Brushless motor for a power tool

The power tool of claim 4, the rotor assembly further comprising:

• a second rotor end cap provided on a second side of the rotor core;
• and
• legs that extend from the second rotor end cap, between the stator teeth, to the rotor end cap to seal air gaps at an inner radial end of the stator core between the stator teeth. The power tool of claim 6, further comprising:
• a gear case mounted to the second rotor end cap by fasteners;
• a second bearing provided in a second bearing holder of the second rotor end cap, wherein the second bearing couples the second rotor end cap to the output shaft, and wherein the second bearing is at least partially within the stator envelope.

A brushless direct current motor, comprising:

• a stator assembly including a stator core having stator laminations with an annular portion and inwardly extending stator teeth,
• a rotor assembly including:
• a rotor core having rotor laminations and defining a central aperture that receives an output shaft;
• and
• a rotor end cap on a first side of the rotor core having a bearing holder and defining a channel, wherein the channel is open on a side of the rotor end cap facing the rotor core,
• a bearing provided in the bearing holder that couples the rotor end cap to the output shaft, and
• a position sensor board assembly provided in the channel of the rotor end cap and configured to provide position information of the rotor core to a motor controller.

A power tool, comprising:

• a housing;
• a controller within the housing;
• and
• a brushless motor within the housing and controlled by the controller, the brushless motor including:
• a stator assembly including a stator core having stator laminations with an annular portion and inwardly extending stator teeth, wherein the stator assembly defines a stator envelope in an axial direction extending between axial ends of stator end caps of the stator assembly,
• a rotor assembly including:
• a rotor core having rotor laminations and defining a central aperture that extends in the axial direction and that receives an output shaft,
• a front rotor end cap provided on a first side of the rotor core, and
• a rear rotor end cap provided on a second side of the rotor core, and
• a position sensor board assembly including position sensors and configured to provide position information of the rotor core to the controller,
• wherein the rotor assembly and the position sensor board assembly are provided at least partially within the stator envelope.