Abstract: A power tool is provided including a housing a motor supported by the housing, a sensor supported by the housing, and an electronic controller. The sensor is configured to generate sensor data indicative of an operational parameter of the power tool. The electronic controller includes an electronic processor, and a memory. The memory includes a machine learning control program for execution by the electronic processor. The electronic processor is configured to receive the sensor data, and process the sensor data, using the machine learning control program. The electronic processor is further configured to generate, using the machine learning control program, an output based on the sensor data, the output indicating a seating value associated with a fastening operation of the power tool. The electronic processor is further configured to control the motor based on the generated output.

Abstract: Kickback control methods for power tools. One power tool includes a movement sensor configured to measure an angular velocity of the housing of the power tool about the rotational axis. The power tool includes an electronic processor coupled to the switching network and the movement sensor and configured to implement kickback control of the power tool. To implement the kickback control, the electronic processor is configured to control the switching network to drive the brushless DC motor, receive measurements of the angular velocity of the housing of the power tool from the movement sensor, determine that a plurality of the measurements of the angular velocity of the housing of the power tool exceed a rotation speed threshold, and control the switching network to cease driving of the brushless DC motor in response to determining that the plurality of the measurements of the angular velocity exceed the rotation speed threshold.

Abstract: A tool attachment includes a first end configured to engage a rotary impact tool, a second end disposed distally from the first end and configured to engage a workpiece, a first concentric body that is coupled to and rotated by the first end, and a second concentric body that is coupled to the second end and rotated by the first concentric body. The second concentric body and the first concentric body are coupled together. The first concentric body rotates relative to the second concentric body to limit the amount of torque delivered from the rotary impact tool to the workpiece.

Abstract: Power tool methods and systems are provided for aligning a power tool to implement an angled cut in a workpiece. The power tool includes a first distance sensor and a second distance sensor. The power tool measures a first distance to the workpiece with the first distance sensor and a second distance to the workpiece with the second distance sensor. The power tool calculates an angle between the power tool and the workpiece based on the first and second distances, and indicates the angle via an angle output indicator of the power tool. The power tool may measure an angle between the power tool and the workpiece using a proximate edge and a distal edge of the workpiece, and indicate whether the power tool maintains a correct angle as it traverses a cut through the workpiece from the proximate edge to the distal edge.

Abstract: Systems and methods for evaluating a crimping application. A power tool includes a pair of jaws configured to crimp a workpiece, a piston cylinder configured to actuate at least one of the pair of jaws, and a pressure sensor configured to provide pressure signals associated with a crimping application. The power tool also includes an electronic processor connected to the pressure sensor. The electronic processor is configured to monitor, while performing the crimping application, a pressure applied by the piston cylinder, construct a pressure curve indicative of a change in the pressure applied during the crimping application, process the pressure curve into a vector indicative of one or more features, evaluate the crimping application based on the vector, and provide an output indicative of the evaluation.

Abstract: A power tool device (102) is controlled to emit sounds that can identify the power tool device and/or be used to encode data for acoustic data transmission. Modulating the switching frequency of electronic components (370) (e.g., transistors, semiconductor switched devices) of the power tool device (102) can create an acoustic signature detectable by a microphone-equipped device (104), such as a cell phone, tablet, security camera, or the like. In this way, power tool identification and/or acoustic data transmission can be realized with existing power tool device circuitry and hardware components.

Abstract: A power tool including a housing, a motor, a first sensing circuit configured to detect a battery pack voltage of a battery pack connected to a battery pack interface, a second sensing circuit configured to detect a current from the battery pack, and a controller. The controller is configured to receive a first signal from the first sensing circuit related to a first measurement of battery pack voltage, receive a second signal from the second sensing circuit related to the current from the battery pack, receive a third signal from the first sensing circuit related to a second measurement of battery pack voltage, and control the motor by adjusting motor control parameters based on the first measurement of battery pack voltage, the second measurement of battery pack voltage, and the current from the battery pack.

Abstract: Data are optically transmitted from a power tool device, such as a power tool, a power tool battery charger, power tool pack adapter, and/or a battery pack. The data are stored in a memory of the power tool device and are encoded as optical signal data to provide an encoded representation of the stored data. An optical transmitter (e.g., a light emitting diode or a flat panel display) transmits the optical signal data, which are detected or otherwise received by an optical receiver device, which may include a camera or other photodetector. The optical signal data may include light signals generated by an LED, where the data are encoded using an encoding scheme that modulates one or more characteristics (e.g., amplitude, wavelength, color) of the generated light signals. The optical signal data may also include images (e.g., barcodes, QR codes) or characters.

Abstract: A stand-alone motor unit for use with a piece of power equipment includes a housing and a flange coupled to the housing on a first side thereof. A plurality of apertures through the flange defines a first bolt pattern that matches an identical, second bolt pattern defined in the piece of power equipment. An electric motor has a power output of at least about 2760 W. The motor includes a stator having a nominal outer diameter of up to about 80 mm and a rotor supported for rotation within the stator. A power take-off shaft receives torque from the rotor and protrudes from one of the flange or a second side of the housing. A controller is positioned within the housing and electrically connected to the motor. A battery pack for powering the motor has battery cells having a nominal voltage of up to about 80 V.

Abstract: A power tool including a motor configured to produce an output, and a sensor configured to measure an acceleration of the power tool along at least one of three spatial axes and generate an output signal related to the acceleration. The power tool further including a controller configured to receive the output signal related to the acceleration of the power tool from the sensor, compare the acceleration of the power tool to a free-fall acceleration threshold, initiate a timer when the acceleration of the power tool corresponds to the free-fall acceleration threshold, compare the timer to a free-fall timer threshold, and stop the motor from producing the output when the timer is greater than or equal to the free-fall timer threshold.

Abstract: A method of controlling a rotary impact tool includes activating a motor to provide torque to a drive assembly, providing rotational impacts to a torque stick coupled to an anvil of the drive assembly in response to a reaction torque on the drive assembly exceeding a threshold value, and sensing a position of the anvil with a position sensor. The position sensor transmits a first signal indicative of the anvil rotating in a first direction and a second signal indicative of the anvil rotating in a second direction, where the second direction is a rebound angle of the anvil. The method further includes calculating a torque transferred from the torque stick to a workpiece by multiplying the rebound angle by a torsional stiffness value of the torque stick and deactivating the motor in response to the torque exerted on the workpiece being substantially equal to a torque limit.

Abstract: A power tool including a housing, a brushless direct current (DC) motor, an impact mechanism including a hammer and an anvil, an output drive device, a position sensor, and a controller. The position sensor is adjacent to a relief feature, which may be a recessed relief feature or a raised relief feature, and is configured to generate an output signal indicative of a position of the anvil. The controller is configured to calculate a drive angle based on the determined position of the anvil, and control the brushless DC motor based on the drive angle of the anvil.

Abstract: A multi-size tool bit holder includes a first sleeve with a first bit holding bore extending along an axis and a first accommodating bore extending through a sidewall of the first bit holding bore, a second sleeve coupled for co-rotation with the first sleeve and movable relative to the first sleeve between a first position and a second position, the second sleeve including a second bit holding bore extending along the axis and a second accommodating bore extending through a sidewall of the second bit holding bore, and a retaining element. The retaining element has a first securing position in which the retaining element extends through the first and second accommodating bores when the second sleeve is in the first position and into a groove in a bit shank to axially secure the bit shank within the second sleeve.

Abstract: Systems and methods for evaluating a crimping application. A power tool includes a pair of jaws configured to crimp a workpiece, a piston cylinder configured to actuate at least one of the pair of jaws, and a pressure sensor configured to provide pressure signals associated with a crimping application. The power tool also includes an electronic processor connected to the pressure sensor. The electronic processor is configured to monitor, while performing the crimping application, a pressure applied by the piston cylinder, construct a pressure curve indicative of a change in the pressure applied during the crimping application, process the pressure curve into a vector indicative of one or more features, evaluate the crimping application based on the vector, and provide an output indicative of the evaluation.

Abstract: Power tool methods and systems are provided for aligning a power tool to implement an angled cut in a workpiece. The power tool includes a first distance sensor and a second distance sensor. The power tool measures a first distance to the workpiece with the first distance sensor and a second distance to the workpiece with the second distance sensor. The power tool calculates an angle between the power tool and the workpiece based on the first and second distances, and indicates the angle via an angle output indicator of the power tool. The power tool may measure an angle between the power tool and the workpiece using a proximate edge and a distal edge of the workpiece, and indicate whether the power tool maintains a correct angle as it traverses a cut through the workpiece from the proximate edge to the distal edge.

Abstract: A power tool includes a housing and a sensor, a machine learning controller, a motor, and an electronic controller supported by the housing. The sensor is configured to generate sensor data indicative of an operational parameter of the power tool. The machine learning controller includes a first processor and a first memory and is coupled to the sensor. The machine learning controller further includes a machine learning control program configured to receive the sensor data, process the sensor data using the machine learning control program, and generate an output based on the sensor data using the machine learning control program. The electronic controller includes a second processor and a second memory and is coupled to the motor and to the machine learning controller. The electronic controller is configured to receive the output from the machine learning controller and control the motor based on the output.

Abstract: A power tool is provided including a housing a motor supported by the housing, a sensor supported by the housing, and an electronic controller. The sensor is configured to generate sensor data indicative of an operational parameter of the power tool. The electronic controller includes an electronic processor, and a memory. The memory includes a machine learning control program for execution by the electronic processor. The electronic processor is configured to receive the sensor data, and process the sensor data, using the machine learning control program. The electronic processor is further configured to generate, using the machine learning control program, an output based on the sensor data, the output indicating a seating value associated with a fastening operation of the power tool. The electronic processor is further configured to control the motor based on the generated output.

Abstract: A device, such as a power tool, configured to receive a battery pack that is operable to determine a type of battery pack that is attached to the device. When the battery pack is connected to the device, the device is configured to determine an impedance of the battery pack. Based on the determined impedance of the battery pack, the device is capable of detecting the particular type of battery pack that has been attached. In some embodiments, the device is configured to be controlled based on the type of battery pack that has been detected by the device.

Abstract: Kickback control methods for power tools. One power tool includes a movement sensor configured to measure an angular velocity of the housing of the power tool about the rotational axis. The power tool includes an electronic processor coupled to the switching network and the movement sensor and configured to implement kickback control of the power tool. To implement the kickback control, the electronic processor is configured to control the switching network to drive the brushless DC motor, receive measurements of the angular velocity of the housing of the power tool from the movement sensor, determine that a plurality of the measurements of the angular velocity of the housing of the power tool exceed a rotation speed threshold, and control the switching network to cease driving of the brushless DC motor in response to determining that the plurality of the measurements of the angular velocity exceed the rotation speed threshold.

Abstract: A power tool battery charger includes a housing, at least one charging circuit coupled to the housing, and an electronic controller coupled to the housing. The electronic controller is configured to receive power tool device data from a power tool device, which may be the same or another power tool battery charger, a battery pack, and/or a power tool. The power tool device data indicate various data associated with the power tool device. Charger operation data are generated by the electronic controller based on the power tool device data, and can include a charging rate, charging target, and/or time indication for when to adjust the charging rate and/or charging target of the at least one charging circuit. A machine learning or artificial intelligence controller can also be used when generating the charger operation data. The at least one charging circuit is then operated based on the charger operation data.