Abstract: A power tool includes a housing and a brushless motor with a rotor and a stator assembly. The motor defines a motor envelope bounded by a rear plane at a rearmost point of the stator assembly and rotor, a front plane at a frontmost point of the stator assembly and rotor, and a generally cylindrical boundary surrounding a radially outermost portion of the stator assembly and rotor. A rotor shaft is rotatably driven by the rotor. A transmission includes an input member rotatably driven by the rotor shaft and an output member. A first bearing supporting the rotor shaft is at least partially received within the motor envelope. A second bearing supporting the rotor shaft or a component of the transmission is at least partially received within the motor envelope. A support plate supporting a component of the transmission may be at least partially received within the motor envelope.

Abstract: A power tool is provided including a tool housing; a rear tool cap separately formed from the tool housing and mounted on a rear end of the tool housing; and a motor. The motor includes a stator, a rotor shaft; a rear bearing mounted on the rotor shaft and supported by a central bearing pocket of the rear tool cap, and a rotor. The rear tool cap further comprises a constraining member extending from the radial body, where the constraining member is configured to engage a portion of the stator to securely locate the stator within the tool housing and pilot the rear bearing relative to the stator independently of the tool housing.

Abstract: A power tool is provided with a tool housing, a support plate provided within the tool housing, a rear tool cap mounted on a rear end of the tool housing, and a brushless direct-current (BLDC) motor received within the housing. The motor includes a stator assembly having a stator core and stator windings, a front motor bearing supported by the support plate, a rear motor bearing supported by the rear tool cap, and a rotor including a rotor core and a magnet ring mounted around the rotor core. The rotor core defines an annular recess within which at portion of the front bearing and a portion of the support plate are located such that the a radial plane intersects the front bearing, the magnet ring, and the stator core.

Abstract: A brushless direct-current (BLDC) motor is provided with a stator assembly including a stator core and stator windings wound around stator teeth, a rotor shaft extending along a longitudinal axis, and a rotor including a rotor core mounted on the rotor shaft supporting at least one permanent magnet. A circuit board is provided including a main body and at least one leg radially projecting from the main body to support at least one magnetic sensor near the permanent magnet. The leg of the circuit board oriented along a radial plane that intersects the stator windings.

Abstract: A power tool includes a housing and a brushless motor with a rotor and a stator assembly. The motor defines a motor envelope bounded by a rear plane at a rearmost point of the stator assembly and rotor, a front plane at a frontmost point of the stator assembly and rotor, and a generally cylindrical boundary surrounding a radially outermost portion of the stator assembly and rotor. A rotor shaft is rotatably driven by the rotor. A transmission includes an input member rotatably driven by the rotor shaft and an output member. A first bearing supporting the rotor shaft is at least partially received within the motor envelope. A second bearing supporting the rotor shaft or a component of the transmission is at least partially received within the motor envelope. A support plate supporting a component of the transmission may be at least partially received within the motor envelope.

Abstract: A brushless DC (BLDC) motor is provided including a stator assembly and a rotor rotatably arranged inside the stator. The stator assembly includes a generally-cylindrical lamination stack including a stator ring and stator teeth extending radially inwardly from the stator ring towards a center bore, where the center bore is arranged to receive the rotor therein. The stator assembly further includes an end insulator disposed at an and of the lamination stack, where the end insulator includes a generally-cylindrical outer ring and teeth portions extending radially inwardly from the outer ring towards a center of the end insulator, and the outer ring and the teeth portion correspond to the stator ring and the stator teeth. Stator windings are wound around the stator teeth and the corresponding teeth portion of the end insulator.