Abstract: A power tool is provided including a tool housing, a brushless DC (BLDC) motor assembly disposed within the tool housing, and a power module including a printed circuit board (PCB) and power switches mounted on the PCB and electrically coupled to the motor assembly. The PCB includes a width that is greater than a diameter of the motor assembly. A mounting bracket is secured to an end of the motor assembly and includes a mating portion arranged to mate with the end of the motor assembly, mount posts extending radially-outwardly from the mating portion, and axial walls extending between outer ends of the mount posts and at least partially housing the power module to support the PCB in a substantially parallel orientation relative to the rear end of the motor assembly.

Abstract: A power tool or a mower is provided including brushless direct-current motor having an inner stator and an outer rotor. A rotor shaft extends through a stator core of the inner stator. The motor includes a first end cap disposed on a first side of the stator and supporting the rotor shaft via a front bearing and a second end cap disposed on a second side of the stator and supporting the rotor shaft via a rear bearing. The front end cap is mounted on a housing of the power tool or a deck of the mower while the rear end cap is located fully outside the housing or the deck.

Abstract: A brushless direct-current motor is provided includes an inner stator and an outer rotor. A rotor shaft extends through a stator core of the inner stator. A first end cap includes a radial back plate disposed on a first side of the stator and a front center opening through which the rotor shaft is supported via a front bearing. A second end cap includes an inner annular body extending axially inwardly and forming a rear center opening, an outer annular body, and a main body extending on a second side of the stator. The inner annular body includes a first portion that extends at least partially into an opening of the stator core and supports the rotor shaft via a rear bearing, and a second portion rearward of the first portion that received a rear end of the rotor shaft therein and houses a sensor board therein.

Abstract: A stator for a brushless DC (BLDC) motor includes a stator core having stator teeth extending radially inwardly towards a center bore, stator windings respectively wound around the stator teeth, and insulating inserts having substantially the same longitudinal length as the stator core. The insulating inserts are longitudinally received between adjacent stator windings at or near inner tips of the adjacent stator teeth to substantially seal the center bore of the stator assembly from the stator windings.

Abstract: A power tool is provided including a tool housing, a brushless DC (BLDC) motor assembly disposed within the tool housing, and a power module including a printed circuit board (PCB) and power switches mounted on the PCB and electrically coupled to the motor assembly. The PCB includes a width that is greater than a diameter of the motor assembly. A mounting bracket is secured to an end of the motor assembly and includes a mating portion arranged to mate with the end of the motor assembly, mount posts extending radially-outwardly from the mating portion, and axial walls extending between outer ends of the mount posts and at least partially housing the power module to support the PCB in a substantially parallel orientation relative to the rear end of the motor assembly.

Abstract: A brushless motor is provided including a rotor rotating around a center axis and a stator including a stator core and stator teeth radially extending from the stator core forming stator slots therebetween. Each stator tooth includes a radial main body and a tooth tip extending substantially laterally from an end of the radial main body opposite the stator core, and stator windings are wound around the stator teeth. Winding retention wedges are axially received within the slots, each winding retention wedge comprising: a first portion received within gaps formed between tooth tips of adjacent stator teeth, and a second portion received at least partially between adjacent stator windings to apply a force substantially in a range of a radially-inward direction to a lateral direction to the adjacent stator windings.

Abstract: An outer-rotor brushless direct-current (BLDC) motor is provided including a stator core having an aperture extending therethrough, a stator mount including an elongated cylindrical member projecting into the aperture of the stator core, an outer rotor, and a rotor mount including an outer rim arranged to couple to the outer rotor and an inner body supporting an outer race of a motor bearing. A piloting pin is provided including a rear portion received within the hollow portion of the elongated cylindrical member of the stator mount and a front portion received within the inner race of the motor bearing.

Abstract: A power tool is provided including a brushless DC (BLDC) motor having a stator assembly and a rotor; a substantially-cylindrical motor housing having an open end for receiving the stator assembly, a rear end, a substantially-cylindrical bearing pocket formed in the rear end to receive the rear bearing of the motor therein, and a radially-extending slot formed at or near its rear end; and a positional sensor board radially received within the slot along a central receiving axis. The positional sensor board includes a curved inner edge shaped to be positioned around the bearing pocket and includes positional sensors mounted around the curved inner edge and facing the rotor to sense a rotational position of the rotor. The curved inner edge is disposed on a side corner of the positional sensor board such that the positional sensor board is asymmetrically-shape in a direction of the receiving axis.

Abstract: A power tool is provided including a motor housing having a substantially-cylindrical main body having an open end and a rear end. A brushless DC motor is provided including a stator assembly received through the open end of the motor housing and secured within the main body of the motor housing. A motor control and power module disposed proximate the rear end of the motor housing includes a printed circuit board (PCB) on which power switch and a controller are mounted. A mounting bracket is secured to the motor housing at the rear end to support the module such that the PCB is substantially parallel to the rear end. The mounting bracket includes a mating portion projecting axially to come to contact with the motor housing around the rear end to structurally support the mounting bracket with respect to the motor housing.

Abstract: A stator for a brushless DC (BLDC) motor includes a stator core having stator teeth extending radially inwardly towards a center bore, stator windings respectively wound around the stator teeth, and insulating inserts having substantially the same longitudinal length as the stator core. The insulating inserts are longitudinally received between adjacent stator windings at or near inner tips of the adjacent stator teeth to substantially seal the center bore of the stator assembly from the stator windings.

Abstract: An outer-rotor brushless direct-current (BLDC) motor is provided including a stator core having an aperture extending therethrough, a stator mount including an elongated cylindrical member projecting into the aperture of the stator core, an outer rotor, and a rotor mount including an outer rim arranged to couple to the outer rotor and an inner body supporting an outer race of a motor bearing. A piloting pin is provided including a rear portion received within the hollow portion of the elongated cylindrical member of the stator mount and a front portion received within the inner race of the motor bearing.

Abstract: A power tool is provided including a brushless DC (BLDC) motor having a stator assembly and a rotor; a substantially-cylindrical motor housing having an open end for receiving the stator assembly, a rear end, a substantially-cylindrical bearing pocket formed in the rear end to receive the rear bearing of the motor therein, and a radially-extending slot formed at or near its rear end; and a positional sensor board radially received within the slot along a central receiving axis. The positional sensor board includes a curved inner edge shaped to be positioned around the bearing pocket and includes positional sensors mounted around the curved inner edge and facing the rotor to sense a rotational position of the rotor. The curved inner edge is disposed on a side corner of the positional sensor board such that the positional sensor board is asymmetrically-shape in a direction of the receiving axis.

Abstract: A brushless motor is provided including a rotor rotating around a center axis and a stator including a stator core and stator teeth radially extending from the stator core forming stator slots therebetween. Each stator tooth includes a radial main body and a tooth tip extending substantially laterally from an end of the radial main body opposite the stator core, and stator windings are wound around the stator teeth. Winding retention wedges are axially received within the slots, each winding retention wedge comprising: a first portion received within gaps formed between tooth tips of adjacent stator teeth, and a second portion received at least partially between adjacent stator windings to apply a force substantially in a range of a radially-inward direction to a lateral direction to the adjacent stator windings.

Abstract: A power tool is provided including a tool housing; at least one battery receptacle accommodated on the tool housing, the battery receptacle being adapted to receive a battery pack having a maximum voltage of at least 60 volts; and a brushless DC (BLDC) motor disposed within the tool housing, the motor including a stator assembly and a rotor assembly rotatably disposed within the stator assembly. A motor control and power module is disposed in close proximity to the motor, including a power switch circuit electrically coupled to the motor and a first controller configured to control a switching operation of the power switch circuit for supply of power from the battery pack to the motor. A battery management control module is disposed in close proximity to the battery receptacle, including a second controller distinct from the first controller, the second controller configured to manage an operation of the battery pack.

Abstract: A power tool is provided including a motor housing having a substantially-cylindrical main body having an open end and a rear end. A brushless DC motor is provided including a stator assembly received through the open end of the motor housing and secured within the main body of the motor housing. A motor control and power module disposed proximate the rear end of the motor housing includes a printed circuit board (PCB) on which power switch and a controller are mounted. A mounting bracket is secured to the motor housing at the rear end to support the module such that the PCB is substantially parallel to the rear end. The mounting bracket includes a mating portion projecting axially to come to contact with the motor housing around the rear end to structurally support the mounting bracket with respect to the motor housing.

Abstract: A power tool motor is provided including a stator assembly and a rotor assembly rotatably disposed within the stator assembly. The stator assembly includes: a generally-cylindrical lamination stack having a stator ring and stator teeth extending radially inwardly towards a center bore arranged to receive the rotor assembly therein; an end insulator disposed at an and of the lamination stack and having an outer ring and teeth portions extending radially inwardly from the outer ring towards a center of the end insulator; and stator windings wound around the stator teeth and the teeth portion of the end insulator. A generally cylindrical seal member is disposed to interface with an end of the stator, which includes a mating surface having indents configured to mate with ends of the stator windings or ends of the teeth portion of the end insulator to substantially seal respective gaps therebetween from entry of workpiece particulate.

Abstract: A power tool is provided including a tool housing; at least one battery receptacle accommodated on the tool housing, the battery receptacle being adapted to receive a battery pack having a maximum voltage of at least 60 volts; and a brushless DC (BLDC) motor disposed within the tool housing, the motor including a stator assembly and a rotor assembly rotatably disposed within the stator assembly. A motor control and power module is disposed in close proximity to the motor, including a power switch circuit electrically coupled to the motor and a first controller configured to control a switching operation of the power switch circuit for supply of power from the battery pack to the motor. A battery management control module is disposed in close proximity to the battery receptacle, including a second controller distinct from the first controller, the second controller configured to manage an operation of the battery pack.

Abstract: A power tool motor is provided including a stator assembly and a rotor assembly rotatably disposed within the stator assembly. The stator assembly includes: a generally-cylindrical lamination stack having a stator ring and stator teeth extending radially inwardly towards a center bore arranged to receive the rotor assembly therein; an end insulator disposed at an and of the lamination stack and having an outer ring and teeth portions extending radially inwardly from the outer ring towards a center of the end insulator; and stator windings wound around the stator teeth and the teeth portion of the end insulator. A generally cylindrical seal member is disposed to interface with an end of the stator, which includes a mating surface having indents configured to mate with ends of the stator windings or ends of the teeth portion of the end insulator to substantially seal respective gaps therebetween from entry of workpiece particulate.

Abstract: A power tool is provided including a tool housing in which an electric motor is disposed. The electric motor includes a stator and an armature rotatably received within the stator. The armature has an armature shaft on which a commutator is mounted. The power tool further includes at least one brush assembly disposed around the commutator, the brush assembly including: a brush having two grooves on opposites surfaces therein; a brush holder comprising two support plates arranged defining guiderails that extend into the grooves of the brush to facilitate movement of the brush along a single axis; and a spring contacting the brush that urges the brush radially inwardly along the axis.