Abstract: A gas spring-powered fastener driver includes a cylinder, a moveable piston positioned within the cylinder, a driver blade attached to the piston and movable therewith between a ready position and a driven position, a lifter to move the driver blade from the driven position to the ready position, and a transmission including an output shaft operatively coupled to the lifter to provide torque to the lifter. The fastener driver also includes an input to provide torque to the transmission and a clutch positioned downstream of the input and operably coupled to the output shaft to limit an amount of torque transferred to the output shaft and the lifter. In response to an application of a reaction torque to the output shaft above a predetermined threshold, torque from the input is diverted from the output shaft via the clutch.

Abstract: A gas spring-powered fastener driver includes a cylinder, a moveable piston positioned within the cylinder, a driver blade attached to the piston and movable between a ready position and a driven position, a lifter engageable with the driver blade to return the driver blade from the driven position to the ready position, and a multi-stage planetary transmission including an output shaft operatively coupled to the lifter to provide torque thereto, a first bearing supporting a first portion of the output shaft for rotation, a second bearing supporting a second portion of the output shaft for rotation, and first and second planetary stages. The fastener driver also includes a housing having a cylinder support portion and a transmission housing portion in which the first and second bearings are received. The cylinder support portion and the transmission housing portion are integrally formed as a single piece.

Abstract: Kickback control methods for power tools. One power tool includes a movement sensor configured to measure an angular velocity of the housing of the power tool about the rotational axis. The power tool includes an electronic processor coupled to the switching network and the movement sensor and configured to implement kickback control of the power tool. To implement the kickback control, the electronic processor is configured to control the switching network to drive the brushless DC motor, receive measurements of the angular velocity of the housing of the power tool from the movement sensor, determine that a plurality of the measurements of the angular velocity of the housing of the power tool exceed a rotation speed threshold, and control the switching network to cease driving of the brushless DC motor in response to determining that the plurality of the measurements of the angular velocity exceed the rotation speed threshold.

Abstract: Kickback control methods for power tools. One power tool includes a movement sensor configured to measure an angular velocity of the housing of the power tool, and an orientation sensor configured to measure an orientation of the housing. The power tool includes an electronic processor coupled to a switching network and a trigger. To implement the kickback control, the electronic processor is configured to receive measurements of the angular velocity of the housing, receive measurements of the orientation of the housing, determine a binding condition of the power tool based on the measurements of the angular velocity and the measurements of orientation, and control the switching network to cease driving of the brushless DC motor.

Abstract: A gas spring-powered fastener driver includes a cylinder, a moveable piston, a driver blade attached to the piston, the driver blade movable with the piston, a lifter including a rotary component operably coupled to the driver blade to move the driver blade from a driven position to a ready position, and a multi-stage planetary transmission. The transmission includes an output shaft operatively coupled to the lifter to provide torque thereto, a first bearing supporting a first portion of the output shaft for rotation, a second bearing supporting a second portion of the output shaft for rotation. The fastener driver also includes a housing having a cylinder support portion in which the cylinder is received and a transmission housing portion in which the first and second bearings are received to rotatably support the output shaft. The cylinder support portion and the transmission housing portion are integrally formed as a single piece.

Abstract: Kickback control methods for power tools. One power tool includes a movement sensor configured to measure an angular velocity of the housing of the power tool about the rotational axis. The power tool includes an electronic processor coupled to the switching network and the movement sensor and configured to implement kickback control of the power tool. To implement the kickback control, the electronic processor is configured to control the switching network to drive the brushless DC motor, receive measurements of the angular velocity of the housing of the power tool from the movement sensor, determine that a plurality of the measurements of the angular velocity of the housing of the power tool exceed a rotation speed threshold, and control the switching network to cease driving of the brushless DC motor in response to determining that the plurality of the measurements of the angular velocity exceed the rotation speed threshold.

Abstract: A clutch mechanism for use in a rotary power tool having a motor comprises an input member to which torque from the motor is transferred and an output member movable between a first position in which the output member is engaged with the input member for co-rotation therewith, and a second position in which the output member is disengaged from the input member. The clutch mechanism further comprises a biasing member biasing the output member into the first position and an electromagnet which, when energized, moves the output member from the first position to the second position.

Abstract: A gas spring-powered fastener driver includes a cylinder, a moveable piston positioned within the cylinder, a driver blade attached to the piston and movable therewith between a ready position and a driven position, a lifter to move the driver blade from the driven position to the ready position, and a transmission including an output shaft operatively coupled to the lifter to provide torque to the lifter. The fastener driver also includes an input to provide torque to the transmission and a clutch positioned downstream of the input and operably coupled to the output shaft to limit an amount of torque transferred to the output shaft and the lifter. In response to an application of a reaction torque to the output shaft above a predetermined threshold, torque from the input is diverted from the output shaft via the clutch.

Abstract: A gas spring-powered fastener driver includes a cylinder, a moveable piston, a driver blade attached to the piston, the driver blade movable with the piston, a lifter including a rotary component operably coupled to the driver blade to move the driver blade from a driven position to a ready position, and a multi-stage planetary transmission. The transmission includes an output shaft operatively coupled to the lifter to provide torque thereto, a first bearing supporting a first portion of the output shaft for rotation, a second bearing supporting a second portion of the output shaft for rotation. The fastener driver also includes a housing having a cylinder support portion in which the cylinder is received and a transmission housing portion in which the first and second bearings are received to rotatably support the output shaft. The cylinder support portion and the transmission housing portion are integrally formed as a single piece.

Abstract: Kickback control methods for power tools. One power tool includes a movement sensor configured to measure an angular velocity of the housing of the power tool, and an orientation sensor configured to measure an orientation of the housing. The power tool includes an electronic processor coupled to a switching network and a trigger. To implement the kickback control, the electronic processor is configured to receive measurements of the angular velocity of the housing, receive measurements of the orientation of the housing, determine a binding condition of the power tool based on the measurements of the angular velocity and the measurements of orientation, and control the switching network to cease driving of the brushless DC motor.

Abstract: Kickback control methods for power tools. One power tool includes a movement sensor configured to measure an angular velocity of the housing of the power tool about the rotational axis. The power tool includes an electronic processor coupled to the switching network and the movement sensor and configured to implement kickback control of the power tool. To implement the kickback control, the electronic processor is configured to control the switching network to drive the brushless DC motor, receive measurements of the angular velocity of the housing of the power tool from the movement sensor, determine that a plurality of the measurements of the angular velocity of the housing of the power tool exceed a rotation speed threshold, and control the switching network to cease driving of the brushless DC motor in response to determining that the plurality of the measurements of the angular velocity exceed the rotation speed threshold.

Abstract: A gas spring-powered fastener driver including a cylinder, a moveable piston positioned within the cylinder, a driver blade attached to the piston and movable therewith between a ready position and a driven position, a lifter operable to move the driver blade from the driven position to the ready position, a transmission for providing torque to the lifter, a first clutch mechanism permitting a transfer of torque to an output shaft of the transmission in a single rotational direction, and a second clutch mechanism limiting an amount of torque transferred to the transmission output shaft and the lifter.

Abstract: Kickback control methods for power tools. One power tool includes a movement sensor configured to measure an angular velocity of the housing of the power tool about the rotational axis. The power tool includes an electronic processor coupled to the switching network and the movement sensor and configured to implement kickback control of the power tool. To implement the kickback control, the electronic processor is configured to control the switching network to drive the brushless DC motor, receive measurements of the angular velocity of the housing of the power tool from the movement sensor, determine that a plurality of the measurements of the angular velocity of the housing of the power tool exceed a rotation speed threshold, and control the switching network to cease driving of the brushless DC motor in response to determining that the plurality of the measurements of the angular velocity exceed the rotation speed threshold.

Abstract: Kickback control methods for power tools. One power tool includes a movement sensor configured to measure an angular velocity of the housing of the power tool about the rotational axis. The power tool includes an electronic processor coupled to the switching network and the movement sensor and configured to implement kickback control of the power tool. To implement the kickback control, the electronic processor is configured to control the switching network to drive the brushless DC motor, receive measurements of the angular velocity of the housing of the power tool from the movement sensor, determine that a plurality of the measurements of the angular velocity of the housing of the power tool exceed a rotation speed threshold, and control the switching network to cease driving of the brushless DC motor in response to determining that the plurality of the measurements of the angular velocity exceed the rotation speed threshold.

Abstract: A clutch mechanism for use in a rotary power tool having a motor comprises an input member to which torque from the motor is transferred and an output member movable between a first position in which the output member is engaged with the input member for co-rotation therewith, and a second position in which the output member is disengaged from the input member. The clutch mechanism further comprises a biasing member biasing the output member into the first position and an electromagnet which, when energized, moves the output member from the first position to the second position.

Abstract: A gas spring-powered fastener driver including a cylinder, a moveable piston positioned within the cylinder, a driver blade attached to the piston and movable therewith between a ready position and a driven position, a lifter operable to move the driver blade from the driven position to the ready position, a transmission for providing torque to the lifter, a first clutch mechanism permitting a transfer of torque to an output shaft of the transmission in a single rotational direction, and a second clutch mechanism limiting an amount of torque transferred to the transmission output shaft and the lifter.

Abstract: A gas spring-powered fastener driver including a cylinder, a moveable piston positioned within the cylinder, a driver blade attached to the piston and movable therewith between a ready position and a driven position, a lifter operable to move the driver blade from the driven position to the ready position, a transmission for providing torque to the lifter, a first clutch mechanism permitting a transfer of torque to an output shaft of the transmission in a single rotational direction, and a second clutch mechanism limiting an amount of torque transferred to the transmission output shaft and the lifter.

Abstract: A gas spring-powered fastener driver including a cylinder, a moveable piston positioned within the cylinder, a driver blade attached to the piston and movable therewith between a ready position and a driven position, a lifter operable to move the driver blade from the driven position to the ready position, a transmission for providing torque to the lifter, a first clutch mechanism permitting a transfer of torque to an output shaft of the transmission in a single rotational direction, and a second clutch mechanism limiting an amount of torque transferred to the transmission output shaft and the lifter.