Black Decker Inc.

Hunter Fan Compnay

Mccormick Technical Consulting, LLC

Garrett Patrick McCormick

Earl M Ortt

Hung T Du

Brandon L Verbrugge

Michael Kenneth Forster

Richard Thomas Walter

Christopher Ryan Yahnker

Michael Jeffrey Agnes

Michael A Zemlock

Kevin M Hogan

John Charles Vanko

Bhanuprasad V Gorti

Jason K Leh

Samuel G Woods

Ren H Wang

David Beers

Frank A Mannarino

Spencer G Maid

Jiaqi Zhang

Shane Ashley Moll

James C Benton

Peter Zhao

John R Cochran

Paul J Wisniewski

Larry T Albert

John Alan Hammar

Eric J Samuelsen

Gary M Marcy

Ren Hong Wang

Larrry T Albert

Kachi Ukeje-Eloagu

David E Abbott

A stator comprises multiple, stacked laminations, which collectively define a core having a number of posts arranged circumferentially about the core. Each post extends into two prongs defining a first slot between the prongs. The spacing between each posts and its two prongs defines a second slot having a radially inner and outer slot. The outer slot geometry has an increasing width extending radially outward from the radially inner end, and transitioning to a decreasing width extending to the radially outer end.

Electric motor

An improved electromechanical Blade Clutch Actuator (BCA) that employs an electric gear motor system to provide more economical, convenient and reliable user control with an electric switch to engage/disengage the cutting blades. The user control may be a switch remotely mounted anywhere on the mower for greater design freedom due to the removal of the manual interface. The BCA also incorporates a novel slip clutch for overload protection.

Blade clutch actuator (BCA) with overload slip clutch

A protective redundancy circuit is provided for a power tool having an electric motor. The protective redundant subsystem is comprised of: a motor switch coupled in series with the motor; a motor control module that controls the switching operation of the motor switch; and a protective control module that monitors switching operation of the motor switch and disables the power tool when the switching operation of the motor switch fails. In the context of an AC powered tool, the switching operation of the motor switch is correlated to and synchronized to the waveform of the AC input signal. During each cycle or half cycle, the motor control module introduces a delay period before closing the motor switch and the protective control module determines the operational status of the motor switch by measuring the voltage across the motor switch during the delay period.

Protective redundant subsystem for power tools

A power tool has a motor having a stator made by separately forming pole pieces and field coils. The field coils are placed over necks of the pole path pieces. An armature has an outside diameter of at least 0.625 the outside diameter of the stator is placed in the stator. The housing has a girth of 200 mm or less with the motor wound to provide a maximum watts out to housing girth ratio of at least 5 maximum watts outs to 1 mm of housing girth. The field coils may be formed so that they extend beyond pole tips of the pole pieces.

Power tool with motor having a multi-piece stator

A universal termination system is provided for power tools. The universal termination system includes criteria for each of the main switch platforms that define the number, type, location and orientation of the terminations. That is, the number, type, location and orientation of the terminations in each main switch platform are standardized and the power tools that use that type main switch platform use the main switch platform having the standardized terminations. That is, power tools that use push button switches use the push button switch with the standardized terminations, power tools that use overhang switches use the overhang switch with the standardized terminations, and power tools that use in-line VSR switches use the in-line VSR switch with the standardized terminations. In an aspect of the invention, a right-angle pin terminal is received in one or more sets of the standardized terminations. In an aspect of the invention, the switch body has features that cooperate with the right-angle pin terminals to reduce the risk of shorting adjacent terminals. In an aspect of the invention, a switch has standardized connections on a bottom of a switch body that mate with terminals of a plug-in control module. In an aspect of the invention, a switch for a hand-held power tool has cord set terminations that are screw-tab terminals.

Universal termination system for power tools

A power tool has an electric motor with field windings. Each field winding includes two coils. When the motor is first energized, the two coils of each field winding are connected in series, reducing in-rush current. Upon expiration of a soft start period, the two coils of each field winding are connected in parallel. In another aspect, the field windings that are connected in series with a separate start winding when the motor is first energized. Upon expiration of the soft start period, the start winding is bypassed. In another aspect, the field windings are connected in series with a start impedance when the motor is first energized and a time delay relay having a set of delay contacts coupled across the start impedance energized. Upon expiration of the soft start period, the time delay contacts close, bypassing the start impedance. In an aspect, the motor is a universal motor.

Soft start for electric motor of a power tool

A power tool has a motor having a stator made by separately forming pole pieces, return path pieces and field coils. The field coils are placed over necks of the pole path pieces and the return path pieces are affixed to the pole pieces. An armature having an outside diameter of at least 0.625 the outside diameter of the stator is placed in the stator. The field coils may be formed so that they extend beyond pole tips of the pole pieces.

Power tools with motor having a multi-piece stator

A tool and method for winding and forming a field coil for field assembly, such as a stator, includes separable tool halves defining a winding cavity therebetween. The winding cavity receives magnet wire that is wound therein, such as by rotating the tool or a winding nozzle. The magnet wire generally conforms to the shape of the winding cavity such that when the tool halves are separated, a field coil having a net shape is produced. Once the magnet wire is sufficiently deposited within the winding cavity, wires of the coil may be bonded together either through a resistive heating process such as by passing an electrical current through the coil or through other heating or chemical bonding methods to thereby maintain the net shape of the field coil once it is removed from the tool.

Tool for manufacturing coils for dynamoelectric machines and method therefor

An electric motor, power tool using the electric motor, and method of making the electric motor includes making a stator that includes pole portions that have axial lengths less than an axial length of a back iron portion. Alternatively, or in addition, the pole portions have axially opposed ends that decrease in width. Alternatively, or in addition, the pole portions have dovetail features that are received in corresponding recesses of the back iron portion.

Field assemblies having pole pieces with axial lengths less than an axial length of a back iron portion and methods of making same

An electric motor, power tool using the electric motor, and method of making the electric motor includes making a stator that includes pole portions that have axially opposed ends that gradually decrease in width. The pole portions may also have dovetail features that are received in corresponding recesses of the back iron portion.

Field assemblies having pole pieces with ends that decrease in width, and methods of making same

An electronically commutated brushless motor including a motor housing, a bulge formed in a sidewall of the motor housing, and a capacitor assembly housed in the bulge. The capacitor assembly includes a capacitor printed circuit board (PCB) having a plurality of longitudinal edges and at least one capacitor mounted on the capacitor PCB. The bulge includes a plurality of channels located along an inside surface of a sidewall of the bulge, in which the longitudinal edges of the capacitor assembly are slideably inserted.

Brushless motor having capacitors mounted on sidewall of motor housing

An electronically commutated brushless motor including a housing for accurately angularly aligning a position sensor relative to a position of a stator. The housing includes an integrally formed bridge for precisely situating the position sensor within the bridge, and a plurality of integrally formed locating ribs formed on an internal surface of a circumferential wall portion of the housing for precisely angularly situating the stator within the housing. Since the locating ribs and the bridge are all integrally formed on the housing, this eliminates the possibility of angular misalignment of the position sensor relative the stator during assembly of the motor.

Brushless motor having housing enabling alignment of stator and sensor

A double insulated electronically commutated brushless motor for coupling to a gearbox of a motor driven product. The motor includes a first layer of electrical insulation that includes a plurality of insulating strips formed in the shape of stator slots and inserted into the stator slots before windings are wound in the stator slots. Additionally, the first layer of electrical insulation includes a plurality of insulating strips wedged between the winding and a mouth of the winding slots after the windings are inserted. The motor further includes a second layer of electrical insulation made up of an insulating tube pressed onto a shaft between the shaft and a rotor stack.

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Manchester, MD, United States of America

Garrett Patrick McCormick