface. The wireless communication controller operates in a connectable state when coupled to a battery pack and transmits tool operational data to the external device and receives tool configuration data from the external device. The wireless communication controller operates in an advertisement state when the wireless communication controller is coupled to and powered by the backup power source. In the advertisement state, the wireless communication controller is configured to transmit the unique tool identifier. The external device may also display an indication of the communication state of the power tool.

Abstract: A power tool system includes a hydraulic power tool. The hydraulic power tool includes a hydraulic drive, a sensor, and a first electronic processor. The sensor is configured to detect an operational parameter of the hydraulic drive during an operation by the hydraulic drive. The first electronic processor is configured to store a plurality of data points based on the operational parameter detected during the operation and send the plurality of data points to an external device. The external device includes a display screen and a second electronic processor configured to receive the plurality of data points from the hydraulic power tool, control the display screen to display an expected data point for the operational parameter for the operation, and control the display screen to display an actual data curve based on the plurality of data points, the actual data curve overlaid on the expected data point.

Abstract: A power tool includes a three-phase DC motor, a power switching network, a power source, and an electronic processor. A first phase of the motor is connected between a first low side electronic switch and a power source electronic switch, and connected to the power source via a first high side electronic switch in parallel with a diode. The electronic processor is configured to receive an indication to stop the motor during operation of the motor and activate the first low side electronic switch and a second low side electronic switch for a first predetermined time responsive to receiving the indication such that a back-electromagnetic force generated by the motor is stored in the first phase. The electronic processor is configured to deactivate the second low side electronic switch after the first predetermined time such that a first regenerative current is provided to the power source via the diode.

Abstract: A rotary power tool includes a housing having a motor housing portion and a handle portion extending therefrom. An electric motor is positioned within the motor housing portion. The rotary power tool further includes a trigger switch configured to activate and deactivate the motor. The rotary power tool further includes a non-contact speed selector switch that is separate from the trigger switch and configured to adjust a rotational speed of the motor. The non-contact speed selector switch is positioned in a foot of the handle portion opposite the motor housing portion.

Abstract: An electrical combination, a tool system, an electric motor, a battery pack, and operating and manufacturing methods. The tool may include a tool housing, a motor supported by the tool housing, the motor having a nominal outer diameter of up to about 80 millimeters (mm), the motor being operable to output at least about 2760 watts (W), and a tool terminal electrically connected to the motor; a battery pack including a pack housing defining a volume of the battery pack, the volume being up to about 5.2×106 cubic millimeters (mm3), battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 80 volts (V), and a pack terminal electrically connectable to the tool terminal to transfer current between the battery pack and the tool; and a controller operable to control the transfer of current.

Abstract: A method for expanding features of a gas engine replacement device that drives power equipment including controlling, by an electronic processor of the gas engine replacement device, a power switching network to selectively provide power from a battery pack to rotate a motor of the gas engine replacement device. A module interface of the gas engine replacement device receives an external electronics module. A type of the external electronics module received by the module interface is detected by the electronic processor of the gas engine replacement device. The gas engine replacement device is configured by the electronic processor based on the type of the received external electronics module. The electronic processor communicates with the external electronics module via the module interface.

Abstract: A programmable power tool and method and systems of programming a power tool using wireless communication. An external device having a processor and a transceiver establishes a communication link with the power tool. The external device receives, with the transceiver, a first mode profile stored on the power tool. The first mode profile is defined by a profile type and a first value associated with a parameter for executing the profile type. The external device displays a control screen including the profile type and the parameter at the first value, and receives a user input. The external device generates, in response to the user input, a second mode profile by modifying the parameter to be at a second value. The external device transmits, with the transceiver, the second mode profile to the power tool.

Abstract: A power tool includes a three-phase DC motor, a power switching network, a power source, and an electronic processor. A first phase of the motor is connected between a first low side electronic switch and a power source electronic switch, and connected to the power source via a first high side electronic switch in parallel with a diode. The electronic processor is configured to receive an indication to stop the motor during operation of the motor and activate the first low side electronic switch and a second low side electronic switch for a first predetermined time responsive to receiving the indication such that a back-electromagnetic force generated by the motor is stored in the first phase. The electronic processor is configured to deactivate the second low side electronic switch after the first predetermined time such that a first regenerative current is provided to the power source via the diode.

Abstract: A power tool system includes a hydraulic power tool. The hydraulic power tool includes a hydraulic drive, a sensor, and a first electronic processor. The sensor is configured to detect an operational parameter of the hydraulic drive during an operation by the hydraulic drive. The first electronic processor is configured to store a plurality of data points based on the operational parameter detected during the operation and send the plurality of data points to an external device. The external device includes a display screen and a second electronic processor configured to receive the plurality of data points from the hydraulic power tool, control the display screen to display an expected data point for the operational parameter for the operation, and control the display screen to display an actual data curve based on the plurality of data points, the actual data curve overlaid on the expected data point.

Abstract: A method for expanding features of a gas engine replacement device that drives power equipment including controlling, by an electronic processor of the gas engine replacement device, a power switching network to selectively provide power from a battery pack to rotate a motor of the gas engine replacement device. A module interface of the gas engine replacement device receives an external electronics module. A type of the external electronics module received by the module interface is detected by the electronic processor of the gas engine replacement device. The gas engine replacement device is configured by the electronic processor based on the type of the received external electronics module. The electronic processor communicates with the external electronics module via the module interface.

Abstract: An electrical combination, a tool system, an electric motor, a battery pack, and operating and manufacturing methods. The tool may include a tool housing, a motor supported by the tool housing, the motor having a nominal outer diameter of up to about 80 millimeters (mm), the motor being operable to output at least about 2760 watts (W), and a tool terminal electrically connected to the motor; a battery pack including a pack housing defining a volume of the battery pack, the volume being up to about 5.2×106 cubic millimeters (mm3), battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 80 volts (V), and a pack terminal electrically connectable to the tool terminal to transfer current between the battery pack and the tool; and a controller operable to control the transfer of current.

Abstract: An expanding tool comprising: an actuator comprising a cylindrical housing that defines an actuator housing cavity; a primary ram disposed within the actuator housing cavity, the primary ram defining an internal primary ram cavity; a secondary ram disposed within the internal primary ram cavity; a cam roller carrier coupled to a distal end of the secondary ram; a drive collar positioned within a distal end of the actuator housing cavity; a roller clutch disposed within an internal cavity defined by an inner surface of the drive collar; a shuttle cam positioned between the roller clutch and a distal end of the primary ram; an expander cone coupled to the primary ram; and an expander head operably coupled to the drive collar.

Abstract: A programmable power tool and method and systems of programming a power tool using wireless communication. An external device having a processor and a transceiver establishes a communication link with the power tool. The external device receives, with the transceiver, a first mode profile stored on the power tool. The first mode profile is defined by a profile type and a first value associated with a parameter for executing the profile type. The external device displays a control screen including the profile type and the parameter at the first value, and receives a user input. The external device generates, in response to the user input, a second mode profile by modifying the parameter to be at a second value. The external device transmits, with the transceiver, the second mode profile to the power tool.

Abstract: A power tool including a housing, a controller within the housing, and a brushless motor within the housing and controlled by the controller. The brushless motor including a stator assembly including a stator core having stator laminations with an annular portion and inwardly extending stator teeth. The stator assembly defines a stator envelope in an axial direction extending between axial ends of stator end caps of the stator assembly. The brushless motor further includes a rotor assembly including a rotor core having rotor laminations and defining a central aperture that extends in the axial direction and that receives a shaft, and a position sensor board assembly including position sensors and configured to provide position information of the rotor core to the controller. The rotor assembly and the position sensor board assembly are provided at least partially within the stator envelope.

Abstract: A power tool having multiple wireless communication states and a method of wirelessly communicating by a power tool. The power tool includes a motor, a battery pack interface that selectively receives a battery pack, a backup power source, and a wireless communication controller coupled to the backup power source and the battery pack interface. The wireless communication controller operates in a connectable state when coupled to a battery pack and transmits tool operational data to the external device and receives tool configuration data from the external device. The wireless communication controller operates in an advertisement state when the wireless communication controller is coupled to and powered by the backup power source. In the advertisement state, the wireless communication controller is configured to transmit the unique tool identifier. The external device may also display an indication of the communication state of the power tool.

Abstract: A power tool and method of detecting impacts of a power tool that includes a motor driving a hammer to impact an anvil. A motor control unit is configured to determine a motor characteristic indicative of a speed of the motor. When the motor characteristic indicates that the speed of the motor is below a speed threshold, the motor control unit employs an acceleration-based technique to detect a first impact based on a change in motor acceleration and generate a first impact indication in response to detecting the first impact. When the motor characteristic indicates that the speed is above the speed threshold, the motor control unit employs a time-based technique to detect a second impact based on an elapsed time and generates a second impact indication in response to detecting the second impact.