Cordless saw having improved cuts per battery charge

A cordless saw for repeated cutting of a workpiece, comprising:

• a saw housing;
• a battery connection port formed in the saw housing for receiving a removable battery pack;
• an electric motor disposed within the housing and configured to rotatably drive an output shaft, wherein the output shaft is coupleable to a saw blade to perform a plurality of cutting operations on the workpiece;
• a trigger switch operable by an operator for selective electronic connection or disconnection of a supply of electric power from the battery pack to the electric motor;
• a power switch circuit disposed between the battery connection port and the electric motor;
• and
• a control unit configured to regulate a switching operation of the power switch circuit for each of the plurality of cutting operations to supply electric power from the battery pack to the motor while the trigger switch is depressed and apply an regenerative braking period after the trigger switch is released, wherein during the regenerative braking period, the control unit applies a plurality of electronic braking periods to electric motor to slow down the rotation of the electric motor and a plurality of regenerative charging periods during which a regenerative energy induced by the electric motor charges the battery pack,
• wherein each of the plurality of cutting operations includes, prior to the regenerative braking period, a start-up period during which an electric current supplied to the motor ramps up to bring an output speed of the motor to a target speed, followed by a cutting period during which the saw blade engages the workpiece, wherein the regenerative braking period is longer than the start-up period, and
• wherein, when the saw blade has a diameter of 304.8 mm±4 mm, the saw is capable of performing, per full discharge cycle of the battery pack, at least 25.3 number of cuts per amp.hour of battery capacity when operating on a Pressure-Treated (PT) lumber workpiece having a cross-sectional size of approximately 89 mm×89 mm±2 mm, at least 40 number of cuts per amp.hour of battery capacity when operating on a Spruce Pine Fir (SPF) lumber workpiece having a cross-sectional size of approximately 38 mm×89 mm±2 mm, or at least 52 number of cuts per amp.hour of battery capacity when operating on a 3¼ Medium Density Fiberboard (MDF) workpiece having a thickness of approximately 19 mm±1 mm and a width of approximately 76 mm±2 mm.

A system for repeated cutting of a workpiece, or workpieces, including a cordless battery-powered saw, wherein the saw comprises:

• a saw housing;
• a battery connection port formed in the saw housing for receiving a battery pack to be coupled to the saw;
• an electric motor, mounted in the housing and for selective electrical connection with the battery pack is inserted into the port;
• a saw blade rotatably driven by the motor;
• a trigger switch operably by an operator for selective electronic connection or disconnection to the motor of the battery pack inserted into the port to the motor;
• and
• a regenerative braking means configured to control the operation of the motor,
• wherein the motor, when electrically connected to the battery via connection of the switch, provides a rotating output, which rotating output is transferred to the saw blade for performing a workpiece cutting operation,
• wherein, on disconnection of the motor from the battery pack via the switch, the regenerative braking means electronically brakes the motor to stop the rotating output and provides a current path for the electrical charge generated from an angular momentum of the rotating output to be applied to the battery pack,
• wherein the saw is configured to perform a series of cutting operations, each including a start-up period, a cutting period, and a ramp-down period, wherein the regenerative braking means is applied during the ramp-down period, and wherein the ramp-down period is controlled to include a duration that is longer than a duration of the start-up period, and
• wherein the electrical charge applied to the battery by the regenerative braking means increases the number of repeated cuttings the saw is able to perform (x) per full discharge cycle of the battery pack, as compared to the number of repeated cuttings achievable by the same saw not employing a regenerative braking means (y) per full discharge cycle of the battery pack, such that x/y is approximately at least one of the following:
• i) 1.1 when cutting a Pressure-Treated (PT) lumber workpiece having a cross-sectional size of approximately 89 mm×89 mm±2 mm, ii) 1.15 when cutting a Spruce Pine Fir (SPF) lumber workpiece having a cross-sectional size of approximately 38 mm×89 mm±2 mm, or iii) 1.25 when cutting Medium Density Fiberboard (MDF) workpiece having a thickness of approximately 19 mm±1 mm and a width of approximately 76 mm±2 mm.