Patents by Inventor Keith Boulanger
Keith Boulanger has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20210234481Abstract: Method and power tool for braking a motor of the power tool. One embodiment provides a method for braking a motor of a power tool. The method includes operating, using a motor controller of the power tool, the motor in accordance with a user input. The method also includes detecting, using the motor controller, a braking event of the power tool and connecting, using a braking switch, a motor braking coil to the motor to brake the motor in response to detecting the braking event of the power tool. The method further includes cooling, using a component of the motor, the motor braking coil.Type: ApplicationFiled: April 24, 2020Publication date: July 29, 2021Inventors: Keith Boulanger, Timothy R. Obermann
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Publication number: 20210170509Abstract: A reciprocating saw includes a housing, a motor, and a drive assembly. The motor is positioned within the housing and includes a stator assembly with a stator body and a rotor assembly with a motor shaft and a rotor ring that surrounds the stator body. The rotor assembly is rotatable relative to the stator assembly about a motor axis. The drive assembly is positioned within the housing and coupled to the motor. The drive assembly includes a spindle configured to reciprocate along a tool axis that is perpendicular to the motor axis.Type: ApplicationFiled: December 10, 2020Publication date: June 10, 2021Inventors: Beth E. Cholst, Troy C. Thorson, Matthew R. Bailey, Keith Boulanger
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Publication number: 20210119502Abstract: A power tool including a housing and a motor assembly positioned within the housing. The motor assembly includes a stator with winding slots that receive stator windings and a rotor. The rotor includes a rotor body with a first slot positioned a first distance from a center of the rotor body, a second slot positioned a second distance from the center of the rotor body, and a third slot positioned a third distance from the center of the rotor body. The first slot, the second slot, and the third slot are curved about a common center. The rotor further includes a first magnet positioned within the first slot, a second magnet positioned within the second slot, and a third magnet positioned within the third slot.Type: ApplicationFiled: October 21, 2020Publication date: April 22, 2021Inventor: Keith Boulanger
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Publication number: 20210067018Abstract: A brushless electric motor includes a stator and a rotor. The stator includes a core defining a plurality of stator teeth, a first end cap proximate a first end of the core, a second end cap proximate a second end of the core, and a plurality of coils disposed on the respective stator teeth. The stator also includes a plurality of coil contact plates overmolded within one of the first end cap or the second end cap that short-circuit diagonally opposite coils on the stator.Type: ApplicationFiled: November 11, 2020Publication date: March 4, 2021Inventors: Andrew T. Beyerl, Keith Boulanger, Matthew R. Bailey, Carl B. Westerby
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Patent number: 10931167Abstract: A power tool including a housing, a controller within the housing, and a brushless motor within the housing and controlled by the controller. The brushless motor includes a stator assembly, a rotor core, and a rotor enclosure. The stator assembly includes a stator core having stator laminations defining a stack length in an axial direction. The rotor enclosure includes a front end cap provided on a first side of the rotor core having a front bearing holder; and a rear end cap provided on a second side of the rotor core. The brushless motor further includes a fan, a front bearing, and a rear bearing. The front bearing holder and the fan define a bearing-to-fan length in the axial direction between axial ends of the front bearing holder and the fan, wherein a difference between the bearing-to-fan length and the stack length is less than 23.5 millimeters.Type: GrantFiled: May 20, 2020Date of Patent: February 23, 2021Assignee: Milwaukee Electric Tool CorporationInventors: Andrew T. Beyerl, Keith Boulanger, Alex Huber, William A. Elger, Jeffrey M. Wackwitz
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Publication number: 20200412202Abstract: A power tool including a housing, a controller within the housing, and a brushless motor within the housing and controlled by the controller. The brushless motor including a stator assembly including a stator core having stator laminations with an annular portion and inwardly extending stator teeth. The stator assembly defines a stator envelope in an axial direction extending between axial ends of stator end caps of the stator assembly. The brushless motor further includes a rotor assembly including a rotor core having rotor laminations and defining a central aperture that extends in the axial direction and that receives a shaft, and a position sensor board assembly including position sensors and configured to provide position information of the rotor core to the controller. The rotor assembly and the position sensor board assembly are provided at least partially within the stator envelope.Type: ApplicationFiled: September 14, 2020Publication date: December 31, 2020Inventors: Andrew T. Beyerl, Keith Boulanger, Alex Huber, William A. Elger, Jeffrey M. Wackwitz
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Patent number: 10848042Abstract: A brushless electric motor includes a stator and a rotor. The stator includes a core defining a plurality of stator teeth, a first end cap proximate a first end of the core, a second end cap proximate a second end of the core, and a plurality of coils disposed on the respective stator teeth. The stator also includes a plurality of coil contact plates overmolded within one of the first end cap or the second end cap that short-circuit diagonally opposite coils on the stator.Type: GrantFiled: February 12, 2018Date of Patent: November 24, 2020Assignee: Milwaukee Electric Tool CorporationInventors: Andrew T. Beyerl, Keith Boulanger, Matthew R. Bailey, Carl B. Westerby
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Publication number: 20200280243Abstract: A power tool including a housing, a controller within the housing, and a brushless motor within the housing and controlled by the controller. The brushless motor includes a stator assembly, a rotor core, and a rotor enclosure. The stator assembly includes a stator core having stator laminations defining a stack length in an axial direction. The rotor enclosure includes a front end cap provided on a first side of the rotor core having a front bearing holder; and a rear end cap provided on a second side of the rotor core. The brushless motor further includes a fan, a front bearing, and a rear bearing. The front bearing holder and the fan define a bearing-to-fan length in the axial direction between axial ends of the front bearing holder and the fan, wherein a difference between the bearing-to-fan length and the stack length is less than 23.5 millimeters.Type: ApplicationFiled: May 20, 2020Publication date: September 3, 2020Inventors: Andrew T. Beyerl, Keith Boulanger, Alex Huber, William A. Elger, Jeffrey M. Wackwitz
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Patent number: 10673305Abstract: A power tool including a housing, a controller within the housing, and a brushless motor within the housing and controlled by the controller. The brushless motor including a stator assembly including a stator core having stator laminations with an annular portion and inwardly extending stator teeth. The stator assembly defines a stator envelope in an axial direction extending between axial ends of stator end caps of the stator assembly. The brushless motor further includes a rotor assembly including a rotor core having rotor laminations and defining a central aperture that extends in the axial direction and that receives a shaft, and a position sensor board assembly including position sensors and configured to provide position information of the rotor core to the controller. The rotor assembly and the position sensor board assembly are provided at least partially within the stator envelope.Type: GrantFiled: July 30, 2019Date of Patent: June 2, 2020Assignee: Milwaukee Electric Tool CorporationInventors: Andrew T. Beyerl, Keith Boulanger, Alex Huber, William A. Elger, Jeffrey M. Wackwitz
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Publication number: 20200162007Abstract: An electrical combination, a motorized device system, a motor assembly, a battery pack, and operating methods. The combination may include an electrical device including a device housing, a load supported by the device housing, the load being operable to output at least about 1800 watts (W), and a device terminal electrically connected to the load; a battery pack including a pack housing, battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 20 volts, and a pack terminal electrically connectable to the device terminal to transfer current between the battery pack and the electrical device; and a controller operable to control the transfer of current.Type: ApplicationFiled: January 24, 2020Publication date: May 21, 2020Inventors: Samuel Sheeks, Keith Boulanger, Andrew T. Beyerl, Timothy R. Obermann, Carl B. Westerby, Matthew J. Mergener, Cameron R. Schulz, Kyle C. Fassbender, Matthew R. Polakowski
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Publication number: 20200127593Abstract: An electrical combination, a tool system, an electric motor, a battery pack, and operating and manufacturing methods. The tool may include a tool housing, a motor supported by the tool housing, the motor having a nominal outer diameter of up to about 80 millimeters (mm), the motor being operable to output at least about 2760 watts (W), and a tool terminal electrically connected to the motor; a battery pack including a pack housing defining a volume of the battery pack, the volume being up to about 5.2×106 cubic millimeters (mm3), battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 80 volts (V), and a pack terminal electrically connectable to the tool terminal to transfer current between the battery pack and the tool; and a controller operable to control the transfer of current.Type: ApplicationFiled: December 2, 2019Publication date: April 23, 2020Inventors: Samuel Sheeks, Jeffrey M. Brozek, Keith Boulanger, Andrew T. Beyerl, Timothy R. Obermann, Alex Huber, Samantha L. Billetdeaux, Lance D. Lamont, Matthew J. Mergener
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Publication number: 20200106380Abstract: An electrical combination, a tool system, an electric motor, a battery pack, and operating and manufacturing methods. The tool may include a tool housing, a motor supported by the tool housing, the motor having a nominal outer diameter of up to about 80 millimeters (mm), the motor being operable to output at least about 2760 watts (W), and a tool terminal electrically connected to the motor; a battery pack including a pack housing defining a volume of the battery pack, the volume being up to about 5.2×106 cubic millimeters (mm3), battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 80 volts (V), and a pack terminal electrically connectable to the tool terminal to transfer current between the battery pack and the tool; and a controller operable to control the transfer of current.Type: ApplicationFiled: December 2, 2019Publication date: April 2, 2020Inventors: Samuel Sheeks, Jeffrey M. Brozek, Keith Boulanger, Andrew T. Beyerl, Timothy R. Obermann, Alex Huber, Samantha L. Billetdeaux, Lance D. Lamont, Matthew J. Mergener
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Publication number: 20190356197Abstract: A power tool including a housing, a controller within the housing, and a brushless motor within the housing and controlled by the controller. The brushless motor including a stator assembly including a stator core having stator laminations with an annular portion and inwardly extending stator teeth. The stator assembly defines a stator envelope in an axial direction extending between axial ends of stator end caps of the stator assembly. The brushless motor further includes a rotor assembly including a rotor core having rotor laminations and defining a central aperture that extends in the axial direction and that receives a shaft, and a position sensor board assembly including position sensors and configured to provide position information of the rotor core to the controller. The rotor assembly and the position sensor board assembly are provided at least partially within the stator envelope.Type: ApplicationFiled: July 30, 2019Publication date: November 21, 2019Inventors: Andrew T. Beyerl, Keith Boulanger, Alex Huber, William A. Elger, Jeffrey M. Wackwitz
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Patent number: 10432065Abstract: A brushless direct current motor for a power tool. The motor includes a stator assembly including a stator core having stator laminations with an annular portion and inwardly extending stator teeth. The motor also includes a rotor assembly including a rotor core having rotor laminations and defining a central aperture that receives an output shaft. The rotor assembly also includes a rotor end cap on a first side of the rotor core having a bearing holder and defining a channel, wherein the channel is open on a side of the rotor end cap facing the rotor core. The motor further includes a bearing provided in the bearing holder that couples the rotor end cap to the output shaft and a position sensor board assembly provided in the channel of the rotor end cap and configured to provide position information of the rotor core to a motor controller.Type: GrantFiled: January 8, 2019Date of Patent: October 1, 2019Assignee: MILWAUKEE ELECTRIC TOOL CORPORATIONInventors: Andrew T. Beyerl, Keith Boulanger, Alex Huber, William A. Elger, Jeffrey M. Wackwitz
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Publication number: 20190140516Abstract: A brushless direct current motor for a power tool. The motor includes a stator assembly including a stator core having stator laminations with an annular portion and inwardly extending stator teeth. The motor also includes a rotor assembly including a rotor core having rotor laminations and defining a central aperture that receives an output shaft. The rotor assembly also includes a rotor end cap on a first side of the rotor core having a bearing holder and defining a channel, wherein the channel is open on a side of the rotor end cap facing the rotor core. The motor further includes a bearing provided in the bearing holder that couples the rotor end cap to the output shaft and a position sensor board assembly provided in the channel of the rotor end cap and configured to provide position information of the rotor core to a motor controller.Type: ApplicationFiled: January 8, 2019Publication date: May 9, 2019Inventors: Andrew T. Beyerl, Keith Boulanger, Alex Huber, William A. Elger, Jeffrey M. Wackwitz
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Patent number: 10205365Abstract: A brushless direct current motor for a power tool. The motor includes a stator assembly including a stator core having stator laminations with an annular portion and inwardly extending stator teeth. The motor also includes a rotor assembly including a rotor core having rotor laminations and defining a central aperture that receives an output shaft. The rotor assembly also includes a rotor end cap on a first side of the rotor core having a bearing holder and defining a channel, wherein the channel is open on a side of the rotor end cap facing the rotor core. The motor further includes a bearing provided in the bearing holder that couples the rotor end cap to the output shaft and a position sensor board assembly provided in the channel of the rotor end cap and configured to provide position information of the rotor core to a motor controller.Type: GrantFiled: March 30, 2017Date of Patent: February 12, 2019Assignee: MILWAUKEE ELECTRIC TOOL CORPORATIONInventors: Andrew T. Beyerl, Keith Boulanger, Alex Huber, William A. Elger, Jeffrey M. Wackwitz
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Publication number: 20190044110Abstract: An electrical combination, a motorized device system, a motor assembly, a battery pack, and operating methods. The combination may include an electrical device including a device housing, a load supported by the device housing, the load being operable to output at least about 1800 watts (W), and a device terminal electrically connected to the load; a battery pack including a pack housing, battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 20 volts, and a pack terminal electrically connectable to the device terminal to transfer current between the battery pack and the electrical device; and a controller operable to control the transfer of current.Type: ApplicationFiled: July 25, 2018Publication date: February 7, 2019Inventors: Samuel Sheeks, Keith Boulanger, Andrew T. Beyerl, Timothy R. Obermann, Carl B. Westerby, Matthew J. Mergener, Cameron R. Schulz, Kyle C. Fassbender, Matthew R. Polakowski
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Publication number: 20190006980Abstract: An electrical combination, a tool system, an electric motor, a battery pack, and operating and manufacturing methods. The tool may include a tool housing, a motor supported by the tool housing, the motor having a nominal outer diameter of up to about 80 millimeters (mm), the motor being operable to output at least about 2760 watts (W), and a tool terminal electrically connected to the motor; a battery pack including a pack housing defining a volume of the battery pack, the volume being up to about 5.2×106 cubic millimeters (mm3), battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 80 volts (V), and a pack terminal electrically connectable to the tool terminal to transfer current between the battery pack and the tool; and a controller operable to control the transfer of current.Type: ApplicationFiled: July 2, 2018Publication date: January 3, 2019Inventors: Samuel Sheeks, Jeffrey M. Brozek, Keith Boulanger, Andrew T. Beyerl, Timothy R. Obermann, Alex Huber, Samantha L. Billetdeaux, Lance D. Lamont, Matthew J. Mergener
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Publication number: 20180262092Abstract: A brushless electric motor includes a stator and a rotor. The stator includes a core defining a plurality of stator teeth, a first end cap proximate a first end of the core, a second end cap proximate a second end of the core, and a plurality of coils disposed on the respective stator teeth. The stator also includes a plurality of coil contact plates overmolded within one of the first end cap or the second end cap that short-circuit diagonally opposite coils on the stator.Type: ApplicationFiled: February 12, 2018Publication date: September 13, 2018Inventors: Andrew T. Beyerl, Keith Boulanger, Matthew R. Bailey, Carl B. Westerby
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Publication number: 20170288499Abstract: A brushless direct current motor for a power tool. The motor includes a stator assembly including a stator core having stator laminations with an annular portion and inwardly extending stator teeth. The motor also includes a rotor assembly including a rotor core having rotor laminations and defining a central aperture that receives an output shaft. The rotor assembly also includes a rotor end cap on a first side of the rotor core having a bearing holder and defining a channel, wherein the channel is open on a side of the rotor end cap facing the rotor core. The motor further includes a bearing provided in the bearing holder that couples the rotor end cap to the output shaft and a position sensor board assembly provided in the channel of the rotor end cap and configured to provide position information of the rotor core to a motor controller.Type: ApplicationFiled: March 30, 2017Publication date: October 5, 2017Inventors: Andrew T. Beyerl, Keith Boulanger, Alex Huber, William A. Elger, Jeffrey M. Wackwitz