Abstract: An electric grinding tool includes a motor housing coupleable to an electrical power source, a motor configured to receive power from the electrical power source and including an output shaft extending along a motor axis, a handgrip coupled to and coaxial with the motor housing, a tool holder rotatably driven upon rotation of the motor, the tool holder configured to receive a shaft of a grinding accessory, and a light unit coupled to and at least partially recessed in a front end portion of the electric grinding tool. The light unit includes a plurality of lights mounted to an at least partially ring shaped printed circuit board that is received in a support ring, and a cover ring received over the lights.

Abstract: A power tool includes a housing, a nosepiece, and an end effector rotatably coupled to the housing. A substantially annular holder body is axially and non-rotatably coupled to the nosepiece. A circuit board is received in an internal substantially annular groove in a rear face of the front wall of the holder body between the holder body and the nosepiece. A light unit is coupled to the circuit board and configured to illuminate the workpiece. A wire assembly electrically couples the light unit to a source of electrical power.

Abstract: A method of operating a power tool having a motor and a controller during a start-up period of the power tool, the start-up period having a plurality of intervals is provided. The method includes: initializing a current clipping threshold to a baseline value, applying the current clipping threshold to the electrical current drawn by the power tool from the battery pack during a first interval of the plurality of intervals, and gradually increasing the current clipping threshold over subsequent intervals of the plurality of intervals to control a ramp-up curve of the rotational speed of the motor.

Abstract: An impact power tool includes a brushless motor, a power switch, an output spindle, and an impact mechanism configured to selectively apply rotational impacts to the output spindle when a torque on the output spindle exceeds a torque threshold. A controller is configured to control power delivery to the motor to selectively cause the motor to operate in a first mode for installing a fastener or in a second mode for removing a fastener. In the first mode, the controller is configured to control the motor with a first conduction band value and a first advance angle value during a first time period until a first parameter is reached, and to control the motor with a second conduction band value and a second advance angle value, at least one of which is greater than the first conduction band value and the first advance angle value, after the first time period.

Abstract: A power tool includes a housing, a brushless motor received in the housing, a power switch coupled to the housing and actuatable by a user, a controller configured to control power delivery to the motor in response to actuation of the power switch, and an output spindle configured to rotate when the motor is energized. The controller is configured to maintain an amount of current delivered to the motor to be less than or equal to a current limit by turning off or reducing power to the motor for a time period if the current exceeds the current limit and then restarting power delivery to the motor. The time period is greater than the duration of one full current cycle.

Abstract: An impact power tool includes a housing, a motor, a controller, an output member configured to be rotated when the motor is energized, and an impact mechanism configured to rotationally drive the output member. The impact mechanism is configured to selectively apply rotational impacts to the output member when a torque on the output member exceeds a torque threshold. The controller is configured to control the motor during a first phase of operation with open loop control and a baseline conduction band and advance angle setting when a sensed tool operation parameter is one of above or below a threshold value. The controller is configured to control the motor during a second phase of operation with closed speed loop control and an increased conduction band and advance angle setting when the sensed tool operation parameter is the other of above or below the threshold value.

Abstract: A power tool includes a housing containing a motor, an output member configured to be driven by the motor to perform an operation on a workpiece, and a handle having a first end portion coupled to the housing and a second end portion. A base is coupled to the second end portion of the handle. A light emitting assembly is pivotably coupled to the base. The light emitting assembly is configured to be operable in a first mode to illuminate a workpiece and a second mode to indicate a condition of the power tool responsive to the power tool signaling the condition to the light emitting assembly.

Abstract: An impact power tool includes a housing, a motor, a controller, an output member configured to be rotated when the motor is energized, and an impact mechanism configured to rotationally drive the output member. The impact mechanism is configured to selectively apply rotational impacts to the output member when a torque on the output member exceeds a torque threshold. The controller is configured to control the motor during a first phase of operation with open loop control and a baseline conduction band and advance angle setting when a sensed tool operation parameter is one of above or below a threshold value. The controller is configured to control the motor during a second phase of operation with closed speed loop control and an increased conduction band and advance angle setting when the sensed tool operation parameter is the other of above or below the threshold value.

Abstract: A power tool includes a housing containing a motor, an output member configured to be driven by the motor to perform an operation on a workpiece, and a handle having a first end portion coupled to the housing and a second end portion. A base is coupled to the second end portion of the handle. A light emitting assembly is pivotably coupled to the base. The light emitting assembly is configured to be operable in a first mode to illuminate a workpiece and a second mode to indicate a condition of the power tool responsive to the power tool signaling the condition to the light emitting assembly.

Abstract: An impact power tool includes a motor, a controller, and an impact mechanism configured to rotationally drive an output spindle. The controller is configured to control power delivered to the motor, during a third phase of operation after a second phase of operation and starting upon expiration of a predetermined time period. The third phase has one or more of a third non-zero target rotational speed, a third duty cycle setting, a third conduction band setting, or a third advance angle setting. The controller is configured to control power delivered to the motor, during a fourth phase of operation after the third phase upon detection of a reduction in load on the output spindle or cessation of impacting. The fourth phase has one or more of a fourth non-zero target rotational speed, a fourth duty cycle setting, a fourth conduction band setting, or a fourth advance angle setting.

Abstract: A power tool includes a housing containing a motor, an output member configured to be driven by the motor to perform an operation on a workpiece, and a handle having a first end portion coupled to the housing and a second end portion. A base is coupled to the second end portion of the handle. A light emitting assembly is pivotably coupled to the base. The light emitting assembly is configured to be operable in a first mode to illuminate a workpiece and a second mode to indicate a condition of the power tool responsive to the power tool signaling the condition to the light emitting assembly.

Abstract: A power tool is provided an electric motor, a nosecone assembly having a metal body, a terminal block that couples to a removable battery pack, and an electronic power module that regulates supply of electric current from the battery pack to the motor. A discharge wire is coupled to the terminal block on a first end and to the metal body of the nosecone assembly on a second end to provide a discharge path from the nosecone directly to the battery pack bypassing the electronic power module.

Abstract: An impact power tool includes a housing, a motor, a controller, an output member configured to be rotated when the motor is energized, and an impact mechanism configured to rotationally drive the output member. The impact mechanism is configured to selectively apply rotational impacts to the output member when a torque on the output member exceeds a torque threshold. The controller is configured to control the motor during a first phase of operation with open loop control and a baseline conduction band and advance angle setting when a sensed tool operation parameter is one of above or below a threshold value. The controller is configured to control the motor during a second phase of operation with closed speed loop control and an increased conduction band and advance angle setting when the sensed tool operation parameter is the other of above or below the threshold value.

Abstract: A power tool includes a housing, a brushless motor received in the housing, a power switch coupled to the housing and actuatable by a user, a controller configured to control power delivery to the motor in response to actuation of the power switch, and an output spindle configured to rotate when the motor is energized. The controller is configured to maintain an amount of current delivered to the motor to be less than or equal to a current limit by turning off or reducing power to the motor for a time period if the current exceeds the current limit and then restarting power delivery to the motor. The time period is greater than the duration of one full current cycle.

Abstract: An impact power tool includes a housing, a motor, a controller, an impact mechanism configured to be driven by the motor, and an output spindle configured to receive rotational impacts from the impact mechanism to rotate the output spindle. The controller is configured to detect a first impact of the rotational impacts or to detect when the motor speed drops below a speed threshold value. The controller is configured to control the motor to have a first non-zero target rotational speed using closed loop control for a predetermined time period after the first impact is detected or when the motor speed dropping below the speed threshold value is detected. The controller is configured to control the motor to have a second non-zero target rotational speed using the closed loop control after the predetermined time period. The first non-zero target rotational speed is less than the second non-zero target rotational speed.

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 stator assembly for a brushless DC motor includes a stator core defining poles and having an outer surface, at least one magnet wire wound on the poles forming phases, 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 is arranged to makes electric contact with a wire supplying electric power to the motor.

Abstract: An adaptor for connecting a power source to a power tool includes a housing having a first end that is configured to connect to a power source and a second end that is configured to connect to a power tool. The adaptor includes a control circuit disposed within the housing. The control circuit is configured to detect a type of the power tool, to detect an overstress condition in the power tool and to control the power tool responsive to detecting the overstress condition based on the detected type of power tool.

Abstract: A power tool includes a tool body including a motor having an output member that drives an accessory. A chuck is coupled for rotation with the output member relative to the tool body and configured to retain the accessory. The chuck has a chuck body that defines at least one light pipe formed therethrough. A light source disposed on a light ring coupled to the tool body and includes at least one light. Each at least one light source aligns with each of the at least one light pipe intermittently during rotation of the chuck.

Abstract: A stator assembly for a brushless DC motor includes a stator core defining poles and having an outer surface, at least one magnet wire wound on the poles forming phases, 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 is arranged to makes electric contact with a wire supplying electric power to the motor.