Abstract: The present invention is directed toward a shield assembly for a handheld tool device such as an angle grinder. The shield assembly is selectively repositionable with respect to the cutting tool. A lock mechanism secures the shield assembly in discrete rotational positions relative to the cutting tool. The shield assembly includes a guard member and a bumper member, and an alignment feature configured to align the relative positions of guard member and the bumper member, thereby positing the members in a predetermined relative orientation. With this configuration, the shield assembly is selectively repositionable via a “hands-free” mechanism that permits a user to adjust the position of the shield assembly by simply contacting the shield assembly against a work surface.

Abstract: A drill includes a housing and a motor coupled to an output member by a transmission. The transmission can selectively couple the output member to an output spindle through a low speed output gear or a high speed output gear for rotating the output spindle at a first speed or a second speed, respectively. Alternatively or additionally, a low speed mode can be provided by actuating an electronic switch that limits the speed of the motor. A rotatably fixed hammer member and a rotatable hammer member can be mounted around the output spindle. A mode collar can be rotatably mounted on the housing and around the output member for movement to positions that correspond to various mode of operation, including a low speed mode, a high speed mode, and a hammer-drilling mode. In the hammer-drilling mode, the transmission operates in the high speed mode.

Abstract: An angle grinder is provided including a radial fan assembly. The radial fan assembly is configured to direct exhaust radially outwardly and axially away from a user of the angle grinder. Brush card assemblies for an angle grinder are also provided. The brush card assemblies provide for the securing of brush cards to a field case of the angle grinder by the interface between the field case and brush cards. Additionally, a spindle lock mechanism and a safety mechanism for an angle grinder are provided.

Abstract: The present invention is directed to an airflow generation and particle dispersion arrangement for a power tool (e.g., an angle grinder). The arrangement includes a motor, an airflow generation assembly, and a particle dispersion assembly. The airflow generation assembly includes a fan driven by the motor. When engaged, the driven fan generates an airstream that is drawn through the power tool. The particle dispersion assembly includes a passive fan that is not driven by the motor, but instead is driven by the airstream. In operation, the passive fan generates centrifugal and mechanical forces sufficient to remove particles from intake air passing through the particle dispersion assembly.

Abstract: The present invention is directed toward a shield assembly for a handheld tool device such as an angle grinder. The shield assembly is selectively repositionable with respect to the cutting tool. A lock mechanism secures the shield assembly in discrete rotational positions relative to the cutting tool. The shield assembly includes a guard member and a bumper member, and an alignment feature configured to align the relative positions of guard member and the bumper member, thereby positing the members in a predetermined relative orientation. With this configuration, the shield assembly is selectively repositionable via a “hands-free” mechanism that permits a user to adjust the position of the shield assembly by simply contacting the shield assembly against a work surface.

Abstract: The present invention is directed to an airflow generation and particle dispersion arrangement for a power tool (e.g., an angle grinder). The arrangement includes a motor, an airflow generation assembly, and a particle dispersion assembly. The airflow generation assembly includes a fan driven by the motor. When engaged, the driven fan generates an airstream that is drawn through the power tool. The particle dispersion assembly includes a passive fan that is not driven by the motor, but instead is driven by the airstream. In operation, the passive fan generates centrifugal and mechanical forces sufficient to remove particles from intake air passing through the particle dispersion assembly.

Abstract: A drill includes a housing with a motor coupled to an output spindle via a transmission. A mode collar can be rotatably mounted on the housing for movement that corresponds to different modes of operation. The mode collar can be coupled to an electronic switch to operate a movable member thereof. The coupling can include a switch housing including a slide member, an actuation spring member and a return spring member. The mode collar can have a cam surface and a cam follower in the form of a shift pin that moves the slide member, causing actuation of the switch. The actuation spring member provides a biasing force that is sufficient to overcome a biasing force of a switch spring member to move the movable member into the actuated position. The mode collar can also enable and disable contact between a fixed hammer member and a movable hammer member mounted around the output spindle.

Abstract: A drill includes a housing and a motor coupled to an output member by a transmission. The transmission can selectively couple the output member to an output spindle through a low speed output gear or a high speed output gear for rotating the output spindle at a first speed or a second speed, respectively. Alternatively or additionally, a low speed mode can be provided by actuating an electronic switch that limits the speed of the motor. A rotatably fixed hammer member and a rotatable hammer member can be mounted around the output spindle. A mode collar can be rotatably mounted on the housing and around the output member for movement to positions that correspond to various mode of operation, including a low speed mode, a high speed mode, and a hammer-drilling mode. In the hammer-drilling mode, the transmission operates in the high speed mode.

Abstract: A drill includes a housing and a motor coupled to an output member by a transmission. The transmission can selectively couple the output member to an output spindle through a low speed output gear or a high speed output gear for rotating the output spindle at a first speed or a second speed, respectively. Alternatively or additionally, a low speed mode can be provided by actuating an electronic switch that limits the speed of the motor. A rotatably fixed hammer member and a rotatable hammer member can be mounted around the output spindle. A mode collar can be rotatably mounted on the housing and around the output member for movement to positions that correspond to various mode of operation, including a low speed mode, a high speed mode, and a hammer-drilling mode. In the hammer-drilling mode, the transmission operates in the high speed mode.

Abstract: An angle grinder is provided including a radial fan assembly. The radial fan assembly is configured to direct exhaust radially outwardly and axially away from a user of the angle grinder. Brush card assemblies for an angle grinder are also provided. The brush card assemblies provide for the securing of brush cards to a field case of the angle grinder by the interface between the field case and brush cards. Additionally, a spindle lock mechanism and a safety mechanism for an angle grinder are provided.

Abstract: A drill includes a housing and a motor coupled to an output member by a transmission. The transmission can selectively couple the output member to an output spindle through a low speed output gear or a high speed output gear for rotating the output spindle at a first speed or a second speed, respectively. Alternatively or additionally, a low speed mode can be provided by actuating an electronic switch that limits the speed of the motor. A rotatably fixed hammer member and a rotatable hammer member can be mounted around the output spindle. A mode collar can be rotatably mounted on the housing and around the output member for movement to positions that correspond to various mode of operation, including a low speed mode, a high speed mode, and a hammer-drilling mode. In the hammer-drilling mode, the transmission operates in the high speed mode.

Abstract: An angle grinder is provided including a radial fan assembly. The radial fan assembly is configured to direct exhaust radially outwardly and axially away from a user of the angle grinder. Brush card assemblies for an angle grinder are also provided. The brush card assemblies provide for the securing of brush cards to a field case of the angle grinder by the interface between the field case and brush cards. Additionally, a spindle lock mechanism and a safety mechanism for an angle grinder are provided.

Abstract: A drill includes a housing and a motor coupled to an output member by a transmission. The transmission can selectively couple the output member to an output spindle through a low speed output gear or a high speed output gear for rotating the output spindle at a first speed or a second speed, respectively. Alternatively or additionally, a low speed mode can be provided by actuating an electronic switch that limits the speed of the motor. A rotatably fixed hammer member and a rotatable hammer member can be mounted around the output spindle. A mode collar can be rotatably mounted on the housing and around the output member for movement to positions that correspond to various mode of operation, including a low speed mode, a high speed mode, and a hammer-drilling mode. In the hammer-drilling mode, the transmission operates in the high speed mode.

Abstract: A multi-mode drill can include a transmission to transfer torque from an output member of a motor to an output spindle. A transmission housing encloses the transmission in an interior cavity formed by a gear case shell and a cover plate. The cover plate can be coupled to the outer shell via screws. A static shift rod can be supported at one end by the cover plate. A shift bracket can be mounted on the shift rod and biased to a mode position by a biasing member exerting a force between the shift bracket and the cover plate. A shift pin can be supported adjacent one end by the cover plate and biased to a mode position by a biasing member exerting a force between the shift pin and the cover plate. A spindle biasing member can bias the output spindle against the cover plate. The shift pin can actuate an electronic switch. A motor housing can be coupled to the transmission housing with fasteners so that the cover fasteners are not accessible.

Abstract: A drill includes a housing with a motor coupled to an output spindle via a transmission. A mode collar can be rotatably mounted on the housing for movement that corresponds to different modes of operation. The mode collar can be coupled to an electronic switch to operate a movable member thereof. The coupling can include a switch housing including a slide member, an actuation spring member and a return spring member. The mode collar can have a cam surface and a cam follower in the form of a shift pin that moves the slide member, causing actuation of the switch. The actuation spring member provides a biasing force that is sufficient to overcome a biasing force of a switch spring member to move the movable member into the actuated position. The mode collar can also enable and disable contact between a fixed hammer member and a movable hammer member mounted around the output spindle.

Abstract: A power tool can include a gear case, a motor having first and second sets of lead wires, a housing assembly, and a field case. The field case may include a front portion configured for engaging the gear case and a rear portion. The housing assembly may include first and second generally symmetrical housing segments configured for engaging the field case and forming a mid-handle grip. The first set of lead wires may be routed through the front portion of the field case directly to a trigger switch assembly. A method for assembling a mid-handle power tool is also provided and may include routing lead wires through a ventilation path between the field case and trigger assembly.

Abstract: A drill includes a housing with a motor coupled to an output spindle via a transmission. A mode collar can be rotatably mounted on the housing for movement that corresponds to different modes of operation. The mode collar can be coupled to an electronic switch to operate a movable member thereof. The coupling can include a switch housing including a slide member, an actuation spring member and a return spring member. The mode collar can have a cam surface and a cam follower in the form of a shift pin that moves the slide member, causing actuation of the switch. The actuation spring member provides a biasing force that is sufficient to overcome a biasing force of a switch spring member to move the movable member into the actuated position. The mode collar can also enable and disable contact between a fixed hammer member and a movable hammer member mounted around the output spindle.

Abstract: A drill includes a housing and a motor coupled to an output member by a transmission. The transmission can selectively couple the output member to an output spindle through a low speed output gear or a high speed output gear for rotating the output spindle at a first speed or a second speed, respectively. Alternatively or additionally, a low speed mode can be provided by actuating an electronic switch that limits the speed of the motor. A rotatably fixed hammer member and a rotatable hammer member can be mounted around the output spindle. A mode collar can be rotatably mounted on the housing and around the output member for movement to positions that correspond to various mode of operation, including a low speed mode, a high speed mode, and a hammer-drilling mode. In the hammer-drilling mode, the transmission operates in the high speed mode.

Abstract: A power tool can include a gear case, a motor having first and second sets of lead wires, a housing assembly, and a field case. The field case may include a front portion configured for engaging the gear case and a rear portion. The housing assembly may include first and second generally symmetrical housing segments configured for engaging the field case and forming a mid-handle grip. The first set of lead wires may be routed through the front portion of the field case directly to a trigger switch assembly. A method for assembling a mid-handle power tool is also provided and may include routing lead wires through a ventilation path between the field case and trigger assembly.

Abstract: A multi-speed drill includes a housing with a motor including an output member. A constant mesh parallel axis transmission can be disposed in the housing and can include a high speed and low speed gears. A clutch member can be associated with the low speed gear. A conical spring can bias the low speed gear and the clutch member together for torque transfer up to a predetermined torque level. Above the predetermined level, cam surfaces between the low speed gear and the clutch member move them apart, thereby limiting torque transfer to the output spindle. In the high speed mode the torque transfer between the input pinion and the output spindle bypasses the clutch member. The maximum torque level capable of being generated at the output spindle in the high speed mode can be less than the predetermined torque level.