Abstract: An aspect of the present disclosure is drawn to an electronic switch module including: a housing having a chute; a plunger member moveably mounted within the chute so as to be able to move along a first axis with a first velocity; a magnet member disposed within the housing; a Hall sensor disposed within the housing; and a displacement mechanism disposed within the housing and operable to displace the magnet member along a second axis with a second velocity by a distance away from the Hall sensor, wherein the first velocity is greater than the second velocity, and wherein the Hall sensor is operable to output a signal associated with a first location of the plunger member along the first axis based on a second location of the magnet member along the second axis.

Abstract: A tool is provided including a motor, a power switch circuit disposed between a power source and the motor, and a control unit that controls the power switch circuit to drive the motor. The control unit is configured to apply a current clip threshold to a current passing through a bus line located between the power source and the power switch circuit to maintain a peak current of the bus line at approximately the current clip threshold. The control unit is further configured to variably control the current clip threshold based on the current passing through the bus line.

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 holder unit for a power tool is provided including a housing having a plurality of walls defining an open end, the housing being sized to receive an auxiliary wireless device therein through the open end. The housing is detachably mounted to a threaded opening provided on a tool housing of the power tool.

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 aspect of the present disclosure is drawn to an electronic switch module including: a housing having a chute; a plunger member moveably mounted within the chute so as to be able to move along a first axis with a first velocity; a magnet member disposed within the housing; a Hall sensor disposed within the housing; and a displacement mechanism disposed within the housing and operable to displace the magnet member along a second axis with a second velocity by a distance away from the Hall sensor, wherein the first velocity is greater than the second velocity, and wherein the Hall sensor is operable to output a signal associated with a first location of the plunger member along the first axis based on a second location of the magnet member along the second axis.

Abstract: A power tool is provided including a gear case having a spindle, a motor case connected to a rear end of the gear case along a longitudinal axis; a handle portion extending from a rear end of the motor case along the longitudinal axis; a motor housed inside the motor case; a fan in rotational connection with the motor; at least one air intake arranged at least one of the motor case or the handle portion near the rear end of the motor case; and a power module including power switches for driving the motor and a heat sink. The power module is housed in at least one of the motor case or the handle portion near the rear end of the motor case such that rotation of the fan causes air flow to enter through the air intake and flow near the heat sink and through the motor.

Abstract: A power tool including an electric motor is provided. The tool includes a substantially disc-shaped printed circuit board (PCB), power switches mounted on the PCB; magnetic sensors mounted on the PCB facing the motor; a heat sink in thermal communication with the power switches disposed between the PCB and the electric motor; and a molded casing structurally securing the heat sink relative to the PCB. The molded casing includes a center opening, at least one first opening provided at a first radial distance from the center opening arranged to receive the magnetic sensors therein, and at least one second opening provided at a second radial distance from the center opening arranged to securely receive the heat sink therein.

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 brushless DC motor includes a stator, a rotor, and motor terminals mounted on the stator. Each motor terminal includes a planar portion extending circumferentially from the end insulator, a wire-receiving member extending from a first end of the planar portion and folded over an outer surface of the planar portion away from the center axis of the stator at an angle of less than 90 degrees, and a tab portion extending from a second end of the planar portion parallel to the center axis of the stator. A circuit board is disposed adjacent the motor including power switches mounted thereon for energizing the stator windings. Slots are formed in the circuit board to align with and securely receive the tab portions of the motor terminals, thus electrically connecting the motor terminals to the power switches.

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 including an electric motor is provided. The tool includes a substantially disc-shaped printed circuit board (PCB), power switches mounted on the PCB; magnetic sensors mounted on the PCB facing the motor; a heat sink in thermal communication with the power switches disposed between the PCB and the electric motor; and a molded casing structurally securing the heat sink relative to the PCB. The molded casing includes a center opening, at least one first opening provided at a first radial distance from the center opening arranged to receive the magnetic sensors therein, and at least one second opening provided at a second radial distance from the center opening arranged to securely receive the heat sink therein.

Abstract: An electronic module is provided for a power tool having an electric motor. The module includes a module housing having a radial portion and a cylindrical portion extending from the radial portion away from the electric motor and defining an open end, a printed circuit board (PCB) received within the module housing through the open end thereof, power switches mounted on the PCB, and magnetic sensors mounted on the PCB facing the motor substantially equidistantly from a center of the PCB. The module housing includes openings disposed in the radial portion angularly around a center of the module housing to receive the magnetic sensors therein to allow the magnetic sensors to magnetically interface with the electric motor.

Abstract: A power tool is provided including a gear case having a spindle, a motor case connected to a rear end of the gear case along a longitudinal axis; a handle portion extending from a rear end of the motor case along the longitudinal axis; a motor housed inside the motor case; a fan in rotational connection with the motor; at least one air intake arranged at least one of the motor case or the handle portion near the rear end of the motor case; and a power module including power switches for driving the motor and a heat sink. The power module is housed in at least one of the motor case or the handle portion near the rear end of the motor case such that rotation of the fan causes air flow to enter through the air intake and flow near the heat sink and through the motor.

Abstract: A brushless DC motor includes a stator, a rotor, and motor terminals mounted on the stator. Each motor terminal includes a planar portion extending circumferentially from the end insulator, a wire-receiving member extending from a first end of the planar portion and folded over an outer surface of the planar portion away from the center axis of the stator at an angle of less than 90 degrees, and a tab portion extending from a second end of the planar portion parallel to the center axis of the stator. A circuit board is disposed adjacent the motor including power switches mounted thereon for energizing the stator windings. Slots are formed in the circuit board to align with and securely receive the tab portions of the motor terminals, thus electrically connecting the motor terminals to the power switches.

Abstract: A power tool is provided including a housing, a brushless direct-current (BLDC) electric motor disposed inside the housing, power switches disposed between a power supply and the electric motor and including high-side switches and low-side switches, and a control unit configured to control a switching operation of the power switches to operate the electric motor and electronically brake the motor by simultaneously activating the high-side switches or the low-side switches to stop the rotation of the motor upon detection of a condition prompting the braking of the motor. The control unit is configured to detect the condition that prompts the braking of the electric motor, set a braking profile for braking the electric motor based on the detected condition, and execute braking of the electric motor using the braking profile.

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: An electronic module is provided for a power tool having an electric motor. The module includes a module housing having a radial portion and a cylindrical portion extending from the radial portion away from the electric motor and defining an open end, a printed circuit board (PCB) received within the module housing through the open end thereof, power switches mounted on the PCB, and magnetic sensors mounted on the PCB facing the motor substantially equidistantly from a center of the PCB. The module housing includes openings disposed in the radial portion angularly around a center of the module housing to receive the magnetic sensors therein to allow the magnetic sensors to magnetically interface with the electric motor.

Abstract: An electronic module is provided for a power tool having an electric motor. The module includes a printed circuit board (PCB) having a first surface and a second surface; first set of power switches mounted on the first surface of the PCB; second set of power switches mounted on the PCB and electrically coupled to the first power switches forming an inverter bridge circuit for driving the electric motor; a first heat sink surface-mounted on the first surface of the PCB and having a planar main body disposed over the first power switches; a module housing arranged to receive the PCB therein; and a second heat sink secured to the module housing in thermal communication with the first heat sink to transfer heat from the first power switches.

Abstract: An electronic module is provided for a power tool having an electric motor. The electronic module includes a printed circuit board (PCB) being substantially disc-shaped; power switches mounted on the PCB forming an inverter bridge circuit for driving the electric motor; a controller mounted on the PCB and configured to control a switching operation of the power switches; positional sensors mounted on the PCB substantially equidistantly from a center of the PCB within the control portion and in communication with the controller to provide positional signals related to a rotational position of the electric motor to the controller; and a module housing arranged to receive the PCB therein. The module housing includes a planar portion in parallel to the PCB and openings disposed in the planar portion angularly around a center of the module housing to receive the positional sensors therein.