Abstract: A power tool including a motor, light unit, and switch unit for selectively connecting the motor and light unit to a power source. A control module includes a controller coupled to a first electronic switch to control power delivery to the motor based on a position of the switch unit, and to a second electronic switch to control power delivery to the light source based on a position of the switch unit. A timer is configured to keep the light unit illuminated for a predetermined amount of time after the switch unit has been activated or deactivated. The control module also includes a boot circuit with a semiconductor switch that continues to deliver power to the controller and to the light unit when the switch unit is deactivated subsequent to being activated, to enable the light unit to remain illuminated after the switch unit has been deactivated.

Abstract: A protective redundancy circuit is provided for a power tool having an electric motor. The protective redundant subsystem is comprised of: a motor switch coupled in series with the motor; a motor control module that controls the switching operation of the motor switch; and a protective control module that monitors switching operation of the motor switch and disables the power tool when the switching operation of the motor switch fails. In the context of an AC powered tool, the switching operation of the motor switch is correlated to and synchronized to the waveform of the AC input signal. During each cycle or half cycle, the motor control module introduces a delay period before closing the motor switch and the protective control module determines the operational status of the motor switch by measuring the voltage across the motor switch during the delay period.

Abstract: A method is provided for operating a power tool having a motor powered by a battery. The method includes: delivering power from the battery to the motor in accordance with an operator input; detecting a condition of the power tool indicating a shutdown of the power is imminent; and fading the power delivered from the battery to the motor, in response to the detected condition, through the use of a controller residing in the power tool.

Abstract: A protective redundancy circuit is provided for a power tool having an electric motor. The protective redundant subsystem is comprised of: a motor switch coupled in series with the motor; a motor control module that controls the switching operation of the motor switch; and a protective control module that monitors switching operation of the motor switch and disables the power tool when the switching operation of the motor switch fails. In the context of an AC powered tool, the switching operation of the motor switch is correlated to and synchronized to the waveform of the AC input signal. During each cycle or half cycle, the motor control module introduces a delay period before closing the motor switch and the protective control module determines the operational status of the motor switch by measuring the voltage across the motor switch during the delay period.

Abstract: A method is provided for operating a power tool having a motor powered by a battery. The method includes: delivering power from the battery to the motor in accordance with an operator input; detecting a condition of the power tool indicating a shutdown of the power is imminent; and fading the power delivered from the battery to the motor, in response to the detected condition, through the use of a controller residing in the power tool.

Abstract: A power tool including a motor, an input unit such as a variable-speed trigger switch, and a controller is provided. The controller controls the speed of the motor as a function of the input level indicated by the electrical signal from the input unit. The function is a first expression within a first predetermined range of the input level and a second expression within a second predetermined range of the input level, where the second expression corresponds to a polynomial of a second degree or higher and is different from the first expression.

Abstract: A power tool including a motor, light unit, and switch unit for selectively connecting the motor and light unit to a power source. A control module includes a controller coupled to a first electronic switch to control power delivery to the motor based on a position of the switch unit, and to a second electronic switch to control power delivery to the light source based on a position of the switch unit. A timer is configured to keep the light unit illuminated for a predetermined amount of time after the switch unit has been activated or deactivated. The control module also includes a boot circuit with a semiconductor switch that continues to deliver power to the controller and to the light unit when the switch unit is deactivated subsequent to being activated, to enable the light unit to remain illuminated after the switch unit has been deactivated.

Abstract: A power tool including a motor, an input unit such as a variable-speed trigger switch, and a controller is provided. The controller controls the speed of the motor as a function of the input level indicated by the electrical signal from the input unit.

Abstract: A method is provided for operating a power tool having a motor powered by a battery. The method includes: delivering power from the battery to the motor in accordance with an operator input; detecting a condition of the power tool indicating a shutdown of the power is imminent; and fading the power delivered from the battery to the motor, in response to the detected condition, through the use of a controller residing in the power tool.

Abstract: A method and apparatus for controlling a plurality of different motors used in a corresponding plurality of power tool applications requiring different operational characteristics. In one implementation a method involves the use of a single universal control module to store a generic, non-application-specific control algorithm. The generic, non-application-specific control algorithm has at least one programmable constant. The programmable constant is selected to transform the generic, non-application-specific control algorithm into an application-specific control algorithm. The programmable constant represents a function parameter relating to a specific functionality of a specific, selected motor used in a specific, selected motor application to implement a phase control over the specific, selected motor.

Abstract: A protective redundancy circuit is provided for a power tool having an electric motor. The protective redundant subsystem is comprised of: a motor switch coupled in series with the motor; a motor control module that controls the switching operation of the motor switch; and a protective control module that monitors switching operation of the motor switch and disables the power tool when the switching operation of the motor switch fails. In the context of an AC powered tool, the switching operation of the motor switch is correlated to and synchronized to the waveform of the AC input signal. During each cycle or half cycle, the motor control module introduces a delay period before closing the motor switch and the protective control module determines the operational status of the motor switch by measuring the voltage across the motor switch during the delay period.

Abstract: A method for controlling the operation of a motor utilizing a generic motor control module. The method includes sampling at least one motor operating criterion during operation of the motor and executing a generic control algorithm at a predetermined periodic interval. Execution of the algorithm provides a firing angle, duty cycle, or other suitable control function solution for an electronic valve for each periodic interval, thereby controlling the behavior of the motor. Additionally, the method includes firing the electronic valve at the calculated timing during each periodic interval such that the motor functions in accordance with desired motor operational parameters.

Abstract: A motor control module designed to control operation of a plurality of different motors in a plurality of different tools a power tool uses an electronic clutch in the module in conjunction with a mechanical clutch in the tool to protect the tool against an overload event. The module is adapted to implement methods to provide aural and/or tactile feedback to a tool user as a warning of an impending or current fault condition in the tool. The module can prevent power from inadvertently turning on either after an overload event has cleared with the tool plugged in and its power switch on, or after plugging in the tool within the power switch on. The control module is adapted to provide torque control for the power tool, to estimate tool motor temperature and to inform a tool user when a servicing need in the tool is required.

Abstract: A method for controlling the operation of a motor utilizing a generic motor control module. The method includes sampling at least one motor operating criterion during operation of the motor and executing a generic control algorithm at a predetermined periodic interval. Execution of the algorithm provides a firing angle, duty cycle, or other suitable control function solution for an electronic valve for each periodic interval, thereby controlling the behavior of the motor. Additionally, the method includes firing the electronic valve at the calculated timing during each periodic interval such that the motor functions in accordance with desired motor operational parameters.

Abstract: A motor control module designed to control operation of a plurality of different motors in a plurality of different tools a power tool uses an electronic clutch in the module in conjunction with a mechanical clutch in the tool to protect the tool against an overload event. The module is adapted to implement methods to provide aural and/or tactile feedback to a tool user as a warning of an impending or current fault condition in the tool. The module can prevent power from inadvertently turning on either after an overload event has cleared with the tool plugged in and its power switch on, or after plugging in the tool within the power switch on. The control module is adapted to provide torque control for the power tool, to estimate tool motor temperature and to inform a tool user when a servicing need in the tool is required.

Abstract: A motor control module designed to control operation of a plurality of different motors in a plurality of different tools a power tool uses an electronic clutch in the module in conjunction with a mechanical clutch in the tool to protect the tool against an overload event. The module is adapted to implement methods to provide aural and/or tactile feedback to a tool user as a warning of an impending or current fault condition in the tool. The module can prevent power from inadvertently turning on either after an overload event has cleared with the tool plugged in and its power switch on, or after plugging in the tool within the power switch on. The control module is adapted to provide torque control for the power tool, to estimate tool motor temperature and to inform a tool user when a servicing need in the tool is required.

Abstract: A motor control module for a power tool includes a controller and a triac for controlling current to the given tool motor. The module includes a circuit within the controller for implementing a plurality of control methodologies related to synchronizing the module to the AC input signal, estimating average current flowing through the triac, compensating for amplifier offset to improve accuracy of current measurements in the module, and providing speed measurement and control for the tool motor using principles of hysteresis in a comparator of the controller. Additionally, the controller is configured to calibrate an oscillation calibration register therein.