Abstract: An improved power tool system includes a power tool and an external power supply connected via a cable to provide utility and safety in a hazardous operation such as loading ammunition into a weapon in an environment of flammable materials and extreme environmental exposure. The power tool includes a sparkless motor, a sparkless controller and sparkless switches, in a sealed enclosure with improved heat transfer means. The power tool has improved torque controlling means to mitigate reaction torque to the operator and equipment when starting or stopping highly inertial loads. A sealed enclosure is provided to prevent liquids from entering the motor and controller cavity and includes a thermally conductive path to conduct heat from the motor and controller through the enclosure to cooling fins and a coolant path formed between the fins and an entrapment wall.

Abstract: An electrical machine comprises a rotor without windings, a stator having an armature winding 24, 25 and a field winding 10 for generating a magnetomotive force in a direction extending transversely of the magnetomotive force generated by the armature winding. An electronic circuit 40 is provided for controlling the current in the armature winding 24, 25 such that periods in which a magnetomotive force in one direction is associated with a first current pulse alternate with periods in which a magnetomotive force in the opposite direction is associated with a second current pulse. A position sensor is provided for monitoring the rotational position of the rotor and for supplying output signals at a rate dependent on the speed of rotation of the rotor. Furthermore a control system supplies control signals to the circuit 40 to control the current in the armature winding 24, 25 in response to the output signals.

Abstract: An electrical motor or generator comprises a rotor 79 without windings, a stator 78 having armature windings comprising at least two coils A1, A2 having active portions positioned within armature winding slots 81 in a stator iron, and field windings F having active portions positioned within field winding slots 80 in the stator iron. An electronic control circuit is provided for controlling the currents in the coils A1, A2 in synchronism with rotation of the rotor such that periods in which a magnetomotive force is generated in one direction by current flow in one of the coils alternate with periods in which a magnetomotive force is generated in the opposite direction by current flow in another of the coils. The armature winding slots and the field winding slots are equal in number and alternate with one another in the stator iron.

Abstract: An electronically commutated brushless motor including a motor housing, a bulge formed in a sidewall of the motor housing, and a capacitor assembly housed in the bulge. The capacitor assembly includes a capacitor printed circuit board (PCB) having a plurality of longitudinal edges and at least one capacitor mounted on the capacitor PCB. The bulge includes a plurality of channels located along an inside surface of a sidewall of the bulge, in which the longitudinal edges of the capacitor assembly are slideably inserted.

Abstract: An alternator/inverter system for use with a portable generator which includes a voltage regulation system. The alternator/inverter incorporates a pair of permanent magnet generators (PMGs), a pair of active rectifier circuits, a pair of DC bus capacitors and a pair of H-bridge inverters, forming two distinct alternator/inverter sections. Each alternator/inverter section provides a 120 VAC output, and a 240 VAC output is formed between the two alternator/inverters sections. The voltage regulation system is formed from a pair of voltage regulation circuits that are associated with each alternator/inverter section. The circuits monitor the DC bus voltage of each alternator/inverter and determine the DC losses resulting from electrical cabling coupling the alternator/inverters to external loads, as well as the H-bridge inverters.

Abstract: An electronically commutated brushless motor including a housing for accurately angularly aligning a position sensor relative to a position of a stator. The housing includes an integrally formed bridge for precisely situating the position sensor within the bridge, and a plurality of integrally formed locating ribs formed on an internal surface of a circumferential wall portion of the housing for precisely angularly situating the stator within the housing. Since the locating ribs and the bridge are all integrally formed on the housing, this eliminates the possibility of angular misalignment of the position sensor relative the stator during assembly of the motor.

Abstract: An electrical machine comprises a rotor without windings, a stator having an armature winding 24, 25 and a field winding 10 for generating a magnetomotive force in a direction extending transversely of the magnetomotive force generated by the armature winding. An electronic circuit 40 is provided for controlling the current in the armature winding 24, 25 such that periods in which a magnetomotive force in one direction is associated with a first current pulse alternate with periods in which a magnetomotive force in the opposite direction is associated with a second current pulse. A position sensor is provided for monitoring the rotational position of the rotor and for supplying output signals at a rate dependent on the speed of rotation of the rotor. Furthermore a control system supplies control signals to the circuit 40 to control the current in the armature winding 24, 25 in response to the output signals.

Abstract: An alternator/inverter system for use with a portable generator which includes a voltage regulation system. The alternator/inverter incorporates a pair of permanent magnet generators (PMGs), a pair of active rectifier circuits, a pair of DC bus capacitors and a pair of H-bridge inverters, forming two distinct alternator/inverter sections. Each alternator/inverter section provides a 120 VAC output, and a 240 VAC output is formed between the two alternator/inverters sections. The voltage regulation system is formed from a pair of voltage regulation circuits that are associated with each alternator/inverter section. The circuits monitor the DC bus voltage of each alternator/inverter and determine the DC losses resulting from electrical cabling coupling the alternator/inverters to external loads, as well as the H-bridge inverters.

Abstract: An alternator/inverter system for use with a portable generator which includes a voltage regulation system. The alternator/inverter incorporates a pair of permanent magnet generators (PMGs), a pair of active rectifier circuits, a pair of DC bus capacitors and a pair of H-bridge inverters, forming two distinct alternator/inverter sections. Each alternator/inverter section provides a 120 VAC output, and a 240 VAC output is formed between the two alternator/inverters sections. The voltage regulation system is formed from a pair of voltage regulation circuits that are associated with each alternator/inverter section. The circuits monitor the DC bus voltage of each alternator/inverter and determine the DC losses resulting from electrical cabling coupling the alternator/inverters to external loads, as well as the H-bridge inverters.

Abstract: A system for heating fluid in an internal combustion engine. The system includes a portable universal battery pack having an output voltage of a specified voltage rating. Additionally, the system includes a receiving unit that is adapted to removably receive the battery pack and transfer power from the battery pack to an immersion heater. The immersion heater includes a heating element that is at least partially immersed in the fluid. Power from the battery pack is utilized by the heater to heat the heating element, thereby heating the fluid in the engine. The system is adapted to readily use any number of different battery packs from a related line of battery packs, wherein that the various battery packs can have different output voltages.

Abstract: An electronically commutated brushless motor including a housing for accurately angularly aligning a position sensor relative to a position of a stator. The housing includes an integrally formed bridge for precisely situating the position sensor within the bridge, and a plurality of integrally formed locating ribs formed on an internal surface of a circumferential wall portion of the housing for precisely angularly situating the stator within the housing. Since the locating ribs and the bridge are all integrally formed on the housing, this eliminates the possibility of angular misalignment of the position sensor relative the stator during assembly of the motor.

Abstract: An electronically commutated brushless motor including a motor housing, a bulge formed in a sidewall of the motor housing, and a capacitor assembly housed in the bulge. The capacitor assembly includes a capacitor printed circuit board (PCB) having a plurality of longitudinal edges and at least one capacitor mounted on the capacitor PCB. The bulge includes a plurality of channels located along an inside surface of a sidewall of the bulge, in which the longitudinal edges of the capacitor assembly are slideably inserted.

Abstract: A double insulated electronically commutated brushless motor for coupling to a gearbox of a motor driven product. The motor includes a first layer of electrical insulation that includes a plurality of insulating strips formed in the shape of stator slots and inserted into the stator slots before windings are wound in the stator slots. Additionally, the first layer of electrical insulation includes a plurality of insulating strips wedged between the winding and a mouth of the winding slots after the windings are inserted. The motor further includes a second layer of electrical insulation made up of an insulating tube pressed onto a shaft between the shaft and a rotor stack.

Abstract: A double insulated electronically commutated brushless motor for coupling to a gearbox of a motor driven product. The motor includes a first layer of electrical insulation that includes a plurality of insulating strips formed in the shape of stator slots and inserted into the stator slots before windings are wound in the stator slots. Additionally, the first layer of electrical insulation includes a plurality of insulating strips wedged between the winding and a mouth of the winding slots after the windings are inserted. The motor further includes a second layer of electrical insulation made up of an insulating tube pressed onto a shaft between the shaft and a rotor stack.

Abstract: The embodiment of the battery charging circuit disclosed herein employs a relay which can be operated both mechanically and electrically. Mechanical operation is achieved by a manually operable push button which when depressed closes a relay contact in series with the relay winding. Current then flows into the winding to actuate the relay and provide a current path for the fast charge of a battery. If the battery temperature is elevated above a level considered safe for recharging, fast charging of the battery cannot occur until the battery has cooled. If the push button is depressed while the battery temperature is so elevated, it still closes the relay contact but no current flows into the winding. However, the push button is maintained in a depressed position by engagement with the relay armature. Once the battery cools, the already closed relay contact permits current to flow into the winding to actuate the relay and initiate a fast charge.