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: Simulated bog-down system and method for power tools. One power tool according to an example embodiment includes a power source and a motor selectively coupled to the power source. The motor includes a rotor and stator windings. The power tool includes an actuator configured to generate a drive request signal and a power switching network configured to selectively couple the power source to the stator windings of the motor. The power tool includes an electronic processor coupled to the power source, the actuator, and the power switching network. The electronic processor is configured to detect a load on the power tool and compare the load to a threshold. The electronic processor is configured to determine that the load is greater than the threshold, and to control the power switching network to simulate bog-down in response to determining that the load is greater than the threshold.

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 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 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: Methods and power tools for sensorless motor control. One embodiment provides a method for automatic control switching for driving a sensorless motor (150) of a power tool (100). The method includes determining, using a motor controller (224), a first load point based on user inputs (232) and determining, using the motor controller (224), a first motor control technique corresponding to the first load point. The method also includes driving the motor (150) based on the first motor control technique. The method further includes determining, using the motor controller (224), a change from the first load point to a second load point and determining, using the motor controller (224), a second motor control technique corresponding to the second load point. The method includes driving the motor (150) based on the second motor control technique.

Abstract: Simulated bog-down system and method for power tools. One power tool according to an example embodiment includes a power source and a motor selectively coupled to the power source. The motor includes a rotor and stator windings. The power tool includes an actuator configured to generate a drive request signal and a power switching network configured to selectively couple the power source to the stator windings of the motor. The power tool includes an electronic processor coupled to the power source, the actuator, and the power switching network. The electronic processor is configured to detect a load on the power tool and compare the load to a threshold. The electronic processor is configured to determine that the load is greater than the threshold, and to control the power switching network to simulate bog-down in response to determining that the load is greater than the threshold.

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 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: An electrical device including a first battery pack receptacle, a second battery pack receptacle, and circuitry including an electronic processor. The first battery pack receptacle is configured to receive a first battery pack. The second battery pack receptacle is configured to receive a second battery pack. The second battery pack is electrically connected in a series-type configuration with the first battery pack. The circuitry is configured to alter a first signal output from the electronic processor to at least one selected from a group consisting of the first battery pack and the second battery pack, and alter a second signal received by the electronic processor from at least one selected from the group consisting of the first battery pack and the second battery pack.

Abstract: Methods and power tools for sensorless motor control. One embodiment provides a method for automatic control switching for driving a sensorless motor (150) of a power tool (100). The method includes determining, using a motor controller (224), a first load point based on user inputs (232) and determining, using the motor controller (224), a first motor control technique corresponding to the first load point. The method also includes driving the motor (150) based on the first motor control technique. The method further includes determining, using the motor controller (224), a change from the first load point to a second load point and determining, using the motor controller (224), a second motor control technique corresponding to the second load point. The method includes driving the motor (150) based on the second motor control technique.

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: An electrical device including a first battery pack receptacle, a second battery pack receptacle, and circuitry including an electronic processor. The first battery pack receptacle is configured to receive a first battery pack. The second battery pack receptacle is configured to receive a second battery pack. The second battery pack is electrically connected in a series-type configuration with the first battery pack. The circuitry is configured to alter a first signal output from the electronic processor to at least one selected from a group consisting of the first battery pack and the second battery pack, and alter a second signal received by the electronic processor from at least one selected from the group consisting of the first battery pack and the second battery pack.

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 is provided with a coating to distribute static electricity away from the surface of the handle of the tool. The tool includes a handle configured to be grasped by a user. The handle includes a surface and a first material having a first surface resistivity. The tool includes a coating covering at least a portion of the handle. The coating is configured to distribute static electricity away from the surface. The coating is made of a second material having a second surface resistivity less than the first surface resistivity.

Abstract: Methods and power tools for sensorless motor control. One embodiment provides a method for automatic control switching for driving a sensorless motor (150) of a power tool (100). The method includes determining, using a motor controller (224), a first load point based on user inputs (232) and determining, using the motor controller (224), a first motor control technique corresponding to the first load point. The method also includes driving the motor (150) based on the first motor control technique. The method further includes determining, using the motor controller (224), a change from the first load point to a second load point and determining, using the motor controller (224), a second motor control technique corresponding to the second load point. The method includes driving the motor (150) based on the second motor control technique.

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 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 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: One embodiment provides a remotely controllable gas engine replacement device including a housing, a battery receptacle coupled to the housing, the battery receptacle configured to removably receive a battery pack, a motor located within the housing, a power take-off shaft receiving torque from the motor and protruding from a side of the housing, a power switching network configured to selectively provide power from the battery pack to the motor, and one or more remote control device interfaces configured to communicate with the remote control device. The remotely controllable gas engine replacement device also includes an electronic processor coupled to the power switching network and the remote control device interface. The electronic processor configured to control the power switching network to rotate the motor, receive a control signal from the remote control device, and execute a responsive action to the control signal from the remote control device.