Abstract: A power tool system includes a power tool having a tool housing. The tool housing includes a battery pack receptacle having a set of tool terminals. A brushless motor includes an output shaft operably coupled to drive a tool element, a stator having an outer diameter of approximately 60 mm to approximately 80 mm, and a stack length of approximately 75% to approximately 125% of the outer diameter of the stator. A controller is operably connected to the set of tool terminals and to the brushless motor to control power delivery to the brushless motor. A battery pack includes a battery pack housing connectable to the battery pack receptacle on the tool housing and a set of battery cells. The set of battery cells includes at least 15 battery cells each having a nominal voltage of approximately 3.6V and an impedance of approximately ?13 m?. A set of battery pack terminals is connectable to the set of tool terminals.

Abstract: A power tool is provided including a housing, a brushless direct-current (BLDC) motor, and a gear assembly. The motor includes a stator having an inner stator, a rotor shaft extending along a center axis and including a first bearing and a second bearing; an outer rotor, a first end cap, and a second end cap. The first end cap includes a radial back plate having a center opening in the radial back plate through which the rotor shaft extends and pins projecting around the rotor shaft and parallel to the rotor shaft. The gear assembly is mounted on the first end cap and includes planetary gears supported by the pins in engagement with the rotor shaft.

Abstract: A socket driving tool includes a housing, a motor received in the housing, a rotating output shaft supported by and rotatable relative to the housing upon rotation of the motor, a socket retainer coupled to the rotating shaft to releasably couple a socket to the rotating shaft, and a socket release actuator coupled to the housing and including a switch that does not rotate together with the rotating shaft. The switch is operable to disengage the socket retainer from the socket to allow the socket to be removed from the rotating shaft.

Abstract: A power tool is provided including a power supply interface receiving a removable battery pack, a brushless direct current (BLDC) motor including a rotor and a stator, and a multi-phase inverter bridge circuit. A controller is provided to output drive signals to the inverter bridge circuit to control flow of current from to the motor, where each drive signal is activated within each corresponding phase of the motor within a conduction band. The controller is configured to control a length of the conduction band at a variable value within a first torque range below a torque threshold and at a substantially constant value within a second torque range above the torque threshold. The torque threshold is greater than approximately 1 Newton-meters and the motor produces a maximum power output of at least approximately 1250 watts at the torque of approximately 1 Newton-meters.

Abstract: A system is provided with a set of removable battery packs and a set of power tools each including a motor, a controller, and a battery receiving portion. For each power tool, the controller is configured to identify a type of battery pack coupled to the battery receiving portion and set a conduction band associated with phases of the motor or an advance angle by which phases of the motor are shifted based on the identified type of the battery pack.

Abstract: An actuator assembly for a power tool includes an actuator with a permanent magnet. The actuator is moveable between a first position for a first mode of operation, and a second position for a second mode of operation. A first positioning member is adjacent the first position composed of a ferromagnetic material to attract the permanent magnet. A second positioning member is adjacent the second position and composed of a ferromagnetic material to attract the permanent magnet. An electromagnet may be energized to move the actuator between the first position and the second position. When the electromagnet is not energized and the actuator is in the first position, the actuator is retained in the first position. When the electromagnet is not energized and the actuator is in the second position, the actuator is retained in the second position. When the electromagnet is energized, the actuator moves between the first and second positions.

Abstract: A system is provided with a set of removable battery packs and a set of power tools each including a motor, a controller, and a battery receiving portion. For each power tool, the controller is configured to identify a type of battery pack coupled to the battery receiving portion and set a conduction band associated with phases of the motor or an advance angle by which phases of the motor are shifted based on the identified type of the battery pack.

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 system includes a power tool having a tool housing. The tool housing includes a battery pack receptacle having a set of tool terminals. A brushless motor includes an output shaft operably coupled to drive a tool element, a stator having an outer diameter of approximately 60 mm to approximately 80 mm, and a stack length of approximately 75% to approximately 125% of the outer diameter of the stator. A controller is operably connected to the set of tool terminals and to the brushless motor to control power delivery to the brushless motor. A battery pack includes a battery pack housing connectable to the battery pack receptacle on the tool housing and a set of battery cells. The set of battery cells includes at least 15 battery cells each having a nominal voltage of approximately 3.6V and an impedance of approximately ?13 m?. A set of battery pack terminals is connectable to the set of tool terminals.

Abstract: A power tool system includes a power tool having a tool housing. The tool housing includes a battery pack receptacle having a set of tool terminals. A brushless motor includes an output shaft operably coupled to drive a tool element, a stator having an outer diameter of approximately 60 mm to approximately 80 mm, and a stack length of approximately 75% to approximately 125% of the outer diameter of the stator. A controller is operably connected to the set of tool terminals and to the brushless motor to control power delivery to the brushless motor. A battery pack includes a battery pack housing connectable to the battery pack receptacle on the tool housing and a set of battery cells. The set of battery cells includes at least 15 battery cells each having a nominal voltage of approximately 3.6V and an impedance of approximately ?13 m?. A set of battery pack terminals is connectable to the set of tool terminals.

Abstract: A power tool is provided including a housing including a grip portion; and a brushless direct-current (BLDC) motor at least partially disposed within the grip portion of the housing. The motor includes a stator having a rotor core, a rotor, and front and rear bearing support structures. The stator core includes a non-segmented construction with a maximum diameter of approximately smaller than or equal to 34 mm, and a ratio of a motor size (Km) constant of the motor to a length of the motor is in the range of approximately 0.39 to 0.59 (Nmm/?W)/mm. When powered by a 20 V battery pack, a ratio of a maximum power output of the motor to a volume of the motor is at least approximately 0.0106 W/mm{circumflex over (?)}3.

Abstract: A power tool is provided including a power supply interface receiving a removable battery pack, a brushless direct current (BLDC) motor including a rotor and a stator, and a multi-phase inverter bridge circuit. A controller is provided to output drive signals to the inverter bridge circuit to control flow of current from to the motor, where each drive signal is activated within each corresponding phase of the motor within a conduction band. The controller is configured to control a length of the conduction band at a variable value within a first torque range below a torque threshold and at a substantially constant value within a second torque range above the torque threshold. The torque threshold is greater than approximately 1 Newton-meters and the motor produces a maximum power output of at least approximately 1250 watts at the torque of approximately 1 Newton-meters.

Abstract: A power tool is provided including a power supply interface receiving a medium-voltage-rated removable battery pack having a maximum rated voltage in the range of 40 to 80 volts, and a brushless direct current (BLDC) motor. The motor includes a rotor and a stator having at least three stator windings corresponding to at least three phases of the motor, the rotor being moveable by the stator when the stator windings are appropriately energized within the corresponding phases. A multi-phase inverter bridge circuit is disposed between the power supply interface and the motor, and a controller is configured to output drive signals to the inverter bridge circuit to control flow of current from the battery pack to the motor such that the motor produces a maximum power output of at least approximately 1750 watts at a torque of approximately 1.5 to 2 Newton-meters.

Abstract: A system is provided with a set of removable battery packs and a set of power tools each including a motor, a controller, and a battery receiving portion. For each power tool, the controller is configured to identify a type of battery pack coupled to the battery receiving portion and set a conduction band associated with phases of the motor or an advance angle by which phases of the motor are shifted based on the identified type of the battery pack.

Abstract: A system is provided with a set of removable battery packs and a set of power tools each including a motor, a controller, and a battery receiving portion. For each power tool, the controller is configured to identify a type of battery pack coupled to the battery receiving portion and limit a maximum amount of electric current drawn from the battery pack by the motor based on the identified type of the battery pack. The greater a ratio of an impedance of the motor to an impedance of the battery pack, the less the controller limits the maximum amount of electric current drawn from the battery pack such that for a given battery pack of the set of removable battery packs, the lower the impedance of the motor, the more current the motor draws from the given battery pack.

Abstract: A power tool is provided including a housing, a brushless direct-current (BLDC) motor, and a gear assembly. The motor includes a stator having an inner stator, a rotor shaft extending along a center axis and including a first bearing and a second bearing; an outer rotor, a first end cap, and a second end cap. The first end cap includes a radial back plate having a center opening in the radial back plate through which the rotor shaft extends and pins projecting around the rotor shaft and parallel to the rotor shaft. The gear assembly is mounted on the first end cap and includes planetary gears supported by the pins in engagement with the rotor shaft.

Abstract: A power tool is provided including a housing including a grip portion; and a brushless direct-current (BLDC) motor at least partially disposed within the grip portion of the housing. The motor includes a stator having a rotor core, a rotor, and front and rear bearing support structures. The stator core includes a non-segmented construction with a maximum diameter of approximately smaller than or equal to 34 mm, and a ratio of a motor size (Km) constant of the motor to a length of the motor is in the range of approximately 0.39 to 0.59 (Nmm/?W)/mm. When powered by a 20V battery pack, a ratio of a maximum power output of the motor to a volume of the motor is at least approximately 0.0106 W/mm{circumflex over (?)}3.

Abstract: In a loaded condition, the controller increases at least one of the conduction band or the advance angle from a baseline value up to a maximum value within a first torque range below a torque threshold to as to maintain the output speed of the motor at a linear speed-torque profile. After the at least one of the conduction band or the advance angle reaches the maximum value, the controller maintains the at least one of the conduction band or the advance angle at the maximum value within a second torque range greater than or equal to the torque threshold so as to maintain the output speed of the motor at a naturally-curved speed-torque profile.

Abstract: A power tool is provided including a power supply interface receiving a medium-voltage-rated removable battery pack having a maximum rated voltage in the range of 40 to 80 volts, and a brushless direct current (BLDC) motor. The motor includes a rotor and a stator having at least three stator windings corresponding to at least three phases of the motor, the rotor being moveable by the stator when the stator windings are appropriately energized within the corresponding phases. A multi-phase inverter bridge circuit is disposed between the power supply interface and the motor, and a controller is configured to output drive signals to the inverter bridge circuit to control flow of current from the battery pack to the motor such that the motor produces a maximum power output of at least approximately 1750 watts at a torque of approximately 1.5 to 2 Newton-meters.

Abstract: Conduction band control schemes are presented for reducing noise and/or lower harmonics in power tools. A controller in the tool is interfaced with a plurality of motor switches and, for each phase, operates to output a pulse-width modulated (PWM) signal to one or more of the motor switches to control power supplied to the electric motor. The controller is also configured to monitor a parameter indicative of the load on the motor. In response to detecting a load greater than a threshold, the controller controls power output of the motor by setting conduction band of the motor switches and the advance angle to baseline values predetermined values. In response to detecting a load less than the threshold, the controller reduces at least one of the conduction band and the advance angle to a value less than the baseline values.