Abstract: An electric motor includes a stator operable to produce a magnetic field and defining an opening, and a rotor at least partially disposed within the opening. The rotor includes a shaft extending along a rotational axis, a first rotor magnetic core portion including a plurality of laminations stacked contiguously on the shaft, and a second rotor magnetic core portion coupled to the plurality of laminations. The first rotor magnetic core portion and the second rotor magnetic core portion cooperate to define the rotor magnetic core. A plurality of windings is coupled to the rotor magnetic core and an air flow path is formed as part of the second rotor magnetic core portion. The air flow path includes an axial portion that passes through the shaft axially along the rotational axis and a radial portion that extends radially outward through the second rotor magnetic core portion.

Abstract: An electric motor includes a stator operable to produce a magnetic field and defining an opening, and a rotor at least partially disposed within the opening. The rotor includes a shaft extending along a rotational axis, a plurality of first core portions each including a plurality of laminations stacked contiguously on the shaft, and a second core portion coupled between each of the first core portions. The first core portions and the second core portion cooperating to define a rotor magnetic core. A plurality of windings is coupled to the rotor magnetic core, and an air flow path is partially defined by the first core portions, the second core portion, and the shaft. The air flow path includes an axial portion that passes through the shaft axially along the rotational axis and a radial portion that extends radially outward through the second core portion.

Abstract: An electric motor includes a stator operable to produce a magnetic field and defining an opening, and a rotor at least partially disposed within the opening. The rotor includes a shaft extending along a rotational axis, a first rotor magnetic core portion including a plurality of laminations stacked contiguously on the shaft, and a second rotor magnetic core portion coupled to the plurality of laminations. The first rotor magnetic core portion and the second rotor magnetic core portion cooperate to define the rotor magnetic core. A plurality of windings is coupled to the rotor magnetic core and an air flow path is formed as part of the second rotor magnetic core portion. The air flow path includes an axial portion that passes through the shaft axially along the rotational axis and a radial portion that extends radially outward through the second rotor magnetic core portion.

Abstract: An electric motor includes a stator operable to produce a magnetic field and defining an opening, and a rotor at least partially disposed within the opening. The rotor includes a shaft extending along a rotational axis, a first rotor magnetic core portion including a plurality of laminations stacked contiguously on the shaft, and a second rotor magnetic core portion coupled to the plurality of laminations. The first rotor magnetic core portion and the second rotor magnetic core portion cooperate to define the rotor magnetic core. A plurality of windings is coupled to the rotor magnetic core and an air flow path is formed as part of the second rotor magnetic core portion. The air flow path includes an axial portion that passes through the shaft axially along the rotational axis and a radial portion that extends radially outward through the second rotor magnetic core portion.

Abstract: A power tool includes a housing, an output shaft supported by the housing for rotation about an axis, a battery terminal selectively operable to receive a DC power supply from a battery, and a receptacle selectively operable to receive an AC power supply from an AC power source. The power tool further includes a motor operable in a first power mode, in response to receipt of the DC power supply, to rotatably drive the output shaft, and also operable in a second power mode, in response to receipt of the AC power supply, to rotatably drive the output shaft. The power tool also includes a mechanical interlock movable between a first position in which the interlock inhibits the flow of the AC power supply to the motor and a second position in which the interlock inhibits the flow of the DC power supply to the motor.

Abstract: An electric motor includes a stator operable to produce a magnetic field and defining an opening, and a rotor at least partially disposed within the opening. The rotor includes a shaft extending along a rotational axis, a plurality of first core portions each including a plurality of laminations stacked contiguously on the shaft, and a second core portion coupled between each of the first core portions. The first core portions and the second core portion cooperating to define a rotor magnetic core. A plurality of windings is coupled to the rotor magnetic core, and an air flow path is partially defined by the first core portions, the second core portion, and the shaft. The air flow path includes an axial portion that passes through the shaft axially along the rotational axis and a radial portion that extends radially outward through the second core portion.

Abstract: An electric motor includes a stator operable to produce a magnetic field and defining an opening, and a rotor at least partially disposed within the opening. The rotor includes a shaft extending along a rotational axis, a first rotor magnetic core portion including a plurality of laminations stacked contiguously on the shaft, and a second rotor magnetic core portion coupled to the plurality of laminations. The first rotor magnetic core portion and the second rotor magnetic core portion cooperate to define the rotor magnetic core. A plurality of windings is coupled to the rotor magnetic core and an air flow path is formed as part of the second rotor magnetic core portion. The air flow path includes an axial portion that passes through the shaft axially along the rotational axis and a radial portion that extends radially outward through the second rotor magnetic core portion.

Abstract: An energy conversion machine and a method of manufacturing an energy conversion machine comprising a composite winding. The composite winding comprises two separate windings having two different wire gauges. One winding is primarily selected to obtain a desired stall torque or a desired short circuit current, while the other winding is primarily selected to obtain a desired no-load speed or open circuit voltage. A machine incorporating a composite winding can be smaller and lower cost than a conventional machine designed to the same parameters.