Abstract: A power tool includes a housing, an output shaft having a tool axis, and a motion sensor that senses motion of the tool housing. A control circuit receives an input signal from the motion sensor, to make a first determination, based on the input signal, whether the tool is being operated in a horizontal mode or a vertical mode. The control circuit makes a second determination, based on the input signal, whether the tool axis is substantially level when the tool is being operated in the horizontal mode or the tool axis is substantially plumb when the tool is being operated in the vertical mode. An indicator receives an output signal from the control circuit that causes the indicator to indicate whether the tool axis is level when being operated in the horizontal mode or plumb when being operated in the vertical mode.

Abstract: A method is provided for operating a power tool having a motor powered by a battery. The method includes: delivering power from the battery to the motor in accordance with an operator input; detecting a condition of the power tool indicating a shutdown of the power is imminent; and fading the power delivered from the battery to the motor, in response to the detected condition, through the use of a controller residing in the power tool.

Abstract: An electronic power apparatus includes a housing, a pair of input power pins and a pair of output power pins, and power components mounted on a power circuit board and electrically connected to the input power pins and the output power pins to modulate a supply of power from the input power pins to the output power pins. A control unit of the electronic power apparatus is arranged on a control circuit board disposed at a distance from the power circuit board inside the housing. A user-actuated input unit of the electronic power apparatus includes a variable-speed actuator having a first portion at least partially arranged outside the housing to be engageable by a user and a second portion movably arranged between the power circuit board and the control circuit board.

Abstract: An electronic power apparatus includes a housing, a pair of input power pins and a pair of output power pins mounted on a power circuit board, and power components mounted on the power circuit board and electrically connected to the input power pins and the output power pins to modulate a supply of power from the input power pins to the output power pins. A control unit of the electronic power apparatus is arranged on a control circuit board disposed at a distance from the power circuit board inside the housing. The output power pins project through corresponding through-holes through the control circuit board to an outside part of the housing, the output pins having at least one side protrusion arranged to spatially support the control circuit board with respect to the power circuit board inside the housing.

Abstract: A power tool system includes a tool body with a motor having an output member that drives an accessory. The output member defines an output member axis. An end effector is coupled for rotation with the output member relative to the tool body. The end effector is configured to retain the accessory. A light source is disposed on the end effector. A consumable tool, such as a holesaw, is removably attachable to the end effector, and has an illumination opening configured to be substantially aligned with the light source. The holesaw may have a generally cylindrical side wall and a base wall that defines a central opening for receiving an arbor, an aperture spaced radially outward by a first distance for receiving a projection on an arbor and an illumination opening spaced radially a second greater distance.

Abstract: A handheld grinder comprising a housing; a grinding disk; a motor; an output shaft connected to the grinding disk and the motor to impart rotary motion thereto; and a circuit board residing in the housing and having thereon a rectifier that receives an alternating current and converts the alternating current to a direct current, a switching arrangement having a plurality of motor switches connected electrically between the rectifier and the motor and operates to deliver the direct current from the rectifier to the motor, a capacitor connected electrically between the rectifier and the switching arrangement, wherein the capacitor is coupled in parallel across the rectifier, a driver circuit interfaced with the motor switches and operable to control switching operation of the motor switches, and a power switch connected electrically between the rectifier and the driver circuit and operable to selectively energize the driver circuit and power on the grinder disk.

Abstract: A portable internal combustion engine and a charging device that generates AC power are supported on a manually movable frame. A coupling mechanism which can include a starter circuit and starting device, or a charging circuit and charging device, or both device couples a battery receptacle terminal block to the internal combustion engine. The battery receptacle can include various features to permit and retain electrical coupling between a battery pack for a cordless power tool. For example, key protrusions and corresponding recesses can be associating with latching projections. Additionally or alternatively, cooperating rails and recesses may be associated with the battery pack and receptacle, respectively. Spring loaded movable clips or resilient flexing clips can be included to act on the battery pack. An electrical cord may also be used to couple receptacle terminals to the coupling mechanism.

Abstract: A power tool system includes a first power tool having a first power tool rated voltage, a second power tool having a second power tool rated voltage that is different from the first power tool rated voltage, and a first battery pack coupleable to the first power tool and to the second power tool. The first battery pack is switchable between a first configuration having a first battery pack rated voltage that corresponds to the first power tool rated voltage such that the first battery pack enables operation of the first power tool, and a second configuration having a convertible battery pack rated voltage that corresponds to the second power tool rated voltage such that the battery pack enables operation of the second power tool.

Abstract: A power tool includes a tool body including a motor having an output member that drives an accessory. A chuck is coupled for rotation with the output member relative to the tool body and configured to retain the accessory. The chuck has a chuck body that defines at least one light pipe formed therethrough. A light source disposed on a light ring coupled to the tool body and includes at least one light. Each at least one light source aligns with each of the at least one light pipe intermittently during rotation of the chuck.

Abstract: A power tool including a motor, light unit, and switch unit for selectively connecting the motor and light unit to a power source. A control module includes a controller coupled to a first electronic switch to control power delivery to the motor based on a position of the switch unit, and to a second electronic switch to control power delivery to the light source based on a position of the switch unit. A timer is configured to keep the light unit illuminated for a predetermined amount of time after the switch unit has been activated or deactivated. The control module also includes a boot circuit with a semiconductor switch that continues to deliver power to the controller and to the light unit when the switch unit is deactivated subsequent to being activated, to enable the light unit to remain illuminated after the switch unit has been deactivated.

Abstract: A protective redundancy circuit is provided for a power tool having an electric motor. The protective redundant subsystem is comprised of: a motor switch coupled in series with the motor; a motor control module that controls the switching operation of the motor switch; and a protective control module that monitors switching operation of the motor switch and disables the power tool when the switching operation of the motor switch fails. In the context of an AC powered tool, the switching operation of the motor switch is correlated to and synchronized to the waveform of the AC input signal. During each cycle or half cycle, the motor control module introduces a delay period before closing the motor switch and the protective control module determines the operational status of the motor switch by measuring the voltage across the motor switch during the delay period.

Abstract: A handheld AC power tool is provided. The power tool is comprised generally of: a brushless DC motor; a power cord connectable to an AC power socket; a converter circuit configured to receive input power from the power cord and operable to output a DC bus voltage, a switching arrangement interposed between the electric motor and the converter circuit; a motor drive circuit interfaced with the motor switches; and a power switch operable by a user to selectively energize the motor drive circuit and thereby power on the tool. The converter circuit includes a rectifier and a capacitor electrically coupled across the rectifier, such that the capacitor has capacitance sized to produce a DC bus voltage whose magnitude from an AC power source is substantially same as magnitude of voltage from a DC power source.

Abstract: A protective redundancy circuit is provided for a power tool having an electric motor. The protective redundant subsystem is comprised of: a motor switch coupled in series with the motor; a motor control module that controls the switching operation of the motor switch; and a protective control module that monitors switching operation of the motor switch and disables the power tool when the switching operation of the motor switch fails. In the context of an AC powered tool, the switching operation of the motor switch is correlated to and synchronized to the waveform of the AC input signal. During each cycle or half cycle, the motor control module introduces a delay period before closing the motor switch and the protective control module determines the operational status of the motor switch by measuring the voltage across the motor switch during the delay period.

Abstract: A method is provided for operating a power tool having a motor powered by a battery. The method includes: delivering power from the battery to the motor in accordance with an operator input; detecting a condition of the power tool indicating a shutdown of the power is imminent; and fading the power delivered from the battery to the motor, in response to the detected condition, through the use of a controller residing in the power tool.

Abstract: A method is provided for operating a power tool having a motor powered by a battery. The method includes: delivering power from the battery to the motor in accordance with an operator input; detecting a condition of the power tool indicating a shutdown of the power is imminent; and fading the power delivered from the battery to the motor, in response to the detected condition, through the use of a controller residing in the power tool.

Abstract: A power tool includes a tool body having an output member that drives an accessory. An end effector is coupled for rotation with the output member. A light source is disposed on the end effector. A primary coil assembly is configured on the tool body and mounted concentric to the output member. The primary coil assembly includes a primary coil that is electrically connected to a power source of the power tool. A secondary coil assembly is configured on the end effector and mounted concentric to the output member. The secondary coil assembly includes a secondary coil that is electrically connected to the light source. Current flowing through the primary coil creates a magnetic field that causes current to flow through the secondary winding and power the light source.

Abstract: A handheld grinder comprising a housing; a grinding disk; a motor; an output shaft connected to the grinding disk and the motor to impart rotary motion thereto; and a circuit board residing in the housing and having thereon a rectifier that receives an alternating current and converts the alternating current to a direct current, a switching arrangement having a plurality of motor switches connected electrically between the rectifier and the motor and operates to deliver the direct current from the rectifier to the motor, a capacitor connected electrically between the rectifier and the switching arrangement, wherein the capacitor is coupled in parallel across the rectifier, a driver circuit interfaced with the motor switches and operable to control switching operation of the motor switches, and a power switch connected electrically between the rectifier and the driver circuit and operable to selectively energize the driver circuit and power on the grinder disk.

Abstract: An electronic power apparatus is provided, including a circuit board having a conductive pads and a sense pad coupled to an output signal, and an actuator having a wiper portion accommodating a conductive wiper. The wiper includes a first end arranged to engage the sense pad and a second end arranged to slidably engage at least one of the conductive pads on the circuit board. The conductive pads are arranged in a first row of conductive pads and a second row of conductive pads in parallel with and at a distance to the first row of conductive pads. An alignment of the second row of conductive pads is offset with respect to the first row of conductive pads.

Abstract: A power tool including a motor, an input unit such as a variable-speed trigger switch, and a controller is provided. The controller controls the speed of the motor as a function of the input level indicated by the electrical signal from the input unit. The function is a first expression within a first predetermined range of the input level and a second expression within a second predetermined range of the input level, where the second expression corresponds to a polynomial of a second degree or higher and is different from the first expression.

Abstract: A portable internal combustion engine and a charging device that generates AC power are supported on a manually movable frame. A coupling mechanism which can include a starter circuit and starting device, or a charging circuit and charging device, or both device couples a battery receptacle terminal block to the internal combustion engine. The battery receptacle can include various features to permit and retain electrical coupling between a battery pack for a cordless power tool. For example, key protrusions and corresponding recesses can be associating with latching projections. Additionally or alternatively, cooperating rails and recesses may be associated with the battery pack and receptacle, respectively. Spring loaded movable clips or resilient flexing clips can be included to act on the battery pack. An electrical cord may also be used to couple receptacle terminals to the coupling mechanism.