Abstract: An electric grinding tool includes a motor housing coupleable to an electrical power source, a motor configured to receive power from the electrical power source and including an output shaft extending along a motor axis, a handgrip coupled to and coaxial with the motor housing, a tool holder rotatably driven upon rotation of the motor, the tool holder configured to receive a shaft of a grinding accessory, and a light unit coupled to and at least partially recessed in a front end portion of the electric grinding tool. The light unit includes a plurality of lights mounted to an at least partially ring shaped printed circuit board that is received in a support ring, and a cover ring received over the lights.

Abstract: A power tool includes a housing, a nosepiece, and an end effector rotatably coupled to the housing. A substantially annular holder body is axially and non-rotatably coupled to the nosepiece. A circuit board is received in an internal substantially annular groove in a rear face of the front wall of the holder body between the holder body and the nosepiece. A light unit is coupled to the circuit board and configured to illuminate the workpiece. A wire assembly electrically couples the light unit to a source of electrical power.

Abstract: A stator assembly for a brushless DC motor includes a stator core including stator poles and an outer surface, at least one magnet wire wound on the poles forming stator windings, and a bus bar including a non-conductive mount arranged on the outer surface and conductive terminals. Each conductive terminal includes: a main portion mounted on the non-conductive mount substantially parallel to the longitudinal axis of the motor, a tang portion folded over the main portion from a first longitudinal end of the main portion, and a connection tab at a second longitudinal end of the main portion. At least a contact portion of the at least one magnet wire is wrapped around the tang portion and fused to make an electric connection to the conductive terminal, and the connection tab makes electric contact with a wire supplying electric power to the motor.

Abstract: A stator assembly for a brushless DC motor includes a stator core including stator poles and an outer surface, at least one magnet wire wound on the poles forming stator windings, and a bus bar including a non-conductive mount arranged on the outer surface and conductive terminals. Each conductive terminal includes: a main portion mounted on the non-conductive mount substantially parallel to the longitudinal axis of the motor, a tang portion folded over the main portion from a first longitudinal end of the main portion, and a connection tab at a second longitudinal end of the main portion. At least a contact portion of the at least one magnet wire is wrapped around the tang portion and fused to make an electric connection to the conductive terminal, and the connection tab makes electric contact with a wire supplying electric power to the motor.

Abstract: A solar power system and method of operation includes a solar array, a plurality of loads electrically coupled in parallel to the solar array, and a control circuit electrically coupled to the solar array and in communication with the loads. The control circuit is configured to cause the solar array to operate at a maximum power point (MPP), prioritize power requirements of the loads, and variably allocate power from the solar array among the loads according to the prioritized power requirements of the loads.

Abstract: A stator assembly for a brushless DC motor includes a stator core defining poles and having an outer surface, at least one magnet wire wound on the poles forming phases, and a bus bar including a non-conductive mount arranged on the outer surface and conductive terminals. Each conductive terminal includes: a main portion mounted on the non-conductive mount substantially parallel to the longitudinal axis of the motor, a tang portion folded over the main portion from a first longitudinal end of the main portion, and a connection tab at a second longitudinal end of the main portion. At least a contact portion of the at least one magnet wire is wrapped around the tang portion and fused to make an electric connection to the conductive terminal, and the connection tab is arranged to makes electric contact with a wire supplying electric power to the motor.

Abstract: A solar power system and method of operation includes a solar array, a plurality of loads electrically coupled in parallel to the solar array, and a control circuit electrically coupled to the solar array and in communication with the loads. The control circuit is configured to cause the solar array to operate at a maximum power point (MPP), prioritize power requirements of the loads, and variably allocate power from the solar array among the loads according to the prioritized power requirements of the loads.

Abstract: An electric motor is provided including: a stator, an armature rotatably received within the stator and having an armature shaft on which a commutator is mounted, and a brush assembly. The brush assembly defines a first side facing the stator and a second side. The brush assembly includes a brush card mount having openings, brushes in sliding contact with the commutator, and thermally-conductive brush holders that support the brushes. Each brush holder includes a base piece disposed between the first side of the brush assembly and the stator, and a main piece including a brush-holder portion and two side flat portions. The brush-holder portion is axially received through a brush card mount opening from the first side of the brush assembly and protrude over the second side to house a brush. The two side flat portions are axially sandwiched between the base piece and the brush card mount.

Abstract: A power tool includes a tool body including a motor having an output member that drives an accessory. A chuck is coupled for rotation with the output member relative to the tool body and configured to retain the accessory. The chuck has a chuck body that defines at least one light pipe formed therethrough. A light source disposed on a light ring coupled to the tool body and includes at least one light. Each at least one light source aligns with each of the at least one light pipe intermittently during rotation of the chuck.

Abstract: A stator assembly for a brushless DC motor includes a stator core defining poles and having an outer surface, at least one magnet wire wound on the poles forming phases, and a bus bar including a non-conductive mount arranged on the outer surface and conductive terminals. Each conductive terminal includes: a main portion mounted on the non-conductive mount substantially parallel to the longitudinal axis of the motor, a tang portion folded over the main portion from a first longitudinal end of the main portion, and a connection tab at a second longitudinal end of the main portion. At least a contact portion of the at least one magnet wire is wrapped around the tang portion and fused to make an electric connection to the conductive terminal, and the connection tab is arranged to makes electric contact with a wire supplying electric power to the motor.

Abstract: A power tool includes a tool body including a motor having an output member that drives an accessory. A chuck is coupled for rotation with the output member relative to the tool body and configured to retain the accessory. The chuck has a chuck body that defines at least one light pipe formed therethrough. A light source disposed on a light ring coupled to the tool body and includes at least one light. Each at least one light source aligns with each of the at least one light pipe intermittently during rotation of the chuck.

Abstract: An electric motor is provided including: a stator, an armature rotatably received within the stator and having an armature shaft on which a commutator is mounted, and a brush assembly. The brush assembly defines a first side facing the stator and a second side. The brush assembly includes a brush card mount having openings, brushes in sliding contact with the commutator, and thermally-conductive brush holders that support the brushes. Each brush holder includes a base piece disposed between the first side of the brush assembly and the stator, and a main piece including a brush-holder portion and two side flat portions. The brush-holder portion is axially received through a brush card mount opening from the first side of the brush assembly and protrude over the second side to house a brush. The two side flat portions are axially sandwiched between the base piece and the brush card mount.

Abstract: An electric motor is provided including: a stator, an armature rotatably received within the stator and having an armature shaft on which a commutator is mounted, and a brush assembly. The brush assembly defines a first surface facing the stator and a second surface opposite the first surface. The brush assembly includes a brush card mount having openings, brushes in sliding contact with the commutator to supply electric current to the commutator, and thermally-conductive brush holders that house the brushes. Each of the brush holders includes a base portion disposed substantially along a same plane as a surface of the brush card mount to form the first surface of the brush assembly, and a main portion protruding from the base portion through a respective opening of the brush card mount to house a respective brush at least partially over the second surface of the brush assembly.

Abstract: An electric motor is provided including a stator, an armature rotatably received within the stator and having an armature shaft on which a commutator is mounted, and a brush assembly. The brush assembly includes a planar portion disposed around the commutator and accommodating a plurality of brushes, a bridge portion disposed at an end of the commutator and extending from the planer portion via two or more legs, and metal routing(s) disposed on or within the bridge portion to electrically couple the brushes.

Abstract: An electric motor is provided including a stator and an armature rotatably received within the stator, the armature having an armature shaft on which a commutator is mounted. The motor also includes a brush assembly having a brush card mount disposed around the commutator, a brush holder mounted on a surface of the brush card mount, and a brush disposed within the brush holder in sliding contact with the commutator to supply electric current to the commutator. A torsion spring is secured to the brush card mount adjacent the brush holder, the spring having a leg arranged to engage the back surface of the brush. A spring stop post is disposed proximate an outer periphery of the brush card mount to limit an outward movement of the leg of the spring away from the back surface of the brush.

Abstract: A power tool includes a housing coupled to an electrical power source, a motor contained in the housing, and a motor control circuit that controls output speed of the motor. A light nut is coupled to the housing to illuminate a work surface. A light unit control circuit controls illumination of the light, unit. A switch unit is coupled to the housing and selectively operable to control the operation of the motor control circuit and the light unit control circuit. The light unit control circuit includes a timer configured to cause the light unit to illuminate a first brightness level when the switch unit is actuated, and to remain illuminated at the first brightness level for a predetermined time period after the trigger is actuated. The predetermined time period restarts if the switch unit is not deactivated before the end of the predetermined time period.

Abstract: An electric motor includes a stator, a shaft rotatable with respect to the stator, and a lamination stack mounted on the shaft and having radially extending teeth forming slots therebetween. An end insulator is provided at an end of the lamination stack having forming slots therebetween. Motor coils are wound in the lamination stack slots and the end insulator slots. A fan having blades attached to a fan ring and mounted to an end of the lamination stack. The fan ring includes longitudinally-extending tongues arranged to be mounted at the end of the lamination stack and the end insulator includes longitudinally-extending notches corresponding to the tongues of the fan ring to allow the tongues to be in direct contact with the end of the lamination stack.

Abstract: A power tool is provided including a housing and an electric motor including a stator and an armature rotatably received within the stator. The armature includes an armature shaft on which a commutator is mounted. The power tool includes a rear bearing mounted on the armature shaft adjacent the armature, and a brush assembly disposed around the commutator. The brush assembly includes a brush card, at least two brushes secured to the brush card around and in contact with the commutator, and a bridge cap extending from the brush card via legs and forming a bearing support for supporting the rearing bearing. At least one electromagnetic interference (EMI) suppression component is provided having a first terminal electrically coupled to the brush(es) and a second terminal electrically coupled to the rear bearing through the bridge cap so as to substantially ground the second terminal of the EMI suppression component.

Abstract: An electric motor is provided including a stator assembly having a stator body and magnets attached to an inner surface of the stator body via an adhesive, and an armature rotatably received within the stator assembly and having an armature shaft on which a commutator is mounted. A brush assembly is provided including a brush card mount disposed around the commutator and a mating housing longitudinally extending from the brush card mount. The mating housing includes a cylindrical wall and a mating surface formed substantially perpendicularly to an inner surface of the cylindrical wall and arranged to mate with an end surface of the stator body. The mating surface of the mating housing includes posts longitudinally extending along the inner surface of the cylindrical wall and recessed surfaces formed therebetween, the posts being mounted on the end surface of the stator body.

Abstract: A power tool includes a housing coupled to an electrical power source, a motor contained in the housing, and a motor control circuit that controls output speed of the motor. A light nut is coupled to the housing to illuminate a work surface. A light unit control circuit controls illumination of the light, unit. A switch unit is coupled to the housing and selectively operable to control the operation of the motor control circuit and the light unit control circuit. The light unit control circuit includes a timer configured to cause the light unit to illuminate a first brightness level when the switch unit is actuated, and to remain illuminated at the first brightness level for a predetermined time period after the trigger is actuated. The predetermined time period restarts if the switch unit is not deactivated before the end of the predetermined time period.