Abstract: An orbital sander is provided having a number of novel features including a high speed permanent magnet DC motor having a relatively flat rpm versus torque curve. The sander includes an AC to DC power supply, a remotely located on/off switch operated by a switch actuator bar extending transversely through the housing enabling the operator to actuate the on/off switch by alternatively pushing opposed ends of the actuator bar. The orbital sander further includes a fan having non-uniformly spaced blades, eliminating the need for a conventional counterweight, and a dust outlet adapted to be alternatively connected to a dust canister or alternate size collector vacuum hoses.

Abstract: A table saw such as a chop saw, a miter saw, compound miter saw or a sliding compound miter saw that is provided with a laser arbor alignment system. An opaque shield or transparent shield having an opaque mask blocks the laser beam from being projected into a range of normal operator eye positions. One or more openings in the shield or opaque mask provide a sight line on a workpiece initially. As the saw is moved into engagement with the workpiece, the shield is pivoted away from the workpiece and a solid laser line is projected on the workpiece.

Abstract: A motor assembly for use in a vacuum cleaner utilizes a clam-shell type housing having a plurality of shell components that cooperate with each other to define a fan cavity and a motor cavity adjacent to the fan cavity. The housing has a fan cavity inlet and a fan cavity outlet. A field is received in the motor cavity. An armature assembly includes an armature shaft extending through the field and extending into the fan cavity. A pair of brushes are mounted to the housing in the motor cavity, and contact a commutator. A fan blade is disposed in the fan cavity and secured to the armature shaft for rotation together therewith. The fan blade rotates with the armature shaft during motor operation to cause airflow from the fan cavity inlet to the fan cavity outlet.

Abstract: A power tool is provided having a housing with a handle for an operator, a rare earth permanent magnet motor oriented within the housing having a rotary output portion operatively driving an implement. The motor has a relatively high horsepower output for its size enabling the location of the motor relative to the implement and the handle to be functionally and ergonomically optimized.

Abstract: A random orbit sander having a speed limiter includes a bearing upon which a platen is rotatably mounted. The speed limiter includes a braking member formed of a non-magnetic, electrically conductive material fixed relative to the platen of the sander. The spin limiter also includes at least one magnet supported by a housing of the sander and being disposed adjacent the braking member. A magnetic field formed by the at least one magnet intersects the braking member wherein relative movement between the at least one magnet and the braking member results in the generation of an eddy current force which inhibits rotation of the platen.

Abstract: A battery housing for a combination of cells which prevents inadvertent short circuiting caused by electrical contact with discarded battery assemblies. An embodiment of the battery housing comprises a conductive connector, electrically connected to the positive battery terminal, for electrically connecting to a mating contact within an appliance. A terminal insulator insulates the conductive connector from electrical contact with a second battery housing. A sleeve, comprising a length of heat-shrinkable tubing, secures the positioning of the combination of cells and the terminal insulator. A non-conductive cap insulates the conductive connector of a battery assembly removed from the appliance from any external electrical contact. An optional orientation slot is included on the terminal insulator to match with a rib incorporated within the appliance to guide a slip-in fit of the battery assembly within the appliance.

Abstract: A recharging system for a battery operated tool such as a lawn mower. A slidable cover is used which is movable between an open position and a closed position. The slidable cover alternately exposes a receptacle adapted to receive a removable fuse key and an electrical connector adapted to receive an electrical power cord. The receptacle and the electrical connector are longitudinally aligned with the cover so that for the cover to move to the open position and expose the electrical connector, the fuse key must be removed. The receptacle is electrically connected in series with an activation switch, the battery and the electric motor to form a motor circuit. When the fuse key is removed to expose the electrical connector, the motor circuit is broken which prevents the electric motor from being activated whether or not the activation switch is engaged.

Abstract: An improved miter table (20) for a circular saw table (10) having a rotating blade (12) includes an elongated guide plate (22) having a track (28) mountable to the saw table (10) and the miter table (20) includes an adjustable follower (30) for slidably engaging the track for longitudinal movement along the track (28) that provides transversely adjustable positioning of the miter table (20) with respect to the track (28) thereby to provide precise alignment of the workpiece with respect to the rotatable blade (12) during such movement.

Abstract: A field assembly for a motor includes a connecting terminal for making electrical contact with a point intermediate the ends of a field winding. A terminal board configuration provides pocket portions for engaging a turn of the winding, including the intermediate contact point, and for retaining the turn of the winding fixed relative to the assembly. The turn is brought out during a winding process and is engaged by one or more of the pocket portions. A frictional terminal is inserted into one of the pocket portions to provide frictional electrical connection to the intermediate point. The terminal boards are each configured to have a plurality of pocket portions. Pocket portions engaging and providing electrical contact with ends of the winding are arranged on terminal boards mounted on one end of the assembly. Pocket portions engaging and providing electrical contact with the intermediate point on the winding are arranged on a terminal board mounted on an opposite end of the assembly.

Abstract: A field assembly for a motor includes a connecting terminal for making electrical contact with a point intermediate the ends of a field winding. A terminal board configuration provides pocket portions for engaging a turn of the winding, including the intermediate contact point, and for retaining the turn of the winding fixed relative to the assembly. The turn is brought out during a winding process and is engaged by one or more of the pocket portions. A frictional terminal is inserted into one of the pocket portions to provide frictional electrical connection to the intermediate point. The terminal boards are each configured to have a plurality of pocket portions. Pocket portions engaging and providing electrical contact with ends of the winding are arranged on terminal boards mounted on one end of the assembly. Pocket portions engaging and provicing electrical contact with the intermediate point on the winding are arranged on a terminal board mounted on an opposite end of the assembly.

Abstract: A modular tool assembly includes a single motor unit and a plurality of toolheads. The housings for the various toolheads include different engaging structures for engaging combinations of control switches of the motor unit, thereby providing different operating characteristics to the various tools formed by engagement of the motor unit and the toolheads. A direction reversing switch of the motor unit is placed in a fixed position by some of the toolheads and is left in a controllable condition by others. An on/off switch is provided in the motor unit, as is an on/off and speed control switch. The various toolheads include engaging means for engaging one or the other of the control switches, thus providing fixed speed or variable speed, fixed direction or reversible direction, for operation of a plurality of tools utilizing a single motor unit.

Abstract: A trammel beam carrying a pair of dove-tail shaped slider blocks rotatably carried on a pair of adjustable trammel points is attached to a workpiece support base which includes a pair of crossed right angle mutually perpendicular dove-tail tracks along which the slider blocks move as the trammel beam or workpiece support base are rotated relative one another. The trammel beam is provided with means permitting it to be mounted to a router or other cutting machine so that if the workpiece support base is attached to the surface of a workpiece, relative movement between the cutting machine and the workpiece will be restricted to an elliptical path as the movement is guided by the trammel.

Abstract: A trigger control switch with speed control having a lock-on button on the side thereof is provided with a tab or protrusion extending radially outwardly of the lock pin, a slot is provided extending longitudinally of the lock barrel and a compression spring surrounding the lock pin within the lock barrel has one end portion thereof torsionally engaged with the lock barrel and the other end portion thereof engaged with the lock pin to bias the tab or protrusion out of alignment with the slot to prevent inadvertent depression of the lock pin while enabling an operator to rotate the tab or protrusion into alignment with the slot and thereafter depress the lock pin to provide lock-on effectuation.