Abstract: A power tool is provided including a housing and an electric motor disposed within the housing, where the electric motor includes a stator and an armature rotatably received within the stator, and the armature includes an armature shaft on which a commutator is mounted. The power tool includes a brush assembly disposed around the commutator. The brush assembly includes at least two brushes in contact with the commutator and a circuit board mounted on the brush assembly and in electrical contact with the brushes. The circuit board includes at least one electromagnetic interference (EMI) suppression component electrically mounted thereon, the EMI suppression component being electrically coupled to the brushes.

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 unit 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: 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 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 power tool having a light for illuminating an area proximate a movable end effector. The light may be mounted in such a way as to transmit light through a rotatable collar on the power tool, through or through a member of a housing of the power tool, or from the moving end effector. The light may be powered by a power source that is used for moving the end effector or from a generator that generates electrical power when the power tool is used.

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 including a motor, light unit, and switch unit for selectively connecting the motor and light unit to a power source. A control module includes a controller coupled to a first electronic switch to control power delivery to the motor based on a position of the switch unit, and to a second electronic switch to control power delivery to the light source based on a position of the switch unit. A timer is configured to keep the light unit illuminated for a predetermined amount of time after the switch unit has been activated or deactivated. The control module also includes a boot circuit with a semiconductor switch that continues to deliver power to the controller and to the light unit when the switch unit is deactivated subsequent to being activated, to enable the light unit to remain illuminated after the switch unit has been deactivated.

Abstract: A power tool is provided including a housing and an electric motor disposed within the housing, where the electric motor includes a stator and an armature rotatably received within the stator, and the armature includes an armature shaft on which a commutator is mounted. The power tool includes a brush assembly disposed around the commutator. The brush assembly includes at least two brushes in contact with the commutator and a circuit board mounted on the brush assembly and in electrical contact with the brushes. The circuit board includes at least one electromagnetic interference (EMI) suppression component electrically mounted thereon, the EMI suppression component being electrically coupled to the brushes.

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 is provided including an electric motor and a tool housing arranged to house the motor. The electric motor includes a stator, an armature rotatably with respect to the stator and having an armature shaft, and a fan rotatably attached to the armature adjacent the stator. The fan includes blades each having an angled side edge such that a longitudinal length of each blade is smaller at an outer periphery of the fan than at an inner edge of the fan blade near the armature shaft. The tool housing includes an annular rib disposed around a periphery of the housing in close proximity to the fan. The annular rib has an angled surface substantially parallel to the angled side edges of the fan blades to contain airflow generated by the fan in a centrifugal direction of the power tool radially from the armature shaft.

Abstract: A permanent magnet electric motor has a stator and a rotor. The stator includes a stator housing with at least a North pole and a South pole, each pole including permanent magnets of the same polarity including two outer magnets arranged at pole tips and at least one inner magnet disposed therebetween. The outer magnets have greater thickness than the inner magnet to provide higher demagnetization resistance than the at least one inner magnet within each pole. The magnets are affixed to an inner surface of the stator housing, and the inner surface of the stator housing include a projected surface within each pole to which the inner magnet is affixed so that surfaces of the inner and outer magnets facing a center of the stator housing are arranged at a same distance from the center of the stator housing.

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: 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 back surface of the brush includes at least one curved surface and a groove. A torsion spring is secured to the brush card mount adjacent the brush holder, the spring having a leg arranged to engage the groove of the back surface of the brush.

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 includes a stator, an armature shaft rotatable with respect to the stator, and a lamination stack mounted on the armature shaft and having radially extending teeth forming slots therebetween circumferentially around a periphery of the lamination stack. An armature end insulator is provided at an end of the lamination stack having a base portion fitted around the armature shaft and insulating teeth corresponding to the radially extending teeth of the lamination stack and forming slots therebetween. Motor coils are wound in the lamination stack slots and the end insulator slots. The motor further includes a fan having blades attached to a fan ring and mounted to an end of the lamination stack.

Abstract: An electric motor includes a stator, an armature rotatably received within the stator and having an armature shaft on which a commutator is mounted, and a brush assembly defining a first surface facing the stator and a second surface opposite the first surface. The brush assembly includes a brush card mount disposed around the commutator, brushes in sliding contact with the commutator to supply electric current to the commutator, and thermally-conductive brush holders. Each brush holder 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 second surface of the brush assembly to house a respective brush. The base portions of the brush holders are exposed on the first surface of the brush assembly to transfer heat generated by the brushes through the first 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 defines a first surface facing the stator and a second surface opposite the first surface. The brush assembly includes a brush card mount, brushes in sliding contact with the commutator to supply electric current to the commutator, and thermally-conductive brush holders disposed on the second surface of the brush assembly to house the brushes and secured to the brush card mount. Each brush holder includes projections formed along a length of an outer surface of the brush holder to increase a total surface area of the brush holder and transfer heat away from the brush holder.

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: A power tool including a end effector rotatable with respect to the housing, a collar rotatable with respect to the housing, a printed circuit board (PCB) rotatably fixed with respect to the housing, and a light element operatively connected to the PCB and adjacent to the end effector and in a recess of the collar and located to illuminate a workpiece machined by the power tool. A method of providing light for a workpiece being machined by a power tool including locating lighting elements around a spindle of a power tool, aligning the lighting elements to shine light on a workpiece being machined by the power tool, operatively connecting the lighting elements to a PCB, containing and supporting the PCB with a guide, supporting wires configured to provide power to the PCB with the guide, locating the lighting elements, PCB and guide in a rotatable collar, and preventing the lighting elements, PCB and guide from rotating when the collar rotates.

Abstract: A power tool includes a housing having a large diameter rear portion and a narrow diameter nosepiece. An end effector is rotatably coupled to the housing. A holder with a substantially annular holder body is received over the nosepiece and non-rotatably coupled to the housing. A substantially annular cover having at least one transparent surface, and an internal annular groove, is received at least partially inside the holder body, and non-rotatably and axially fixed with respect to the holder. A substantially annular printed circuit board is received at least partially inside the annular groove in the cover, and non-rotatably and axially fixed with respect to the cover. A plurality of lighting elements is operatively connected to the printed circuit board and radially disposed about the printed circuit board. The lighting elements are aligned with the at least one transparent surface so as to illuminate a workpiece.