High-power cordless, hand-held power tool including a brushless direct current motor
A cordless, hand-held power tool, such as a hammer drill/driver, a drill/driver, an impact driver, an impact wrench, etc., that includes a brushless direct current (“BLDC”) motor. Each of the hand-held power tool includes a removable and rechargeable battery pack, electronics, and a BLDC motor that have been designed and balanced to produce a high-performance-capable (e.g., high-power, high-current, high-torque) hand-held power tool. The hand-held power tool is capable of delivering high instantaneous (i.e., short duration) current to the BLDC motor for short-duration high power operation and high continuous (i.e., long duration) current to the BLDC motor for long duration high power operation. Additionally, the short and long duration power is capable of being provided in a smaller (in size) and lighter (in weight).
1. A power tool comprising:
a housing;
a battery pack having a nominal voltage of 18 Volts to 36 Volts and removably coupled to the housing;
a brushless direct-current (“BLDC”) motor, the BLDC motor having an outer diameter of between 50 millimeters and 80 millimeters, wherein a stator weight of the BLDC motor is 195 grams to 400 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 5.5 milli-Ohms;
a controller configured to generate a control signal to selectively enable and disable the plurality of switching FETs in the switching array to drive the BLDC motor with power provided from the battery pack;
wherein the power tool is configured to produce a maximum short-duration power output of at least 600 watts and an average long-duration power output, throughout a discharge cycle of the battery pack, of at least 400 Watts, and
wherein an energy consumed by the power tool for providing the average long-duration power output is at least 30 Watt Hours.
2. The power tool of claim 1 , wherein the maximum short-duration power output refers to a power output during a duration of between 20 seconds and 25 seconds.
3. The power tool of claim 2 , wherein a stator length of the BLDC motor is between 22 millimeters and 35 millimeters.
4. The power tool of claim 3 , wherein a rotor diameter of the BLDC motor is between 17 millimeters and 30 millimeters.
5. The power tool of claim 4 , wherein the battery pack is configured to provide a power input of at least 650 Watts during the maximum short-duration power output.
6. The power tool of claim 5 , wherein a ratio of the average long-duration power output of the power tool to the outer diameter of the BLDC motor is at least 7 W: 1 mm.
7. The power tool of claim 6 , further comprising:
a fan driven by the BLDC motor to generate a cooling air flow.
8. A power tool comprising:
a housing;
a battery pack having a nominal voltage of 18 Volts to 36 Volts and removably coupled to the housing;
a brushless direct-current (“BLDC”) motor, wherein a stator weight of the BLDC motor is 195 grams to 400 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 5.5 milli-Ohms;
a controller configured to generate a control signal to selectively enable and disable the plurality of switching FETs in the switching array to drive the BLDC motor with power provided from the battery pack;
wherein the power tool is configured to produce a maximum short-duration power output of at least 600 watts and an average long-duration power output, throughout a discharge cycle of the battery pack, of at least 400 Watts, and
wherein an energy consumed by the power tool for providing the average long-duration power output is at least 30 Watt Hours.
9. The power tool of claim 8 , wherein a ratio of the average long-duration power output of the power tool to the outer diameter of the BLDC motor is at least 7 W:1 mm.
10. The power tool of claim 9 , wherein a stator length of the BLDC motor is between 22 millimeters and 35 millimeters.
11. The power tool of claim 10 , wherein the BLDC motor has an outer diameter of 40 millimeters to 80 millimeters.
12. The power tool of claim 11 , wherein the BLDC motor has an outer diameter of 50 millimeters to 80 millimeters.
13. The power tool of claim 12 , wherein the maximum short-duration power output refers to a power output during a duration of between 20 seconds and 25 seconds.
14. A power tool comprising:
a housing;
a battery pack having a nominal voltage of 18 Volts to 36 Volts and removably coupled to the housing;
a brushless direct-current (“BLDC”) motor;
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 5.5 milli-Ohms;
a controller configured to generate a control signal to selectively enable and disable the plurality of switching FETs in the switching array to drive the BLDC motor with power provided from the battery pack;
wherein the power tool is configured to produce a maximum short-duration power output of at least 600 watts and an average long-duration power output, throughout a discharge cycle of the battery pack, of at least 400 Watts, and
wherein a stator weight of the BLDC motor is 195 grams to 400 grams.
15. The power tool of claim 14 , further comprising:
a fan driven by the BLDC motor to generate a cooling air flow.
16. The power tool of claim 15 , wherein a stator length of the BLDC motor is between 22 millimeters and 35 millimeters.
17. The power tool of claim 16 , wherein the maximum short-duration power output refers to a power output during a duration of between 20 seconds and 25 seconds.
18. The power tool of claim 17 , wherein the BLDC motor has an outer diameter of 50 millimeters to 80 millimeters.
19. The power tool of claim 18 , wherein a ratio of the average long-duration power output of the power tool to the outer diameter of the BLDC motor is at least 7 W: 1 mm.
20. The power tool of claim 19 , wherein an energy consumed by the power tool for providing the average long-duration power output is at least 30 Watt Hours.
21. A power tool comprising:
a housing;
a battery pack having a nominal voltage of 18 Volts to 36 Volts and removably coupled to the housing;
a brushless direct-current (“BLDC”) motor, wherein a stator weight of the BLDC motor is 195 grams to 400 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 5.5 milli-Ohms;
a controller configured to generate a control signal to selectively enable and disable the plurality of switching FETs in the switching array to drive the BLDC motor with power provided from the battery pack;
wherein the power tool is configured to produce a maximum short-duration power output of at least 600 watts and an average long-duration power output, throughout a discharge cycle of the battery pack, of at least 400 Watts, and
wherein a ratio of the average long-duration power output of the power tool to the outer diameter of the BLDC motor is at least 7 W: 1 mm.
22. The power tool of claim 21 , wherein the battery pack is configured to provide a power input of at least 650 Watts during the maximum short-duration power output.
23. The power tool of claim 22 , wherein the maximum short-duration power output refers to a power output during a duration of between 20 seconds and 25 seconds.
24. The power tool of claim 23 , wherein a stator length of the BLDC motor is between 22 millimeters and 35 millimeters.
25. The power tool of claim 24 , wherein an energy consumed by the power tool for providing the average long-duration power output is at least 30 Watt Hours.
26. The power tool of claim 25 , wherein a ratio of the maximum short-duration power output to a stator outer diameter of the BLDC motor is at least 10:1.
27. The power tool of claim 26 , wherein the BLDC motor has an outer diameter of 50 millimeters to 80 millimeters.