High-power cordless, hand-held power tool including a brushless direct current motor

A hand-held power tool comprising:

• a battery pack having a nominal voltage of between 18 Volts and 36 Volts and removably coupled to a housing of the hand-held power tool, the battery pack including a plurality of lithium-based battery cells;
• a brushless direct-current (“BLDC”) motor, the BLDC motor having an outer diameter of between 50 millimeters and 60 millimeters and a weight between 540 grams and 720 grams;
• a switching array including a plurality of switching field effect transistors (“FETs”) electrically connected between the BLDC motor and the battery pack, the plurality of switching FETs configured for controlling application of power to the BLDC motor, wherein the plurality of switching FETs have a drain-to-source resistance of below 3 milli-Ohms;
• a controller configured to generate a control signal to selectively enable and disable each of the plurality of switching FETs in the switching array to drive the BLDC motor with power provided from the battery pack;
• and
• an output shaft coupled to the BLDC motor to provide an output of the hand-held power tool,
• wherein the hand-held power tool is configured to produce a maximum short-duration power output of at least 650 Watts.

A hand-held power tool comprising:

• a battery pack having a nominal voltage of between 18 Volts and 36 Volts removably coupled to a housing of the hand-held power tool, the battery pack including a plurality of lithium-based battery cells;
• a brushless direct-current (“BLDC”) motor, the BLDC motor having an outer diameter of between 50 millimeters and 80 millimeters and a weight between 540 grams and 720 grams;
• a switching array including a plurality of switching field effect transistors (“FETs”) electrically connected between the BLDC motor and the battery pack, the plurality of switching FETs configured for controlling application of power to the BLDC motor;
• a controller configured to generate a control signal to selectively enable and disable each of the plurality of switching FETs in the switching array to drive the BLDC motor with power provided from the battery pack;
• and
• an output shaft coupled to the BLDC motor to provide an output of the hand-held power tool,
• wherein the hand-held power tool is configured to produce a maximum short-duration power output of at least 650 Watts and an average long-duration power output of at least 400 Watts, and
• wherein the average long-duration power output is the average power output over one discharge cycle of the battery pack continuously from a fully-charged level until the battery pack reaches a low-voltage cutoff.

A hand-held power tool comprising:

• a battery pack interface;
• a battery pack received configured to be received by the battery pack interface and having a nominal voltage of between 18 Volts and 36 Volts;
• a brushless direct-current (“BLDC”) motor, the BLDC motor having an outer diameter of between 50 millimeters and 80 millimeters and a weight between 540 grams and 720 grams;
• a switching array including a plurality of switching field effect transistors (“FETs”) electrically connected between the BLDC motor and the battery pack interface, the plurality of switching FETs configured for controlling application of power to the BLDC motor;
• a controller configured to generate a control signal to selectively enable and disable each of the plurality of switching FETs in the switching array to drive the BLDC motor with power provided from the battery pack;
• and
• an output shaft coupled to the BLDC motor to provide an output of the hand-held power tool,
• wherein the hand-held power tool is configured to produce a maximum short-duration power output of at least 650 Watts and an average long-duration power output of at least 400 Watts, and
• wherein the average long-duration power output is the average power output over one discharge cycle of the battery pack from a fully-charged level until the battery pack reaches a low-voltage cutoff.