Abstract: A power adapter for use with a power tool having an electric motor, and configured to supply electric power from an alternating current power supply to the power tool, is provided. The adapter includes a housing and an auxiliary capacitor circuit housed within the housing. The auxiliary capacitor circuit includes an auxiliary capacitor, a switch in series with the auxiliary capacitor, and a switch control circuit. A state of the switch creates either a charging path for the auxiliary capacitor or both the charging path and a discharging path for the auxiliary capacitor, and the switch control circuit is configured to detect voltage associated with the power supply or the power tool and to control state of the switch in accordance with magnitude of the detected voltage.

Abstract: A power tool is provided, including a housing; a brushless DC (BLDC) motor arranged within the housing, the motor including a stator and a rotor rotatably disposed within the stator; a power module electrically disposed between the motor and a power supply, the power module including power switches; an actuator engageable by a user; and a control module configured to control a switching operation of the power switches to begin supply power to the motor when the actuator is engaged. The control module monitors engagement and disengagement events of the actuator, and ignores a subsequent engagement of the actuator if at least one of number of actuator engagement events and/or number of actuator disengagement events exceeds a predetermined threshold value within a predetermined time.

Abstract: A power adapter for use with a power tool having an electric motor, and configured to supply electric power from an alternating current power supply to the power tool, is provided. The adapter includes a housing and an auxiliary capacitor circuit housed within the housing. The auxiliary capacitor circuit includes an auxiliary capacitor, a switch in series with the auxiliary capacitor, and a switch control circuit. A state of the switch creates either a charging path for the auxiliary capacitor or both the charging path and a discharging path for the auxiliary capacitor, and the switch control circuit is configured to detect voltage associated with the power supply or the power tool and to control state of the switch in accordance with magnitude of the detected voltage.

Abstract: A power tool is provided, including a housing; a brushless DC (BLDC) motor arranged within the housing, the motor including a stator and a rotor rotatably disposed within the stator; a power module electrically disposed between the motor and a power supply, the power module including power switches; an actuator engageable by a user; and a control module configured to control a switching operation of the power switches to begin supply power to the motor when the actuator is engaged. The control module monitors engagement and disengagement events of the actuator, and ignores a subsequent engagement of the actuator if at least one of number of actuator engagement events and/or number of actuator disengagement events exceeds a predetermined threshold value within a predetermined time.

Abstract: A power tool is configured to receive power from a power supply. The power tool may include a rectifier that may output a rectified signal to a DC power bus. A switching arrangement may operate to deliver electric power from the DC power bus to an electric motor. A switch path may be electrically coupled in parallel with the rectifier on the DC power bus. The switch path includes an auxiliary capacitor in series with a switch and a state of the switch controls a discharging path for the auxiliary capacitor. A switch control circuit may be configured to detect voltage associated with at least one of the AC power supply or the DC power bus and to control state of the switch in accordance with magnitude of the detected voltage.

Abstract: A power tool is configured to receive power from a power supply. The power tool may include a rectifier that may output a rectified signal to a DC power bus. A switching arrangement may operate to deliver electric power from the DC power bus to an electric motor. A switch path may be electrically coupled in parallel with the rectifier on the DC power bus. The switch path includes an auxiliary capacitor in series with a switch and a state of the switch controls a discharging path for the auxiliary capacitor. A switch control circuit may be configured to detect voltage associated with at least one of the AC power supply or the DC power bus and to control state of the switch in accordance with magnitude of the detected voltage.

Abstract: A protective redundancy circuit is provided for a power tool having an electric motor. The protective redundant subsystem is comprised of: a motor switch coupled in series with the motor; a motor control module that controls the switching operation of the motor switch; and a protective control module that monitors switching operation of the motor switch and disables the power tool when the switching operation of the motor switch fails. In the context of an AC powered tool, the switching operation of the motor switch is correlated to and synchronized to the waveform of the AC input signal. During each cycle or half cycle, the motor control module introduces a delay period before closing the motor switch and the protective control module determines the operational status of the motor switch by measuring the voltage across the motor switch during the delay period.

Abstract: A power tool for operating on a workpiece, the power tool having a housing and a motor disposed within the housing. A controller is connected to the motor and receives user inputs for turning on the motor and a power tool battery pack is connected to the controller and the motor. At least one light is connected to the controller for illuminating the workpiece. The controller can turn on the light in a predetermined pattern to alert the user to a tool condition, such as the charge level being below a predetermined level.

Abstract: A protective redundancy circuit is provided for a power tool having an electric motor. The protective redundant subsystem is comprised of: a motor switch coupled in series with the motor; a motor control module that controls the switching operation of the motor switch; and a protective control module that monitors switching operation of the motor switch and disables the power tool when the switching operation of the motor switch fails. In the context of an AC powered tool, the switching operation of the motor switch is correlated to and synchronized to the waveform of the AC input signal. During each cycle or half cycle, the motor control module introduces a delay period before closing the motor switch and the protective control module determines the operational status of the motor switch by measuring the voltage across the motor switch during the delay period.

Abstract: A protective redundancy circuit is provided for a power tool having an electric motor. The protective redundant subsystem is comprised of: a motor switch coupled in series with the motor; a motor control module that controls the switching operation of the motor switch; and a protective control module that monitors switching operation of the motor switch and disables the power tool when the switching operation of the motor switch fails. In the context of an AC powered tool, the switching operation of the motor switch is correlated to and synchronized to the waveform of the AC input signal. During each cycle or half cycle, the motor control module introduces a delay period before closing the motor switch and the protective control module determines the operational status of the motor switch by measuring the voltage across the motor switch during the delay period.

Abstract: A power tool for operating on a workpiece, the power tool having a housing and a motor disposed within the housing. A controller is connected to the motor and receives user inputs for turning on the motor and a power tool battery pack is connected to the controller and the motor. At least one light is connected to the controller for illuminating the workpiece. The controller can turn on the light in a predetermined pattern to alert the user to a tool condition, such as the charge level being below a predetermined level.

Abstract: A method and apparatus for controlling a plurality of different motors used in a corresponding plurality of power tool applications requiring different operational characteristics. In one implementation a method involves the use of a single universal control module to store a generic, non-application-specific control algorithm. The generic, non-application-specific control algorithm has at least one programmable constant. The programmable constant is selected to transform the generic, non-application-specific control algorithm into an application-specific control algorithm. The programmable constant represents a function parameter relating to a specific functionality of a specific, selected motor used in a specific, selected motor application to implement a phase control over the specific, selected motor.

Abstract: A protective redundancy circuit is provided for a power tool having an electric motor. The protective redundant subsystem is comprised of: a motor switch coupled in series with the motor; a motor control module that controls the switching operation of the motor switch; and a protective control module that monitors switching operation of the motor switch and disables the power tool when the switching operation of the motor switch fails. In the context of an AC powered tool, the switching operation of the motor switch is correlated to and synchronized to the waveform of the AC input signal. During each cycle or half cycle, the motor control module introduces a delay period before closing the motor switch and the protective control module determines the operational status of the motor switch by measuring the voltage across the motor switch during the delay period.

Abstract: A method for controlling the operation of a motor utilizing a generic motor control module. The method includes sampling at least one motor operating criterion during operation of the motor and executing a generic control algorithm at a predetermined periodic interval. Execution of the algorithm provides a firing angle, duty cycle, or other suitable control function solution for an electronic valve for each periodic interval, thereby controlling the behavior of the motor. Additionally, the method includes firing the electronic valve at the calculated timing during each periodic interval such that the motor functions in accordance with desired motor operational parameters.

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 method for controlling the operation of a motor utilizing a generic motor control module. The method includes sampling at least one motor operating criterion during operation of the motor and executing a generic control algorithm at a predetermined periodic interval. Execution of the algorithm provides a firing angle, duty cycle, or other suitable control function solution for an electronic valve for each periodic interval, thereby controlling the behavior of the motor. Additionally, the method includes firing the electronic valve at the calculated timing during each periodic interval such that the motor functions in accordance with desired motor operational parameters.

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 system of cordless power tools includes a cordless power tool adapted to removably receive a rechargeable battery pack. The battery pack and the power tool can have complementary grooves and rails or L-shaped surfaces that aid in aligning the positive and negative blade terminals of the battery pack to the positive and negative tool terminals, respectively, of the power tool.

Abstract: A system of cordless power tools includes a cordless power tool adapted to removably receive a rechargeable battery pack. The battery pack and the power tool can have complementary grooves and rails or L-shaped surfaces that aid in aligning the positive and negative blade terminals of the battery pack to the positive and negative tool terminals, respectively, of the power tool.