Abstract: An electric motor may include a rotor assembly including a rotor shaft. An electric motor may include a stator assembly including a plurality of stator segments arranged adjacent one another in a circumferential direction of the stator assembly, at least one stator segment including a core having a core yoke portion and a core tooth portion, an insulator at least partially covering the core and having an insulator yoke portion and an insulator tooth portion, a stator segment yoke portion formed by the core yoke portion and the insulator yoke portion, a stator segment tooth portion formed by the core tooth portion and the insulator tooth portion, and a stator winding extending about the stator segment tooth portion including a wire lead. The insulator yoke portion includes a standoff portion that defines a wire notch. The wire notch at least partially receives the wire lead.

Abstract: An electric motor includes a rotor and a stator. The stator includes a first stator segment including a first annular back portion, a first tooth extending radially inward from the first annular back portion, a first flange extending away from the first tooth, a first insulation portion at least partially covering the first annular back portion, the first tooth, and the first flange, and a first coil wound around the first tooth. The stator also includes a second stator segment separate from the first stator segment and axially coupled to the first stator segment, the second stator segment including a second annular back portion, a second tooth extending radially inward from the second annular back portion, a second flange extending away from the second tooth and toward the first flange, a second insulation portion at least partially covering the second annular back portion, the second tooth, and the second flange.

Abstract: A method of cooling an electric motor configured for use in a power tool. The electric motor has a motor shaft rotatable about a motor axis. The power tool further includes a fan assembly attachable to the motor shaft and an energy storage device coupled to the motor shaft and to the fan assembly. The method includes activating the electric motor to supply torque to the motor shaft. The method further includes rotating the motor shaft and the fan assembly about the motor axis. The fan assembly generates an airflow to cool the electric motor. Moreover, the method includes supplying torque from the electric motor to the energy storage device and deactivating the electric motor to stall rotation of the motor shaft. The fan assembly continues to rotate about the motor axis to generate the airflow after rotation of the motor shaft has ceased.

Abstract: A power tool including a battery pack interface and a consequent pole motor. The battery pack interface is configured to receive a removable and rechargeable battery pack. The consequent pole motor includes a stator including a plurality of stator teeth configured to receive a plurality of stator coils, and a rotor configured to rotate with respect to the stator. The rotor includes a first permanent magnet positioned within the rotor, a second permanent magnet positioned within the rotor, and a consequent pole located between the first permanent magnet and the second permanent magnet. The consequent pole has a length and a width. The consequent pole is made of a non-magnetic material.

Abstract: A stator includes insulation including a back insulation portion covering a back stator portion, a first tooth portion covering a first tooth, a second tooth portion covering a second tooth. A first flange portion has a first face that is in facing relationship with the back insulation portion. A second flange portion has a second face that is in facing relationship with the back insulation portion. The first face and the second face together substantially defining a boundary plane, such that a cross-sectional slot area is defined between the back insulation portion, the first tooth portion, the second tooth portion, and the boundary plane. A plurality of conductive wires are arranged in the cross-sectional slot area, the wires defining a cross-sectional winding area within the cross-sectional slot area. A ratio of the cross-sectional winding area to the cross-sectional slot area is greater than or equal to 0.45.

Abstract: An electric motor may include a rotor assembly including a rotor shaft defining a rotational axis. An electric motor may include a stator assembly including a core, an insulator at least partially covering the core, and a plurality of windings, the insulator defining one of a post that protrudes in an axial direction parallel with the rotational axis or a receptacle in which the post is receivable. An electric motor may include a bus bar assembly including a non-conductive body and a plurality of conductors configured to make an electrical connection between at least two windings of the plurality of windings, the non-conductive body including the other of the post or the receptacle, wherein the receptacle includes at least one of an aperture or a recess, and wherein the post is received within the receptacle to secure the non-conductive body to the insulator.

Abstract: A power tool may include a battery pack interface configured to receive a removable and rechargeable battery pack. A device may include an outer rotor motor including a stator including a plurality of stator teeth configured to receive a plurality of stator coils and a rotor configured to rotate around the stator. The rotor includes a first permanent magnet positioned on an inner surface of the rotor, a second permanent magnet positioned on the inner surface of the rotor, and an air slot located between the first permanent magnet and the second permanent magnet on the inner surface of the rotor. The air slot has a length and a width. The length of the air slot is greater than a length of the first permanent magnet or the second permanent magnet.

Abstract: An electric motor includes a rotor assembly including a rotor shaft, a rotor body fixedly coupled to the rotor shaft, and a plurality of magnets coupled to the rotor body. The electric motor also includes a stator assembly at least partially received within the rotor body. The stator assembly includes a stator mount including a stator support portion and a motor support portion. The stator assembly also includes a stator core assembly fixedly supported by the stator mount, the stator core assembly defining a central bore that receives the rotor shaft and the stator support portion. The electric motor also includes a bearing having an outer race and an inner race, the outer race being supported by the stator core assembly, and the inner race supporting the rotor shaft for rotation relative to the stator assembly. The stator core assembly further defines a bearing pocket adjacent to the central bore.

Abstract: An electric motor includes a rotor assembly including a rotor shaft and a stator assembly including a plurality of stator segments. Each stator segment includes a core, an insulator at least partially covering the core and including a mounting portion, and a coil winding including a wire lead. The plurality of stator segments include a first stator segment and a second stator segment adjacent the first stator segment in a circumferential direction. The electric motor also includes a printed circuit board assembly coupled to the mounting portions and configured to direct electric current to each coil winding. The printed circuit board assembly includes a plurality of peripheral slots formed at intervals about a periphery thereof. The wire leads are received into the peripheral slots and soldered to electrically connect the wire leads to the printed circuit board assembly.

Abstract: A method of manufacturing a brushless electric motor including providing a stator that includes a core defining a plurality of stator teeth, positioning a rotor within the stator, coupling a stator end cap to an end of the core, winding a plurality of coils on the plurality of stator teeth, and overmolding a plurality of coil contact plates within the stator end cap. The coil contact plates short-circuit diagonally opposite coils on the stator.

Abstract: Power tools described herein include a housing, a brushless direct current (DC) motor, a non-conductive terminal mount, and a plurality of terminals. The housing has a motor housing portion, a handle portion, and a battery pack interface. The brushless DC motor is located within the motor housing portion and has a rotor and a stator. The non-conductive terminal mount is located on an outer peripheral surface of the stator and includes an angled surface. The angled surface is not substantially parallel to a longitudinal axis of the motor. The plurality of terminals is mounted on the angled surface of the terminal mount. Each of the terminals is angled in a first direction such that the terminals are not substantially parallel to the longitudinal axis of the motor.

Abstract: A power tool includes a housing and an electric motor. The electric motor includes a rotor assembly including a rotor shaft and a stator assembly including a plurality of stator segments. Each stator segment includes a core, an insulator at least partially covering the core, and a coil winding. The insulator includes a mounting portion. The electric motor also includes a printed circuit board assembly configured to direct electric current to each coil winding, and a bus bar assembly attached to at least one of the mounting portions and configured to electrically connect the coil windings to the printed circuit board assembly. The bus bar assembly includes a molded body and a plurality of conductors. The bus bar assembly defines a bearing pocket. The electric motor further includes rotor bearing that is received into the bearing pocket and that supports the rotor shaft for rotation relative to the stator assembly.

Abstract: A motor assembly for use with a power tool includes a motor housing, a brushless electric motor disposed at least partially in the motor housing, and a PCB assembly coupled to the motor housing. The PCB assembly includes a heat sink, a power PCB coupled to a first side of the heat sink, and a position sensor PCB coupled to a second side of the heat sink opposite the first side and in facing relationship with the motor.

Abstract: A power tool including a battery pack interface configured to receive a removable and rechargeable battery pack, a motor including a rotor and a stator, the rotor operable to rotate relative to the stator, and a switching module that includes a plurality of switching devices connected between the battery pack interface and the motor. The power tool further includes a controller including a processor and a memory. The controller is configured to receive a signal from an external device, control the switching module to provide a high frequency current signal from battery pack to the motor in response to receiving the signal, the motor configured to emit an audible sound in response to the high frequency current signal, and control the switching module to stop providing the high frequency current signal to the motor.

Abstract: Power tools described herein include a housing, a brushless direct current (DC) motor, a non-conductive terminal mount, and a plurality of terminals. The housing has a motor housing portion, a handle portion, and a battery pack interface. The brushless DC motor is located within the motor housing portion and has a rotor and a stator. The non-conductive terminal mount is located on an outer peripheral surface of the stator and includes an angled surface. The angled surface is not substantially parallel to a longitudinal axis of the motor. The plurality of terminals is mounted on the angled surface of the terminal mount. Each of the terminals is angled in a first direction such that the terminals are not substantially parallel to the longitudinal axis of the motor.

Abstract: A method of cooling an electric motor configured for use in a power tool. The electric motor has a motor shaft rotatable about a motor axis. The power tool further includes a fan assembly attachable to the motor shaft and an energy storage device coupled to the motor shaft and to the fan assembly. The method includes activating the electric motor to supply torque to the motor shaft. The method further includes rotating the motor shaft and the fan assembly about the motor axis. The fan assembly generates an airflow to cool the electric motor. Moreover, the method includes supplying torque from the electric motor to the energy storage device and deactivating the electric motor to stall rotation of the motor shaft. The fan assembly continues to rotate about the motor axis to generate the airflow after rotation of the motor shaft has ceased.

Abstract: A power tool includes a motor having a motor shaft that rotates about a motor axis in a first rotational direction. The power tool also includes a fan assembly attachable to the motor shaft for rotation in the first rotational direction. The fan assembly includes a fan body, a bearing having a race that rotates with the fan body, and a flywheel rotatably affixed to the fan body. The race is freely rotatable relative to the motor shaft in the first rotational direction, and fixed against rotation relative to the motor shaft in a second rotational direction opposite the first rotational direction. The flywheel has a central portion that defines a central bore, and the race is received into the central bore and rotatably affixed to the flywheel.

Abstract: A stator includes insulation including a back insulation portion covering a back stator portion, a first tooth portion covering a first tooth, a second tooth portion covering a second tooth. A first flange portion has a first face that is in facing relationship with the back insulation portion. A second flange portion has a second face that is in facing relationship with the back insulation portion. The first face and the second face together substantially defining a boundary plane, such that a cross-sectional slot area is defined between the back insulation portion, the first tooth portion, the second tooth portion, and the boundary plane. A plurality of conductive wires are arranged in the cross-sectional slot area, the wires defining a cross-sectional winding area within the cross-sectional slot area. A ratio of the cross-sectional winding area to the cross-sectional slot area is greater than or equal to 0.45.

Abstract: A power tool includes a housing and an electric motor. The electric motor includes a rotor assembly including a rotor shaft and a stator assembly including a plurality of stator segments. Each stator segment includes a core, an insulator at least partially covering the core, and a coil winding. The insulator includes a mounting portion. The electric motor also includes a printed circuit board assembly configured to direct electric current to each coil winding, and a bus bar assembly attached to at least one of the mounting portions and configured to electrically connect the coil windings to the printed circuit board assembly. The bus bar assembly includes a molded body and a plurality of conductors. The bus bar assembly defines a bearing pocket. The electric motor further includes rotor bearing that is received into the bearing pocket and that supports the rotor shaft for rotation relative to the stator assembly.

Abstract: Power tools described herein include a housing, a brushless direct current (DC) motor, a non-conductive terminal mount, and a plurality of terminals. The housing has a motor housing portion, a handle portion, and a battery pack interface. The brushless DC motor is located within the motor housing portion and has a rotor and a stator. The non-conductive terminal mount is located on an outer peripheral surface of the stator and includes an angled surface. The angled surface is not substantially parallel to a longitudinal axis of the motor. The plurality of terminals is mounted on the angled surface of the terminal mount. Each of the terminals is angled in a first direction such that the terminals are not substantially parallel to the longitudinal axis of the motor.