Patents by Inventor Shailesh P. Waikar
Shailesh P. Waikar has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20240364159Abstract: A brushless direct-current (BLDC) motor is provided. The motor includes a stator including a stator core, stator teeth, and windings; a rotor shaft disposed within the stator and extending along a longitudinal axis; and a rotor. The rotor includes a rotor core including a body extending around the longitudinal axis, a permanent magnet mounted on the body of the rotor core, and a mold structure formed at least partially through the rotor core. In an embodiment, the mold structure engages two axial ends of the permanent magnet to axially retain the permanent magnet relative to the rotor core and integrally forms a fan adjacent the rotor core. In an embodiment, the permanent magnet includes at least one tooth extending from an axial end thereof and having angled side edges, and the mold structure engages the at least one tooth to fixedly secure the permanent magnet to the rotor core.Type: ApplicationFiled: July 11, 2024Publication date: October 31, 2024Applicant: Black & Decker Inc.Inventors: Tong ZHENG, Yeli GU, Fulong LIU, Changxing LU, Abraham SANCHEZ, Shailesh P. WAIKAR, David J. SMITH
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Patent number: 12068639Abstract: A brushless direct-current (BLDC) motor is provided. The motor includes a stator including a stator core, stator teeth, and windings; a rotor shaft disposed within the stator and extending along a longitudinal axis; and a rotor. The rotor includes a rotor core having a cylindrical body, a permanent magnet ring mounted on an outer surface of the cylindrical body with no intermediate adhesive therebetween, and metal sleeve securely fitted outside the permanent magnet ring. The metal sleeve includes a flange extending radially inwardly that covers an axial end of the permanent magnet ring and is bonded to the rotor core to secure the permanent magnet ring to the rotor core.Type: GrantFiled: June 3, 2022Date of Patent: August 20, 2024Assignee: Black & Decker Inc.Inventors: Changxing Lu, Abraham Sanchez, Tong Zheng, Fulong Liu, Yeli Gu, David J. Smith, Shailesh P. Waikar
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Publication number: 20240072599Abstract: An electric power apparatus includes a main planar body having a circular opening that supports a brushless direct-current (BLDC) motor. The motor includes a stator, a rotor, a motor spindle extending through the circular opening, a first end cap formed on a first side of the stator and mounted on the main planar body; and a second end cap formed on a second side of the stator and secured to the first end cap to form a substantially watertight seal around the stator and the rotor. A ratio of a maximum power output of the motor when powered by at least one battery pack to a height of the motor as measured from an upper surface of the main planar body to a top surface of the motor is greater than or equal to approximately 34 watts/mm.Type: ApplicationFiled: August 22, 2023Publication date: February 29, 2024Applicant: BLACK & DECKER INC.Inventors: JOHN B. FOGLE, KEVIN L. PULLEY, MARK J. CLEMENTI, JAMES M. NOBIS, SHAILESH P. WAIKAR, DAVID M. KELLY, NATHANIEL K. BYRNE, TIMOTHY A. CLAPP
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Publication number: 20240072613Abstract: An electric power apparatus includes a main planar body having a circular opening that supports a brushless direct-current (BLDC) motor. The motor includes a stator, a rotor, a motor spindle extending through the circular opening, a first end cap formed on a first side of the stator and mounted on the main planar body; and a second end cap formed on a second side of the stator and secured to the first end cap to form a substantially airtight sealed compartment around the stator and the rotor. The rotor includes a series of openings in a radial wall that generates an airflow circulating through the sealed compartment to transfer heat from the stator to the first end cap and the second end cap.Type: ApplicationFiled: August 22, 2023Publication date: February 29, 2024Applicant: BLACK & DECKER INC.Inventors: JOHN B. FOGLE, KEVIN L. PULLEY, MARK J. CLEMENTI, JAMES M. NOBIS, SHAILESH P. WAIKAR, VINCENT W. ZOU
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Publication number: 20240072604Abstract: An electric motor is provided including a stator, a rotor, a motor spindle coupled to the rotor and extending along a center axis, a first end cap formed on a first side of the stator, a second end cap formed on a second side of the stator and secured to the first end cap to form a first compartment around the stator and the rotor, an electro-magnetic brake module disposed on a side of the second end cap opposite the stator and engaged with the motor spindle, and a motor cover mounted on the second end cap to form a second compartment around the electro-magnetic brake module. The first end cap, the second end cap, and the motor cover form a substantially watertight seal around the stator, the rotor, and the position sensor assembly.Type: ApplicationFiled: August 22, 2023Publication date: February 29, 2024Applicant: BLACK & DECKER INC.Inventors: JOHN B. FOGLE, KEVIN L. PULLEY, MARK J. CLEMENTI, JAMES M. NOBIS, SHAILESH P. WAIKAR, DAVID M. KELLY, NATHANIEL K. BYRNE, TIMOTHY A. CLAPP
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Publication number: 20240072586Abstract: An electric motor is provided including a stator, a rotor, a motor spindle coupled to the rotor and extending along a center axis, a first end cap formed on a first side of the stator, a second end cap formed on a second side of the stator and secured to the first end cap to form a first compartment around the stator and the rotor, and a motor component mounted on the second end cap outside the first compartment. A motor cover is mounted on the second end cap to form a second compartment around the motor component. The first end cap, the second end cap, and the motor cover form a substantially watertight seal around the stator, the rotor, and the position sensor assembly.Type: ApplicationFiled: August 22, 2023Publication date: February 29, 2024Applicant: BLACK & DECKER INC.Inventors: JOHN B. FOGLE, KEVIN L. PULLEY, MARK J. CLEMENTI, JAMES M. NOBIS, SHAILESH P. WAIKAR
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Patent number: 11916447Abstract: A brushless direct-current (BLDC) motor is provided. The motor includes a stator including a stator core, stator teeth, and windings; a rotor shaft disposed within the stator and extending along a longitudinal axis; and a rotor. The rotor includes a rotor core including an inner body mounted on the rotor shaft and radial projections projecting outwardly from the inner body, a permanent magnet mounted on an outer end of the radial projections, and a mold structure formed in contact with the radial projections and configured to secure the permanent magnet to the rotor core.Type: GrantFiled: June 3, 2022Date of Patent: February 27, 2024Assignee: Black & Decker Inc.Inventors: Tong Zheng, Yeli Gu, Fulong Liu, Changxing Lu, Abraham Sanchez, Shailesh P. Waikar, David J. Smith
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Publication number: 20230361697Abstract: A control unit for a brushless DC motor of a power tool having a rotor and a stator is provided. The control unit detects an initial position of the rotor, commutates the motor beginning at the initial position of the rotor using a low-speed motor commutation scheme until an output speed of the rotor exceeds a speed threshold, and commutates the motor based on a back-electromotive force (back-EMF) voltage of the motor after the output speed of the rotor exceeds the speed threshold. In the low-speed commutation scheme, the control unit applies a first set of voltage pulses to a present sector and a second set of voltage pulses to a next sector, and detects a transition of the rotor from the present sector to the next sector based on motor current measurements associated with the first set of voltage pulses and the second set of voltage pulses.Type: ApplicationFiled: July 14, 2023Publication date: November 9, 2023Applicant: Black & Decker Inc.Inventors: Shailesh P. WAIKAR, Zhi QU, Wing LIN, John C. VANKO
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Patent number: 11750124Abstract: A control unit for a brushless DC motor of a power tool having a rotor and a stator is provided. The control unit detects an initial position of the rotor, commutates the motor beginning at the initial position of the rotor using a low-speed motor commutation scheme until an output speed of the rotor exceeds a speed threshold, and commutates the motor based on a back-electromotive force (back-EMF) voltage of the motor after the output speed of the rotor exceeds the speed threshold. In the low-speed commutation scheme, the control unit applies a first set of voltage pulses to a present sector and a second set of voltage pulses to a next sector, and detects a transition of the rotor from the present sector to the next sector based on motor current measurements associated with the first set of voltage pulses and the second set of voltage pulses.Type: GrantFiled: June 22, 2022Date of Patent: September 5, 2023Assignee: Black & Decker Inc.Inventors: Shailesh P. Waikar, Zhi Qu, Wing Lin, John C. Vanko
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Patent number: 11750069Abstract: A power adaptor is provided including a housing receiving a first power cord couplable to a power source through a and a second power cord couplable to a load through a second axial end, a protective capacitor mounted on a circuit board within the housing, a first set of terminals mounted on a first side of the circuit board adjacent the protective capacitor and configured to electrically couple line and neutral wires of the first power cord to the protective capacitor, and a second set of terminals mounted on a second side of the circuit board adjacent the protective capacitor and configured to electrically couple line and neutral wires of the second power cord to the protective capacitor. The protective capacitor is configured to discharge when current draw by the load exceeds a current threshold.Type: GrantFiled: September 14, 2021Date of Patent: September 5, 2023Assignee: Black & Decker Inc.Inventors: Erik A. Ekstrom, Shailesh P. Waikar, Joseph B. Narbut, Alexandros T. Theos, Daniel F. Nace, Zachary S. Olmsted
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Publication number: 20220393534Abstract: A brushless direct-current (BLDC) motor is provided. The motor includes a stator including a stator core, stator teeth, and windings; a rotor shaft disposed within the stator and extending along a longitudinal axis; and a rotor. The rotor includes a rotor core having a cylindrical body, a permanent magnet ring mounted on an outer surface of the cylindrical body with no intermediate adhesive therebetween, and metal sleeve securely fitted outside the permanent magnet ring. The metal sleeve includes a flange extending radially inwardly that covers an axial end of the permanent magnet ring and is bonded to the rotor core to secure the permanent magnet ring to the rotor core.Type: ApplicationFiled: June 3, 2022Publication date: December 8, 2022Inventors: Changxing LU, Abraham SANCHEZ, Tong ZHENG, Fulong LIU, Yeli GU, David J. SMITH, Shailesh P. WAIKAR
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Publication number: 20220393559Abstract: A brushless direct-current (BLDC) motor is provided. The motor includes a stator including a stator core, stator teeth, and windings; a rotor shaft disposed within the stator and extending along a longitudinal axis; and a rotor. The rotor includes a rotor core including an inner body mounted on the rotor shaft and radial projections projecting outwardly from the inner body, a permanent magnet mounted on an outer end of the radial projections, and a mold structure formed in contact with the radial projections and configured to secure the permanent magnet to the rotor core.Type: ApplicationFiled: June 3, 2022Publication date: December 8, 2022Inventors: Tong ZHENG, Yeli GU, Fulong LIU, Changxing LU, Abraham SANCHEZ, Shailesh P. WAIKAR, David J. SMITH
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Publication number: 20220329180Abstract: A control unit for a brushless DC motor of a power tool having a rotor and a stator is provided. The control unit detects an initial position of the rotor, commutates the motor beginning at the initial position of the rotor using a low-speed motor commutation scheme until an output speed of the rotor exceeds a speed threshold, and commutates the motor based on a back-electromotive force (back-EMF) voltage of the motor after the output speed of the rotor exceeds the speed threshold. In the low-speed commutation scheme, the control unit applies a first set of voltage pulses to a present sector and a second set of voltage pulses to a next sector, and detects a transition of the rotor from the present sector to the next sector based on motor current measurements associated with the first set of voltage pulses and the second set of voltage pulses.Type: ApplicationFiled: June 22, 2022Publication date: October 13, 2022Inventors: Shailesh P. WAIKAR, Zhi QU, Wing LIN, John C. VANKO
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Publication number: 20220085699Abstract: A power adaptor is provided including a housing receiving a first power cord couplable to a power source through a and a second power cord couplable to a load through a second axial end, a protective capacitor mounted on a circuit board within the housing, a first set of terminals mounted on a first side of the circuit board adjacent the protective capacitor and configured to electrically couple line and neutral wires of the first power cord to the protective capacitor, and a second set of terminals mounted on a second side of the circuit board adjacent the protective capacitor and configured to electrically couple line and neutral wires of the second power cord to the protective capacitor. The protective capacitor is configured to discharge when current draw by the load exceeds a current threshold.Type: ApplicationFiled: September 14, 2021Publication date: March 17, 2022Inventors: Erik A. EKSTROM, Shailesh P. WAIKAR, Joseph B. NARBUT, JR., Alexandros T. THEOS, Daniel F. NACE, Zachary S. OLMSTED
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Patent number: 11171586Abstract: A power tool is provided including a brushless motor having a stator defining a plurality of phases, a rotor rotatable relative to the stator, and power terminals electrically connected to the phases of the motor. A power unit is provided including power switches. A control unit is interfaced with the power unit to output a drive signal to one or more of the motor switches to drive the phases of the motor over a series of sectors of the rotor rotation. The control unit is configured detect incorrect rotation of the rotor by applying a first series of voltage pulses to a present sector and a second series of voltage pulses to a previous sector, measuring motor currents associated with the first and second series of voltage pulses, and comparing corresponding motor current measurements to detect a transition from the present sector to the previous sector.Type: GrantFiled: April 20, 2020Date of Patent: November 9, 2021Assignee: Black & Decker Inc.Inventors: Shailesh P. Waikar, Zhi Qu, Wing Lin
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Patent number: 10992207Abstract: A power tool has a housing, a motor disposed within the housing, a power supply circuit for providing power to the motor, a controller circuit for controlling the power provided to the motor, and an electric static discharge (ESD) protection circuit connected to the power supply circuit and the housing. The ESD protection circuit includes a first resistor connected to the power supply circuit and the housing. The first resistor may be a high impedance resistor. The ESD protection circuit may also have a first capacitor connected in parallel to the first resistor, a second resistor connected in series to the first resistor, and a second capacitor connected in series to the first capacitor and in parallel to the second resistor.Type: GrantFiled: June 10, 2019Date of Patent: April 27, 2021Assignee: BLACK & DECKER INC.Inventors: Scott J. Eshleman, Shailesh P. Waikar, Ganapati K. Pai, Joseph Narbut
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Publication number: 20200343839Abstract: A power tool is provided including a brushless motor having a stator defining a plurality of phases, a rotor rotatable relative to the stator, and power terminals electrically connected to the phases of the motor. A power unit is provided including power switches. A control unit is interfaced with the power unit to output a drive signal to one or more of the motor switches to drive the phases of the motor over a series of sectors of the rotor rotation. The control unit is configured detect incorrect rotation of the rotor by applying a first series of voltage pulses to a present sector and a second series of voltage pulses to a previous sector, measuring motor currents associated with the first and second series of voltage pulses, and comparing corresponding motor current measurements to detect a transition from the present sector to the previous sector.Type: ApplicationFiled: April 20, 2020Publication date: October 29, 2020Inventors: Shailesh P. WAIKAR, Zhi QU, Wing LIN
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Publication number: 20190393761Abstract: A power tool has a housing, a motor disposed within the housing, a power supply circuit for providing power to the motor, a controller circuit for controlling the power provided to the motor, and an electric static discharge (ESD) protection circuit connected to the power supply circuit and the housing. The ESD protection circuit includes a first resistor connected to the power supply circuit and the housing. The first resistor may be a high impedance resistor. The ESD protection circuit may also have a first capacitor connected in parallel to the first resistor, a second resistor connected in series to the first resistor, and a second capacitor connected in series to the first capacitor and in parallel to the second resistor.Type: ApplicationFiled: June 10, 2019Publication date: December 26, 2019Inventors: Scott J. Eshleman, Shailesh P. Waikar, Ganapati K. Pai, Joseph Narbut
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Patent number: 10414033Abstract: A mode selector switch for a power tool that can have a source of a magnetic field and use a magnetoresistive component to produce an output signal that changes when the strength of the magnetic field changes. The power tool can have a microprocessor that changes an operational mode of the power tool based on a change of the output signal from the magnetoresistive component. The magnetoresistive component can be a Hall effect sensor and the power tool can be a nailer. The power tool can have a switching means which changes an operational mode based upon a change in the strength of the magnetic field upon a magnetoresistive component. A method of controlling a power tool, having a step of changing an operational mode of a power tool based upon identifying a change in output from a magnetoresistor.Type: GrantFiled: March 15, 2013Date of Patent: September 17, 2019Assignee: Black & Decker Inc.Inventors: Erik Ekstrom, Stuart E. Garber, Jongsoo Lim, David J. Smith, Shailesh P. Waikar
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Publication number: 20180034346Abstract: A power tool is provided including a housing, a brushless DC motor housed inside the housing, and a control unit housed inside the housing for controlling an operation of the brushless DC motor. The control unit includes a potting boat having an open portion, a circuit board received within the potting boat through the open portion, power switching elements mounted on the circuit board, a potting compound receiving within the potting boat to substantially surround the circuit board, and a heat sink in thermal communication with the power switching elements. The heat sink has a surface exposed outside the potting compound through the open portion of the potting boat.Type: ApplicationFiled: October 10, 2017Publication date: February 1, 2018Applicant: Black & Decker Inc.Inventors: Madhur M. Purohit, Shailesh P. Waikar, Marcell E. Coates