Milwaukee Electric Tool Corporation

Matthew R Bailey

Andrew T Beyerl

Keith Boulanger

Carl B Westerby

Jeffrey Charles Hessenberger

Will Didier

Keith M Klosterman

Timothy Ryan Obermann

Ryan B Jipp

Gerald A Zucca

Jorge L Ibarra

Lu Yang

Shi-Uk Chung

Hongru Huang

A power tool including a battery pack interface configured to receive a removable and rechargeable battery pack, a motor including a rotor and a stator, the rotor operable to rotate relative to the stator, and a switching module that includes a plurality of switching devices connected between the battery pack interface and the motor. The power tool further includes a controller including a processor and a memory. The controller is configured to receive a signal from an external device, control the switching module to provide a high frequency current signal from battery pack to the motor in response to receiving the signal, the motor configured to emit an audible sound in response to the high frequency current signal, and control the switching module to stop providing the high frequency current signal to the motor.

Non-rotating location identification in power tools

A method of manufacturing a brushless electric motor including providing a stator that includes a core defining a plurality of stator teeth, positioning a rotor within the stator, coupling a stator end cap to an end of the core, winding a plurality of coils on the plurality of stator teeth, and overmolding a plurality of coil contact plates within the stator end cap. The coil contact plates short-circuit diagonally opposite coils on the stator.

Brushless direct current motor for power tools

A method of cooling an electric motor configured for use in a power tool. The electric motor has a motor shaft rotatable about a motor axis. The power tool further includes a fan assembly attachable to the motor shaft and an energy storage device coupled to the motor shaft and to the fan assembly. The method includes activating the electric motor to supply torque to the motor shaft. The method further includes rotating the motor shaft and the fan assembly about the motor axis. The fan assembly generates an airflow to cool the electric motor. Moreover, the method includes supplying torque from the electric motor to the energy storage device and deactivating the electric motor to stall rotation of the motor shaft. The fan assembly continues to rotate about the motor axis to generate the airflow after rotation of the motor shaft has ceased.

Inertial fan for power tool

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.

Electric motor

A power tool includes a housing and an electric motor. The electric motor includes a rotor assembly including a rotor shaft and a stator assembly including a plurality of stator segments. Each stator segment includes a core, an insulator at least partially covering the core, and a coil winding. The insulator includes a mounting portion. The electric motor also includes a printed circuit board assembly configured to direct electric current to each coil winding, and a bus bar assembly attached to at least one of the mounting portions and configured to electrically connect the coil windings to the printed circuit board assembly. The bus bar assembly includes a molded body and a plurality of conductors. The bus bar assembly defines a bearing pocket. The electric motor further includes rotor bearing that is received into the bearing pocket and that supports the rotor shaft for rotation relative to the stator assembly.

Electric motor having segmented stator

A motor assembly for use with a power tool includes a motor housing, a brushless electric motor disposed at least partially in the motor housing, and a PCB assembly coupled to the motor housing. The PCB assembly includes a heat sink, a power PCB coupled to a first side of the heat sink, and a position sensor PCB coupled to a second side of the heat sink opposite the first side and in facing relationship with the motor.

Power tools described herein include a housing, a brushless direct current (DC) motor, a non-conductive terminal mount, and a plurality of terminals. The housing has a motor housing portion, a handle portion, and a battery pack interface. The brushless DC motor is located within the motor housing portion and has a rotor and a stator. The non-conductive terminal mount is located on an outer peripheral surface of the stator and includes an angled surface. The angled surface is not substantially parallel to a longitudinal axis of the motor. The plurality of terminals is mounted on the angled surface of the terminal mount. Each of the terminals is angled in a first direction such that the terminals are not substantially parallel to the longitudinal axis of the motor.

Brushless motor for a power tool

A power tool includes a motor having a motor shaft that rotates about a motor axis in a first rotational direction. The power tool also includes a fan assembly attachable to the motor shaft for rotation in the first rotational direction. The fan assembly includes a fan body, a bearing having a race that rotates with the fan body, and a flywheel rotatably affixed to the fan body. The race is freely rotatable relative to the motor shaft in the first rotational direction, and fixed against rotation relative to the motor shaft in a second rotational direction opposite the first rotational direction. The flywheel has a central portion that defines a central bore, and the race is received into the central bore and rotatably affixed to the flywheel.

A brushless electric motor includes a stator and a rotor. The stator includes a core defining a plurality of stator teeth, a first end cap proximate a first end of the core, a second end cap proximate a second end of the core, and a plurality of coils disposed on the respective stator teeth. The stator also includes a plurality of coil contact plates overmolded within one of the first end cap or the second end cap that short-circuit diagonally opposite coils on the stator.

Growing community of inventors

Racine, WI, United States of America

Matthew R Bailey