Abstract: A chop saw includes a base assembly and a saw assembly pivotally attached to the base assembly. The base assembly has a workpiece-supporting plane. The saw assembly has a blade and a motor driving the blade. A hinged connection between the base assembly and a saw assembly allows a user to rotate the saw assembly from a position where the plane of the blade extends through the workpiece-supporting plane to a position where the plane of the blade does not extend through the workpiece-supporting plane. In such position, the plane of blade may be substantially parallel to the workpiece-supporting plane. A switch or sensor may detect when the saw assembly is in the pivoted position so that the motor cannot be activated in such position.

Abstract: A spindle lock assembly (410, 710) for a power tool (10) includes a first rotatable part (904, 704) fixedly connected to an output member (404) of a power tool transmission (16), and a second rotatable part (426, 726) fixedly connected to the power tool output spindle (430) and operatively engaging the first rotatable part. A lock ring (908, 708) surrounds the first and second rotatable parts. The lock ring being is retained in the housing in a substantially stationary manner with a dampener (954, 754) disposed between the lock ring and the power tool housing (772) and to dampen movements of the lock ring relative to the housing in a rotational direction. The spindle lock assembly transmits rotary motion from the transmission output member to the output spindle when the rotary output member is being driven by the motor and inhibits transmittal of rotary motion from the output spindle to the transmission output member when the output spindle is driven by an external force.

Abstract: A chop saw includes a base assembly and a saw assembly pivotally attached to the base assembly. The base assembly has a workpiece-supporting plane. The saw assembly has a blade and a motor driving the blade. A hinged connection between the base assembly and a saw assembly allows a user to rotate the saw assembly from a position where the plane of the blade extends through the workpiece-supporting plane to a position where the plane of the blade does not extend through the workpiece-supporting plane. In such position, the plane of blade may be substantially parallel to the workpiece-supporting plane. A switch or sensor may detect when the saw assembly is in the pivoted position so that the motor cannot be activated in such position.

Abstract: A power tool includes a housing, an electric motor, an end effector coupled to the motor, a control circuit configured to control electrical power delivery to the motor, and a switch for selectively providing electrical power to the control circuit. The switch includes an elongated outer casing having at least a portion exterior of the housing. The casing is linearly moveable in a first linear direction generally transverse to a longitudinal axis of the housing. A linkage is disposed inside of the housing and coupled to the casing such that linear movement of the casing in the first direction causes linear movement of the linkage in a second direction generally transverse to the first direction. An electrical switch is disposed inside the housing and coupled to the linkage such that linear movement of the linkage in the second direction causes activation of the electrical switch.

Abstract: A transmission generally includes a shaft member having a cylindrical outer surface in which longitudinal grooves are formed. Rolling members are disposed in the longitudinal grooves. A gear member having lobes the lobes is disposed between the rolling members and over the shaft member. A clutch spring that at least partially encircles the rolling members and the lobes is also disposed. The clutch spring includes a reduced torque condition that at least defines the clutch spring stretching to accommodate the rolling members leaving the longitudinal grooves and moving to the outer cylindrical surface such that the clutch spring forms a generally elliptical shape in the reduced torque condition.

Abstract: A power tool can utilize a handle that engages with a large portion of the housing and can distribute the stresses incurred by the handle over a larger area. The handle of the power tool can be a stick handle or a guard handle. The handle may be utilized to position sensors therein at positions that are remote from the working bit of the power tool. Accessory handles, such as a bail handle and a side handle, can be mounted to a single set of machined passages on the housing.

Abstract: A transmission generally includes a shaft member having a continuous cylindrical surface portion longitudinally disposed next to a cylindrical outer surface portion interrupted by longitudinal grooves. A first gear assembly has a first clutch spring that holds a first set of rolling members between lobes that extend from a first output gear. A second gear assembly has a second clutch spring that holds a second set of rolling members between lobes that extend from a second output gear. The first gear assembly and the second gear assembly are configured to move longitudinally along the shaft member to a position where at least one of the first gear assembly and the second gear assembly is engaged for rotation with the shaft member when a value of torque at the shaft member is below a torque threshold value.

Abstract: A compliant shifting mechanism can change the operation of a power tool between first and second operating conditions. The shifting mechanism can provide two distinct forces on a gear set during movement of the gear set between the two operating conditions. The shifting mechanism can provide a user with a tactile sensation of the completion of the transition between the two operating conditions without the gear set completing the full transition. A shifting mechanism can automatically complete the change between operating conditions, regardless of an alignment between the gear set and another component. The two distinct forces can be a torsional resistance force and a bending resistance force.

Abstract: A transmission generally includes a shaft member having a continuous cylindrical surface portion longitudinally disposed next to a cylindrical outer surface portion interrupted by longitudinal grooves. A first gear assembly has a first clutch spring that holds a first set of rolling members between lobes that extend from a first output gear. A second gear assembly has a second clutch spring that holds a second set of rolling members between lobes that extend from a second output gear. The first gear assembly and the second gear assembly are configured to move longitudinally along the shaft member to a position where at least one of the first gear assembly and the second gear assembly is engaged for rotation with the shaft member when a value of torque at the shaft member is below a torque threshold value.

Abstract: A transmission generally includes a shaft member having a continuous cylindrical surface portion longitudinally disposed next to a cylindrical outer surface portion interrupted by longitudinal grooves. A first gear assembly has a first clutch spring that holds a first set of rolling members between lobes that extend from a first output gear. A second gear assembly has a second clutch spring that holds a second set of rolling members between lobes that extend from a second output gear. The first gear assembly and the second gear assembly are configured to move longitudinally along the shaft member to a position where at least one of the first gear assembly and the second gear assembly is engaged for rotation with the shaft member when a value of torque at the shaft member is below a torque threshold value.

Abstract: A transmission generally includes a shaft member having a cylindrical outer surface in which longitudinal grooves are formed. Rolling members are disposed in the longitudinal grooves. A gear member having lobes the lobes is disposed between the rolling members and over the shaft member. A clutch spring that at least partially encircles the rolling members and the lobes is also disposed. The clutch spring includes a reduced torque condition that at least defines the clutch spring stretching to accommodate the rolling members leaving the longitudinal grooves and moving to the outer cylindrical surface such that the clutch spring forms a generally elliptical shape in the reduced torque condition.

Abstract: A transmission generally includes a shaft member having a continuous cylindrical surface portion longitudinally disposed next to a cylindrical outer surface portion interrupted by longitudinal grooves. A first gear assembly has a first clutch spring that holds a first set of rolling members between lobes that extend from a first output gear. A second gear assembly has a second clutch spring that holds a second set of rolling members between lobes that extend from a second output gear. The first gear assembly and the second gear assembly are configured to move longitudinally along the shaft member to a position where at least one of the first gear assembly and the second gear assembly is engaged for rotation with the shaft member when a value of torque at the shaft member is below a torque threshold value.

Abstract: A compliant shifting mechanism can change the operation of a power tool between first and second operating conditions. The shifting mechanism can provide two distinct forces on a gear set during movement of the gear set between the two operating conditions. The shifting mechanism can provide a user with a tactile sensation of the completion of the transition between the two operating conditions without the gear set completing the full transition. A shifting mechanism can automatically complete the change between operating conditions, regardless of an alignment between the gear set and another component. The two distinct forces can be a torsional resistance force and a bending resistance force.

Abstract: A power tool can utilize a handle that engages with a large portion of the housing and can distribute the stresses incurred by the handle over a larger area. The handle of the power tool can be a stick handle or a guard handle. The handle may be utilized to position sensors therein at positions that are remote from the working bit of the power tool. Accessory handles, such as a bail handle and a side handle, can be mounted to a single set of machined passages on the housing.

Abstract: A power tool for drilling a hole in a workpiece made of wood or a wood material. The power tool generally includes a tool housing defining a handle and a motor contained within the tool housing that includes an output shaft that spins about a motor axis. A gear housing is connected to the tool housing. An output spindle is supported for rotation about a spindle axis in the gear housing. The spindle axis is disposed about ninety degrees from the motor axis. A gear portion on the output shaft is engaged to a gear portion on the output spindle. The motor and the gear portions are configured to rotate the output spindle at a speed in range from about five thousand revolutions per minute to about twenty-five thousand revolutions per minute. A cutting member is connected to the output spindle. The cutting member includes fluted cutting blades. A carriage assembly includes a base member and a head member connected by a first post having a first compliant member and a second post.

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 power tool for drilling a hole in a workpiece made of wood or a wood material. The power tool generally includes a tool housing defining a handle and a motor contained within the tool housing that includes an output shaft that spins about a motor axis. A gear housing is connected to the tool housing. An output spindle is supported for rotation about a spindle axis in the gear housing. The spindle axis is disposed about ninety degrees from the motor axis. A gear portion on the output shaft is engaged to a gear portion on the output spindle. The motor and the gear portions are configured to rotate the output spindle at a speed in range from about five thousand revolutions per minute to about twenty-five thousand revolutions per minute. A cutting member is connected to the output spindle. The cutting member includes fluted cutting blades. A carriage assembly includes a base member and a head member connected by a first post having a first compliant member and a second post.

Abstract: A transmission generally includes a shaft member having a continuous cylindrical surface portion longitudinally disposed next to a cylindrical outer surface portion interrupted by longitudinal grooves. A first gear assembly has a first clutch spring that holds a first set of rolling members between lobes that extend from a first output gear. A second gear assembly has a second clutch spring that holds a second set of rolling members between lobes that extend from a second output gear. The first gear assembly and the second gear assembly are configured to move longitudinally along the shaft member to a position where at least one of the first gear assembly and the second gear assembly is engaged for rotation with the shaft member when a value of torque at the shaft member is below a torque threshold value.

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.