Abstract: An overspeed protection subsystem is provided for a power tool having an electric motor. The overspeed protection subsystem is comprised of: a motor switch coupled in series with the motor; a motor control module interfaced with the motor switch to control switching operation of the motor switch; and an overspeed detection module that determines rotational speed of the motor and disables the power tool when the rotational speed of the motor exceeds a threshold.

Abstract: A power tool includes a tool body having an output member that drives an accessory. An end effector is coupled for rotation with the output member. A light source is disposed on the end effector. A primary coil assembly is configured on the tool body and mounted concentric to the output member. The primary coil assembly includes a primary coil that is electrically connected to a power source of the power tool. A secondary coil assembly is configured on the end effector and mounted concentric to the output member. The secondary coil assembly includes a secondary coil that is electrically connected to the light source. Current flowing through the primary coil creates a magnetic field that causes current to flow through the secondary winding and power the light source.

Abstract: A portable power driven system has a manually movable frame. In one example, an internal combustion engine and a generator device that generates AC power are supported on the frame. The internal combustion engine drives the generator device. An electrically powered starting device is coupled to the internal combustion engine. A control panel is coupled to the frame and includes at least one AC outlet and a battery receptacle that is electrically coupled to the starting device. The battery receptacle is materially the same as a foot of a cordless power tool that receives a battery pack. According to one aspect, the battery pack for the cordless power tool may be permanently mounted in the battery receptacle and provides electrical power to the starting device. The battery receptacle may be contained in an enclosure. The enclosure may provide biasing members urging the battery pack into the battery receptacle.

Abstract: A fastening device that drives one or more fasteners into a workpiece generally includes a tool housing and a multistage solenoid contained in the tool housing. The multistage solenoid includes an armature member that travels through at least a first stage, a second stage, and a sense coil disposed therebetween. A driver blade assembly includes a blade member connected to the armature member. The driver blade assembly is operable between an extended condition and a retracted condition. A control module determines a position of the armature member relative to at least one of the first stage and the second stage based on a signal from the sense coil. The control module adjusts a force imparted on the armature by at least one of the first stage, the second stage, and a combination thereof based on the signal from the sense coil.

Abstract: A portable generator system having an internal combustion engine, a starting device for starting the internal combustion engine and a power generating device for generating an AC signal for powering a charger assembly, the charger assembly adapted to receive the AC signal and to generate a DC charging signal. The charger assembly includes a first user controllable switch and a second user controllable switch.

Abstract: A portable generator system having a generator for generating an electrical output signal, an internal combustion engine for driving the generator, a starter for starting the internal combustion engine, an alternator for generating an AC signal for powering a charger assembly, a battery pack, and a charger subsystem. The charger system has a charger assembly that receives the AC signal and generates a DC charging signal for recharging the battery pack. The charger assembly has a first switch and a second switch. The first switch is used to apply an output of the battery to energize the starter. The second switch, when placed in a Start position, enables current from the battery pack to energize the starter while inhibiting the application of the DC charging signal to the battery pack. When placed in the Charge position, the second switch inhibits the battery pack output from energizing the starter while enabling the DC charging signal to be applied to the battery pack.

Abstract: An overspeed protection subsystem is provided for a power tool having an electric motor. The overspeed protection subsystem is comprised of: a motor switch coupled in series with the motor; a motor control module interfaced with the motor switch to control switching operation of the motor switch; and an overspeed detection module that determines rotational speed of the motor and disables the power tool when the rotational speed of the motor exceeds a threshold.

Abstract: A motor control module designed to control operation of a plurality of different motors in a plurality of different tools a power tool uses an electronic clutch in the module in conjunction with a mechanical clutch in the tool to protect the tool against an overload event. The module is adapted to implement methods to provide aural and/or tactile feedback to a tool user as a warning of an impending or current fault condition in the tool. The module can prevent power from inadvertently turning on either after an overload event has cleared with the tool plugged in and its power switch on, or after plugging in the tool within the power switch on. The control module is adapted to provide torque control for the power tool, to estimate tool motor temperature and to inform a tool user when a servicing need in the tool is required.

Abstract: A power tool having an integrated control system includes a workpiece supporting surface, a cutting instrument extendable above the workpiece supporting surface, a guard assembly securable above the workpiece supporting surface for covering at least a portion of the cutting instrument, the guard assembly having a first state for providing a first level of protection and a second state for providing a second level of protection, a motor coupled with the cutting instrument, and a power switch operable for starting the motor for driving the cutting instrument. The power tool includes a control system in communication with the guard assembly for determining if the guard assembly is in the first state or the second state. Before the motor is started, the control system automatically disables the motor if it determines that the guard assembly is in the second state. The control system includes a bypass switch for enabling starting of the motor when the guard assembly is in the second state.

Abstract: A portable power driven system has a manually movable frame. In one example, an internal combustion engine and a generator device that generates AC power are supported on the frame. The internal combustion engine drives the generator device. An electrically powered starting device is coupled to the internal combustion engine. A control panel is coupled to the frame and includes at least one AC outlet and a battery receptacle that is electrically coupled to the starting device. The battery receptacle is materially the same as a foot of a cordless power tool that receives a battery pack. According to one aspect, the battery pack for the cordless power tool may be permanently mounted in the battery receptacle and provides electrical power to the starting device. The battery receptacle may be contained in an enclosure. The enclosure may provide biasing members urging the battery pack into the battery receptacle.

Abstract: A portable generator system having a generator for generating an electrical output signal, an internal combustion engine for driving the generator, a starter for starting the internal combustion engine, an alternator for generating an AC signal for powering a charger assembly, a battery pack, and a charger subsystem. The charger system has a charger assembly that receives the AC signal and generates a DC charging signal for recharging the battery pack. The charger assembly has a first switch and a second switch. The first switch is used to apply an output of the battery to energize the starter. The second switch, when placed in a Start position, enables current from the battery pack to energize the starter while inhibiting the application of the DC charging signal to the battery pack. When placed in the Charge position, the second switch inhibits the battery pack output from energizing the starter while enabling the DC charging signal to be applied to the battery pack.

Abstract: A motor control module designed to control operation of a plurality of different motors in a plurality of different tools a power tool uses an electronic clutch in the module in conjunction with a mechanical clutch in the tool to protect the tool against an overload event. The module is adapted to implement methods to provide aural and/or tactile feedback to a tool user as a warning of an impending or current fault condition in the tool. The module can prevent power from inadvertently turning on either after an overload event has cleared with the tool plugged in and its power switch on, or after plugging in the tool within the power switch on. The control module is adapted to provide torque control for the power tool, to estimate tool motor temperature and to inform a tool user when a servicing need in the tool is required.

Abstract: A motor control module designed to control operation of a plurality of different motors in a plurality of different tools a power tool uses an electronic clutch in the module in conjunction with a mechanical clutch in the tool to protect the tool against an overload event. The module is adapted to implement methods to provide aural and/or tactile feedback to a tool user as a warning of an impending or current fault condition in the tool. The module can prevent power from inadvertently turning on either after an overload event has cleared with the tool plugged in and its power switch on, or after plugging in the tool within the power switch on. The control module is adapted to provide torque control for the power tool, to estimate tool motor temperature and to inform a tool user when a servicing need in the tool is required.

Abstract: A motor control module for a power tool includes a controller and a triac for controlling current to the given tool motor. The module includes a circuit within the controller for implementing a plurality of control methodologies related to synchronizing the module to the AC input signal, estimating average current flowing through the triac, compensating for amplifier offset to improve accuracy of current measurements in the module, and providing speed measurement and control for the tool motor using principles of hysteresis in a comparator of the controller. Additionally, the controller is configured to calibrate an oscillation calibration register therein.

Abstract: The charger includes a controller, a battery power source having at least two power settings connected to the controller, a power supply connectable to an outside power source, the power supply receiving a current and voltage from the outside power source for providing power to at least one of the controller and the battery power source, and a foldback circuit for switching between two power settings depending upon at least one of the current and voltage received from the outside power source.

Abstract: A motor control module designed to control operation of a plurality of different motors in a plurality of different tools a power tool uses an electronic clutch in the module in conjunction with a mechanical clutch in the tool to protect the tool against an overload event. The module is adapted to implement methods to provide aural and/or tactile feedback to a tool user as a warning of an impending or current fault condition in the tool. The module can prevent power from inadvertently turning on either after an overload event has cleared with the tool plugged in and its power switch on, or after plugging in the tool within the power switch on. The control module is adapted to provide torque control for the power tool, to estimate tool motor temperature and to inform a tool user when a servicing need in the tool is required.

Abstract: A motor control module for a power tool includes a controller and a triac for controlling current to the given tool motor. The module includes a circuit within the controller for implementing a plurality of control methodologies related to synchronizing the module to the AC input signal, estimating average current flowing through the triac, compensating for amplifier offset to improve accuracy of current measurements in the module, and providing speed measurement and control for the tool motor using principles of hysteresis in a comparator of the controller. Additionally, the controller is configured to calibrate an oscillation calibration register therein.

Abstract: The charger includes a controller, a battery power source having at least two power settings connected to the controller, a power supply connectable to an outside power source, the power supply receiving a current and voltage from the outside power source for providing power to at least one of the controller and the battery power source, and a foldback circuit for switching between two power settings depending upon at least one of the current and voltage received from the outside power source.

Abstract: A hand held motor driven electrically powered tool, in particular a rotary hammer, comprising a spindle (40) for rotatingly driving a tool or bit (68), a spindle rotary drive train (14, 5, 10) for rotatingly driving the spindle (40) and an arrangement for detecting blocking events (16, 17). Blocking events occur when the tool or bit of the tool become rotationally fixed in the material being bored in which case the rotary drive on the spindle from the motor causes the tool housing to rotate in a user's grip.

Abstract: The charger includes a controller, a battery power source having at least two power settings connected to the controller, a power supply connectable to an outside power source, the power supply receiving a current and voltage from the outside power source for providing power to at least one of the controller and the battery power source, and a foldback circuit for switching between two power settings depending upon at least one of the current and voltage received from the outside power source.