Abstract: A brushless direct-current (BLDC) motor includes a stator assembly and a rotor assembly including a rotor supporting permanent magnets rotatable relative to the stator assembly. The stator assembly includes a stator comprising a stator core and stator teeth radially extending from the stator core and defining slots therebetween. A first set of stator windings is wound on the stator teeth, and a second set of stator windings is also wound on the stator teeth such that, on each stator tooth, the first and second windings are provided in an electrically parallel configuration.

Abstract: A brushless direct-current (BLDC) motor for a power tool includes a rotor assembly and a stator assembly including stator windings. A ratio of a motor size (Km) constant of the motor to an electrical envelope of the motor including electrical parts of the motor is greater than approximately 900 (N·m/?W)/m{circumflex over (?)}3. A ratio of a motor size (Km) constant of the motor to a magnetic envelope of the motor including stator core and windings is greater than approximately 810 (N·m/?W)/m{circumflex over (?)}3.

Abstract: A brushless direct-current (BLDC) motor for a power tool includes a rotor assembly and a stator assembly including a stator comprising a stator core and stator teeth radially extending from the stator core and defining slots therebetween, and stator windings wound on the stator teeth. The stator has an inner diameter defined by inner ends of the stator teeth and an outer diameter defined by an outer surface of the stator core. A ratio of the inner diameter to the outer diameter is in the range of 0.5 to 0.53. The stator core has a variable thickness and, for each slot, includes a first portion forming an approximately right angle with the respective stator tooth and a second portion that is substantially normal to a radius of the stator assembly and forms an angle of approximately 25 to 35 degrees with the first portion.

Abstract: A brushless direct-current (BLDC) motor for a power tool includes a motor housing having a radial wall, a rotor, a stator assembly including stator windings, and stator terminals extending substantially parallel to the longitudinal axis from the stator assembly. The stator terminals are substantially aligned with centerlines of slots of the stator assembly. A circuit board is mounted on the stator terminals adjacent the stator assembly. The circuit board includes conductive traces facilitating a one of a delta or a series connection between the stator windings. The circuit board may be mounted inside the motor housing in contact with the radial member. A second circuit board may be provided with power switches for driving the motor proximate the circuit board.

Abstract: A brushless direct-current (BLDC) motor includes a stator assembly and a rotor assembly including a rotor supporting permanent magnets rotatable relative to the stator assembly. The stator assembly includes a stator comprising a stator core and stator teeth radially extending from the stator core and defining slots therebetween. A first set of stator windings is wound on the stator teeth, and a second set of stator windings is also wound on the stator teeth such that, on each stator tooth, the first and second windings are provided in an electrically parallel configuration.

Abstract: A brushless direct-current (BLDC) motor for a power tool includes a rotor assembly; a stator assembly including a stator having stator teeth forming slots therebetween and stator windings wound around the stator teeth; stator terminals extending substantially parallel to the longitudinal axis from the stator assembly and being substantially aligned with centerlines of the slots of the stator assembly; and a circuit board mounted on the stator terminals adjacent the stator assembly. The circuit board includes conductive traces facilitating a one of a delta or a series connection between the stator windings. An end insulator is provided at an axial end of the stator to electrically insulate the stator from the stator windings, the end insulator including support members to support the stator terminals relative to the stator assembly. The circuit board is mounted and fastened to the support members.