Milwaukee Electric Tool Corporation

Derek J Schwab

Andrew T Beyerl

Hans T Banholzer

Kyle Greunke

Samantha L Billetdeaux

Carmen J Castanos

Michael A Matthews

Michael R Sande

Nikos A Gainacopulos

Steve Cunningham

Christopher J Derksen

Patrick Owens

Sean Kelley

A method of arranging windings in a parallel delta configuration in a stator assembly includes connecting a first lead of a first winding to a first terminal. The first terminal is electrically connected to a printed circuit board assembly (PCBA) located at a first axial end of the stator assembly. The method also includes wrapping the first winding about a first tooth of a lamination stack to form a first coil, extending the first winding about at least a portion of a circumference of the lamination stack at a second axial end of the stator assembly toward a second tooth located opposite the first tooth, connecting the first winding to a second terminal electrically connected to the PCBA, wrapping the first winding about the second tooth of the lamination stack to form a second coil, and connecting a second lead of the first winding to the first terminal.

Electric motor including windings having crossovers

An electric motor assembly includes a circuit board, a rotor assembly, and a stator assembly having a first end coupled to the circuit board and a second end opposite the first end. The stator assembly also includes an annular stator body having a plurality of inwardly projecting teeth. The stator assembly further includes windings wrapped about the stator body to form a plurality of coils. The stator assembly also includes a terminal coupled to an outer periphery of the stator body and extending longitudinally between the first end and the second end. The terminal is coupled to the circuit board at the first end and is coupled to the windings at the second end to electrically connect the windings to the circuit board. The terminal is molded to an attachment member, and the attachment member is molded to the outer periphery of the stator body.

Electric motor for a power tool

An electric motor includes a stator assembly including a lamination stack and a printed circuit board assembly (PCBA) coupled to the lamination stack at an axial end of the stator assembly. The stator assembly also includes a plurality of windings wrapped about the lamination stack to form a plurality of coils. The plurality of windings includes a first winding defining a first coil of the plurality of coils and a second coil of the plurality of coils located opposite from the first coil. The stator assembly further includes a plurality of terminals configured to electrically connect the plurality of windings to the PCBA. The plurality of terminals include a first terminal and a second terminal. The first coil and the second coil are connected in parallel between the first terminal the second terminal.

Motor winding design for an electric motor

A power tool includes a housing having a rear wall, a motor assembly coupled to the rear wall, and a plurality of mounting legs projecting from the rear wall toward the motor assembly. The motor assembly defines a motor axis, and includes a stator assembly defining a plurality of axially extending mounting apertures. Each mounting leg defines a threaded boss corresponding to a respective mounting aperture of the stator assembly, and each threaded boss is configured to receive a threaded fastener. The mounting legs are angularly spaced at unequal intervals about the motor axis.

An electric motor includes a stator assembly including a lamination stack, a printed circuit board assembly (PCBA), and a plurality of windings. The PCBA is coupled to the lamination stack at a first axial end of the stator assembly. The windings are wrapped about the lamination stack to form coils. Each winding includes crossover portions extending about a portion of a circumference of the stator assembly to connect pairs of opposite coils. The crossover portions are located at a second axial end of the stator assembly opposite the first axial end.

System for cooling a power tool. One exemplary power tool includes a housing including an air intake and an air exhaust. The power tool further includes a motor and a fan configured to pull cooling air into the housing through the air intake, and exhaust the cooling air out of the housing through the air exhaust. The power tool further includes a plurality of field-effect transistors (FETs). The FETs couple the stator coils to a power source. The power tool further includes a FET board within the housing. The power tool further includes a heat sink within the housing. The heat sink includes a first mounting portion and a second mounting portion. Each of the mounting portions includes a horizontal fin extending toward a respective side of the housing. A plurality of vertical fins extends from a top surface of each of the horizontal fins.

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Milwaukee, WI, United States of America

Derek J Schwab