Abstract: A power tool including a housing, a motor at least partially positioned within the housing, a driver blade extending along a driving axis, and a cam assembly including a cam that is configured to rotate about a rotational axis to move the driver blade. The cam includes a target that rotates with the cam. A sensor is configured to detect the target when the target is at a predetermined rotational position of the cam. A controller is connected to the motor and the sensor. The controller is configured to receive a signal from the sensor indicating that the target is at the predetermined rotational position of the cam, compare a motor parameter to a threshold value, and initiate a speed ramp down in response to the target being at the predetermined rotational position of the cam and the motor parameter being greater than or equal to the threshold value.

Abstract: A powered fastener driver includes a housing, a nosepiece extending from the housing, a driver blade movable within the nosepiece between a ready position and a driven position the driver blade comprising a plurality of drive teeth on a first side of the driver blade and a plurality of locking projections on a second side of the driver blade, a piston coupled to the driver blade for movement therewith, a driver cylinder within which the piston is movable, a storage chamber cylinder containing pressurized gas therein and in fluid communication with the driver cylinder, a first end of the driver cylinder being affixed to a corresponding first end of the storage chamber cylinder, and a latch actuator assembly adjacent the driver blade, wherein the latch actuator assembly includes a latch to engage one of the plurality of locking projections to prevent the driver blade from moving toward the driven position.

Abstract: A power tool that includes a housing, a brushless motor, a power switching circuit, and an electronic controller. The brushless motor is within the housing. The brushless motor includes a rotor and a stator. The rotor is coupled to a motor shaft arranged to rotate about a longitudinal axis. The motor shaft is arranged to produce a rotational output to a drive mechanism. The power switching circuit provides a supply of power from a battery pack to the brushless motor. The electronic controller is configured to determine a parameter associated with the battery pack, assign a classification to the battery pack based on the determined parameter, and control field weakening applied to the brushless motor based on the classification of the battery pack.

Abstract: Systems and methods for implementing an electronic clutch in a powered fastener driver. One fastener driver includes a motor, a trigger, a position sensor, a speed sensor, and a controller. The position sensor is configured to sense a position of the lifting assembly. The speed sensor is configured to sense a speed of the motor. The controller is configured to provide power to the motor. The controller is configured to receive speed signals from the speed sensor indicative of the speed of the motor, and determine whether the speed of the motor has dropped by a speed drop threshold within a first period of time. The controller is configured to activate an electronic clutch to electronically brake the motor for a second period of time. In response to the second period of time having passed, the controller is configured to provide power to the motor.

Abstract: A powered fastener driver includes a housing, a cylinder within the housing, the cylinder containing a pressurized gas, a piston within the cylinder and movable from a top-dead-center position to a bottom-dead-center position, a driver blade movably coupled to the piston, a lifter, a drive unit configured to provide torque to the lifter, and a sensor. The driver blade has a plurality of teeth defining a predetermined number of edges. The sensor is configured to detect an edge of one or more of the plurality of teeth and a controller in communication with the drive unit and the sensor. The controller is configured to count a number of edges detected by the sensor, compare the number of detected edges to the predetermined number of edges, and stop the drive unit when the number of detected edges is less than the predetermined number of edges.

Abstract: Power tools described herein include a tool output, a motor driving the tool output, a battery pack interface, a power switching network coupled between the battery pack interface and the motor, and a controller coupled to the power switching network to control operation of the motor. The controller is configured to operate the motor at a no-load speed at startup and detect a load state of the power tool. The load state indicates whether the power tool is in a loaded state or an unloaded state. The controller is also configured to incrementally ramp up a speed of the motor from the no-load speed to a selected speed when the power tool is in the loaded state and incrementally ramp down the speed of the motor from the selected speed to the no-load speed when the power tool is in the unloaded state.

Abstract: Power tools described herein include a tool output, a motor driving the tool output, a battery pack interface, a power switching network coupled between the battery pack interface and the motor, and a controller coupled to the power switching network to control operation of the motor. The controller is configured to operate the motor at a no-load speed at startup and detect a load state of the power tool. The load state indicates whether the power tool is in a loaded state or an unloaded state. The controller is also configured to incrementally ramp up a speed of the motor from the no-load speed to a selected speed when the power tool is in the loaded state and incrementally ramp down the speed of the motor from the selected speed to the no-load speed when the power tool is in the unloaded state.

Abstract: Systems and methods for implementing an electronic clutch in a powered fastener driver. One fastener driver includes a motor, a trigger, a position sensor, a speed sensor, and a controller. The position sensor is configured to sense a position of the lifting assembly. The speed sensor is configured to sense a speed of the motor. The controller is configured to provide power to the motor. The controller is configured to receive speed signals from the speed sensor indicative of the speed of the motor, and determine whether the speed of the motor has dropped by a speed drop threshold within a first period of time. The controller is configured to activate an electronic clutch to electronically brake the motor for a second period of time. In response to the second period of time having passed, the controller is configured to provide power to the motor.

Abstract: A power tool includes a housing having a motor housing portion and a handle portion. A motor having a motor axis is positioned within the motor housing portion. The power tool further includes a first printed circuit board positioned within the motor housing portion. The first printed circuit board intersects the motor axis. The power tool also includes a second printed circuit board positioned within the motor housing. The second printed circuit board intersects the motor axis. The second printed circuit board includes a conductive high impedance trace that is configured to interrupt electric power to the motor in response to a current that exceeds a current limit.

Abstract: A powered fastener driver includes a housing, a nosepiece extending from the housing, a driver blade movable within the nosepiece between a ready position and a driven position the driver blade comprising a plurality of drive teeth on a first side of the driver blade and a plurality of locking projections on a second side of the driver blade, a piston coupled to the driver blade for movement therewith, a driver cylinder within which the piston is movable, a storage chamber cylinder containing pressurized gas therein and in fluid communication with the driver cylinder, a first end of the driver cylinder being affixed to a corresponding first end of the storage chamber cylinder, and a latch actuator assembly adjacent the driver blade, wherein the latch actuator assembly includes a latch to engage one of the plurality of locking projections to prevent the driver blade from moving toward the driven position.

Abstract: Power tools described herein include a tool output, a motor driving the tool output, a battery pack interface, a power switching network coupled between the battery pack interface and the motor, and a controller coupled to the power switching network to control operation of the motor. The controller is configured to operate the motor at a no-load speed at startup and detect a load state of the power tool. The load state indicates whether the power tool is in a loaded state or an unloaded state. The controller is also configured to incrementally ramp up a speed of the motor from the no-load speed to a selected speed when the power tool is in the loaded state and incrementally ramp down the speed of the motor from the selected speed to the no-load speed when the power tool is in the unloaded state.

Abstract: A gas spring-powered fastener driver includes a cylinder, a moveable piston positioned within the cylinder, and a driver blade attached to the piston and movable therewith between a top-dead-center (TDC) position and a driven or bottom-dead-center (BDC) position. The driver blade defines a driving axis. The driver blade includes a body having a first side and an opposite, second side with the driving axis passing therebetween. A plurality of teeth extends from the first side of the body. A plurality of projections extends from the second side of the body. The body, the teeth, and the projections are bisected by a common plane. A lifter is operable to move the driver blade from the BDC position toward the TDC position, and is engageable with the teeth. A latch assembly is movable between a latched state, and a released state. The latch assembly is configured to engage with the projections.