Abstract: A method for automatic control switching for driving a sensorless motor of a power tool, the method including generating, using a signal generator, a high-frequency injection signal. The method includes coupling, using a coupling circuit, the high-frequency injection signal to an injection coil of the sensorless motor. The method includes decoupling, using a de-coupling circuit, a response to the high-frequency injection signal from a phase coil of the sensorless motor. The method includes determine a sensorless motor condition based upon the response of the injection coil to the high-frequency injection signal. The method includes driving, using a controller of the power tool, the sensorless motor based upon the sensorless motor condition.

Abstract: Position sensing related to a component within a power tool. The component within the power tool is, for example, a hammer of an impact mechanism and can include one or more sensible features that allow a controller of the power tool to precisely determine the position, speed, and acceleration of the component. One or more sensors can be used to determine the rotational position of the hammer and the axial position of the hammer. The rotational position of the hammer can then be used to calculate, for example, rotational speed and acceleration of the hammer. With precise determinations of the rotational and axial position of the hammer, the controller of the power tool is able to precisely time the impact between the hammer and the anvil to optimize the impact between the hammer and the anvil (e.g., to maximize energy transfer between the hammer and the anvil).

Abstract: Electronic spindle lock for a power tool. One embodiment provides a power tool including a housing, a bit receiving portion provided on the housing for receiving a power tool bit, a motor within the housing configured to rotate the bit receiving portion, and a controller coupled to the motor. The controller is configured to enter an electronic spindle lock mode, and detect rotation of the bit receiving portion in a first direction. The controller is also configured to control motor to rotate in a second direction in response to detecting rotation of the bit receiving portion in the first direction.

Abstract: A wireless hoist system including a first hoist device having a first motor and a first wireless transceiver and a second hoist device having a second motor and a second wireless transceiver. The wireless hoist system includes a controller in wireless communication with the first wireless transceiver and the second wireless. The controller is configured to receive a user input and determine a first operation parameter and a second operation parameter based on the user input. The controller is also configured to provide, wirelessly, a first control signal indicative of the first operation parameter to the first hoist device and provide, wirelessly, a second control signal indicative of the second operation parameter to the second hoist device. The first hoist device operates based on the first control signal and the second hoist device operates based on the second control signal.

Abstract: Apparatus and method for motor braking using selectively connectable resistance. The method includes controlling, using a motor controller of the power tool, a power switching network to drive a motor of the power tool in response to actuation of a user input and determining, using the motor controller, a variable tool characteristic. The method further includes determining, using the motor controller, that the user input is de-actuated. The method also includes controlling, using the motor controller, the power switching network to brake the motor when the variable tool characteristic satisfies the tool characteristic threshold and controlling, using the motor controller, a braking circuit to brake the motor when the variable tool characteristic does not satisfy the tool characteristic threshold. The braking circuit includes one or more resistive loads and is selectively coupled to the motor terminals of the motor.

Abstract: An electronic processor of a wireless fob is configured to establish a first communication link between the wireless fob and an external device, and receive, over the first communication link, first identification information and credential information of a power tool device from the external device. The electronic processor is further configured to receive, via the wireless transceiver, an identification signal including second identification information from the power tool device. The electronic processor is further configured to identify the power tool device by determining that the first identification information matches with the second identification information. The electronic processor is further configured to transmit the credential information to the power tool device to establish a second communication link between the wireless fob and the power tool device and transmit, over the second communication link, a command to the power tool device to control an operation of the power tool device.

Abstract: One embodiment provides an adapter for configuring device settings of a gas engine replacement device. The adapter includes a transceiver, a user interface, and an electronic processor. The electronic processor is configured to connect the adapter to the gas engine replacement device and generate a graphical user interface showing a plurality of configurable device settings. The electronic processor is also configured to receive user input to choose one or more device settings to configure and receive user input to configure the one or more device setting chosen and generate changed device settings. The electronic processor is also configured to transmit the changed device settings to the gas engine replacement device. The gas engine replacement device is then used to drive power equipment in accordance with the changed device settings.

Abstract: A programmable power tool and method and systems of programming a power tool using wireless communication. An external device having a processor and a transceiver establishes a communication link with the power tool. The external device receives, with the transceiver, a first mode profile stored on the power tool. The first mode profile is defined by a profile type and a first value associated with a parameter for executing the profile type. The external device displays a control screen including the profile type and the parameter at the first value, and receives a user input. The external device generates, in response to the user input, a second mode profile by modifying the parameter to be at a second value. The external device transmits, with the transceiver, the second mode profile to the power tool.

Abstract: A power tool includes a three-phase DC motor, a power switching network, a power source, and an electronic processor. A first phase of the motor is connected between a first low side electronic switch and a power source electronic switch, and connected to the power source via a first high side electronic switch in parallel with a diode. The electronic processor is configured to receive an indication to stop the motor during operation of the motor and activate the first low side electronic switch and a second low side electronic switch for a first predetermined time responsive to receiving the indication such that a back-electromagnetic force generated by the motor is stored in the first phase. The electronic processor is configured to deactivate the second low side electronic switch after the first predetermined time such that a first regenerative current is provided to the power source via the diode.

Abstract: Methods and power tools for sensorless motor control. One embodiment provides a method for automatic control switching for driving a sensorless motor (150) of a power tool (100). The method includes determining, using a motor controller (224), a first load point based on user inputs (232) and determining, using the motor controller (224), a first motor control technique corresponding to the first load point. The method also includes driving the motor (150) based on the first motor control technique. The method further includes determining, using the motor controller (224), a change from the first load point to a second load point and determining, using the motor controller (224), a second motor control technique corresponding to the second load point. The method includes driving the motor (150) based on the second motor control technique.

Abstract: One embodiment provides an adapter for configuring device settings of a gas engine replacement device. The adapter includes a transceiver, a user interface, and an electronic processor. The electronic processor is configured to connect the adapter to the gas engine replacement device and generate a graphical user interface showing a plurality of configurable device settings. The electronic processor is also configured to receive user input to choose one or more device settings to configure and receive user input to configure the one or more device setting chosen and generate changed device settings. The electronic processor is also configured to transmit the changed device settings to the gas engine replacement device. The gas engine replacement device is then used to drive power equipment in accordance with the changed device settings.

Abstract: An electrical combination, a tool system, an electric motor, a battery pack, and operating and manufacturing methods. The tool may include a tool housing, a motor supported by the tool housing, the motor having a nominal outer diameter of up to about 80 millimeters (mm), the motor being operable to output at least about 2760 watts (W), and a tool terminal electrically connected to the motor; a battery pack including a pack housing defining a volume of the battery pack, the volume being up to about 5.2×106 cubic millimeters (mm3), battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 80 volts (V), and a pack terminal electrically connectable to the tool terminal to transfer current between the battery pack and the tool; and a controller operable to control the transfer of current.

Abstract: A programmable power tool and method and systems of programming a power tool using wireless communication. An external device having a processor and a transceiver establishes a communication link with the power tool. The external device receives, with the transceiver, a first mode profile stored on the power tool. The first mode profile is defined by a profile type and a first value associated with a parameter for executing the profile type. The external device displays a control screen including the profile type and the parameter at the first value, and receives a user input. The external device generates, in response to the user input, a second mode profile by modifying the parameter to be at a second value. The external device transmits, with the transceiver, the second mode profile to the power tool.

Abstract: Power tool devices described herein include a motor, an actuator configured to be actuated by a user, a plurality of power switching elements configured to drive the motor, a gate driver coupled to the plurality of power switching elements and configured to control the plurality of power switching elements, a first printed circuit board (PCB), an antenna, and a combined chip. The combined chip is located on the first PCB and is coupled to the actuator, the antenna, and the gate driver. The combined chip includes a memory and an electronic processor configured to determine that the actuator has been actuated, and provide, in response to determining that the actuator has been actuated, a signal to the gate driver, control the signal based on the motor position information, wirelessly transmit power tool device information to an external device, and wirelessly receive configuration information from the external device via the antenna.

Abstract: Kickback control methods for power tools. One power tool includes a movement sensor configured to measure an angular velocity of the housing of the power tool about the rotational axis. The power tool includes an electronic processor coupled to the switching network and the movement sensor and configured to implement kickback control of the power tool. To implement the kickback control, the electronic processor is configured to control the switching network to drive the brushless DC motor, receive measurements of the angular velocity of the housing of the power tool from the movement sensor, determine that a plurality of the measurements of the angular velocity of the housing of the power tool exceed a rotation speed threshold, and control the switching network to cease driving of the brushless DC motor in response to determining that the plurality of the measurements of the angular velocity exceed the rotation speed threshold.

Abstract: A power adapter assembly and an electrical system. The power adapter assembly is operable to supply power to an electrical device. The power adapter assembly includes a power box including a housing, an electrical circuit supported by the housing, the electrical circuit being operable to receive as input AC power and to output DC power, an adapter controller operable to control the adapter assembly; and an adapter electrically connected to the power box, the adapter including an adapter engagement portion connectable to a device engagement portion to connect the adapter to the electrical device, DC power being output from the electrical circuit through the adapter to the electrical device to power the load, when the adapter engagement portion is connected to the device engagement portion, a communication interface between the adapter assembly and the electrical device being active even when power is not being output to power the load.

Abstract: A power tool includes a three-phase DC motor, a power switching network, a power source, and an electronic processor. A first phase of the motor is connected between a first low side electronic switch and a power source electronic switch, and connected to the power source via a first high side electronic switch in parallel with a diode. The electronic processor is configured to receive an indication to stop the motor during operation of the motor and activate the first low side electronic switch and a second low side electronic switch for a first predetermined time responsive to receiving the indication such that a back-electromagnetic force generated by the motor is stored in the first phase. The electronic processor is configured to deactivate the second low side electronic switch after the first predetermined time such that a first regenerative current is provided to the power source via the diode.

Abstract: An example system includes a cutting tool and a device configured to remotely control the cutting tool. In response to receiving information indicative of actuation of a first user interface item, the device sends a first signal to the cutting tool so as to request enabling the cutting tool to be operated remotely. The cutting tool sends a second signal to the device indicating that remote operation of the cutting tool has been enabled. The cutting tool receives information indicating that the trigger has been activated, and sends a third signal to the device indicating that the cutting tool is ready to perform a cutting operation. The device receives information indicative of actuation of a second user interface item, and responsively, sends a fourth signal to the cutting tool so as to cause the cutting tool to perform the cutting operation.

Abstract: A stator includes insulation including a back insulation portion covering a back stator portion, a first tooth portion covering a first tooth, a second tooth portion covering a second tooth. A first flange portion has a first face that is in facing relationship with the back insulation portion. A second flange portion has a second face that is in facing relationship with the back insulation portion. The first face and the second face together substantially defining a boundary plane, such that a cross-sectional slot area is defined between the back insulation portion, the first tooth portion, the second tooth portion, and the boundary plane. A plurality of conductive wires are arranged in the cross-sectional slot area, the wires defining a cross-sectional winding area within the cross-sectional slot area. A ratio of the cross-sectional winding area to the cross-sectional slot area is greater than or equal to 0.45.

Abstract: An electrical combination, a tool system, an electric motor, a battery pack, and operating and manufacturing methods. The tool may include a tool housing, a motor supported by the tool housing, the motor having a nominal outer diameter of up to about 80 millimeters (mm), the motor being operable to output at least about 2760 watts (W), and a tool terminal electrically connected to the motor; a battery pack including a pack housing defining a volume of the battery pack, the volume being up to about 5.2×106 cubic millimeters (mm3), battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 80 volts (V), and a pack terminal electrically connectable to the tool terminal to transfer current between the battery pack and the tool; and a controller operable to control the transfer of current.