Abstract: Thermal overload of the power tool is sensed by comparing a continually updated thermal model of the tool with a predetermined limit. The thermal model is updated in accordance with operating parameters such as motor speed and power delivered (conduction angle) and implemented using numerical integration based on a look-up table matrix. When overload is detected, power to the tool is gradually reduced, with attendant reduction in speed, followed by a cyclic or warbling increase and decrease in power to provide fluctuating low speed behavior, which may be readily recognized by the tool operator as an overload warning.