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: 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: 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 battery pack, an electrical combination and a method of operating a battery pack. The battery pack may include a housing; a plurality of battery cells supported by the housing; a plurality of terminals including a positive power terminal, a negative power terminal, and a low power terminal; a low power circuit connecting the plurality of battery cells to the low power terminal and the negative terminal to output a first voltage; and a power circuit connecting the plurality of battery cells to the positive power terminal and the negative terminal to output a second voltage, the second voltage being greater than the first voltage. A terminal block for one of a battery pack and an electrical device may include a terminal with a terminal blade, and a terminal support portion.

Abstract: An electronic power tool device includes an electronic processor, a communication interface in communication with the electronic processor, and a wake-up sensor configured to generate a wake signal for activating the communication interface and the electronic processor responsive to a stimulus. The communication interface is configured to receive a first electronic message that includes an activation state and transmit the first received electronic message to the electronic processor. The electronic processor is configured to control the activation state of the electronic power tool device to allow or prevent operation of the electronic power tool device based on the first received electronic message.

Abstract: An electrical device including a first battery pack receptacle, a second battery pack receptacle, and circuitry including an electronic processor. The first battery pack receptacle is configured to receive a first battery pack. The second battery pack receptacle is configured to receive a second battery pack. The second battery pack is electrically connected in a series-type configuration with the first battery pack. The circuitry is configured to alter a first signal output from the electronic processor to at least one selected from a group consisting of the first battery pack and the second battery pack, and alter a second signal received by the electronic processor from at least one selected from the group consisting of the first battery pack and the second battery pack.

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 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 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 electronic power tool device includes an electronic processor, a communication interface in communication with the electronic processor, and a wake-up sensor configured to generate a wake signal for activating the communication interface and the electronic processor responsive to a stimulus. The communication interface is configured to receive a first electronic message that includes an activation state and transmit the first received electronic message to the electronic processor. The electronic processor is configured to control the activation state of the electronic power tool device to allow or prevent operation of the electronic power tool device based on the first received electronic message.

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: 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, and an orientation sensor configured to measure an orientation of the housing. The power tool includes an electronic processor coupled to a switching network and a trigger. To implement the kickback control, the electronic processor is configured to receive measurements of the angular velocity of the housing, receive measurements of the orientation of the housing, determine a binding condition of the power tool based on the measurements of the angular velocity and the measurements of orientation, and control the switching network to cease driving of the brushless DC motor.

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: 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 power tool is provided with a coating to distribute static electricity away from the surface of the handle of the tool. The tool includes a handle configured to be grasped by a user. The handle includes a surface and a first material having a first surface resistivity. The tool includes a coating covering at least a portion of the handle. The coating is configured to distribute static electricity away from the surface. The coating is made of a second material having a second surface resistivity less than the first surface resistivity.

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: Method and power tool for braking a motor of the power tool. One embodiment provides a method for braking a motor of a power tool. The method includes operating, using a motor controller of the power tool, the motor in accordance with a user input. The method also includes detecting, using the motor controller, a braking event of the power tool and connecting, using a braking switch, a motor braking coil to the motor to brake the motor in response to detecting the braking event of the power tool. The method further includes cooling, using a component of the motor, the motor braking coil.

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 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: 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.