Granted Patent B2

US 12,506,422 · App. 17/051,508 · Granted Dec 23, 2025

Inventors: Keith Boulanger (Kenosha, WI); Timothy R. Obermann (Waukesha, WI)

Assignee: Milwaukee Electric Tool Corporation

H02P3/06H02K3/12H02K9/14H02K11/33B25F5/008H02K1/16

Abstract

Claims (62)

1 . A power tool comprising:

a housing;

a brushless direct current motor provided in the housing, the brushless direct current motor including a stator, a rotor, and a stator lamination stack;

a power source providing operating power to the motor;

a motor drive circuit coupled between the power source and the motor to drive the motor, the motor drive circuit including:

a plurality of switching elements controllable to drive the motor,

a motor braking coil wound around a circumference of the stator lamination stack, wherein the stator lamination stack is configured to absorb heat generated by the motor braking coil, and

a braking switch configured to selectively connect the motor braking coil to the motor, the motor braking coil and the braking switch electrically connected between a terminal of the power source and the plurality of switching elements and configured to form a current path between the power source and the plurality of switching elements; and

a motor controller connected to the motor drive circuit and configured to:

control the plurality of switching elements to operate the motor in accordance with a user input,

detect a braking event of the power tool,

connect, using the braking switch, the motor braking coil to the motor to brake the motor in response to detecting the braking event of the power tool.

2 . The power tool of claim 1 , wherein:

the motor braking coil is wound around a stator of the motor; and

the stator of the motor is configured to absorb the heat generated by the motor braking coil.

3 . The power tool of claim 1 , wherein:

the motor braking coil is would around a component of the power tool; and

the component of the power tool is configured to absorb the heat generated by the motor braking coil.

4 . The power tool of claim 1 , wherein the motor further includes:

a stator having a plurality of stator teeth; and

a plurality of stator windings wound around the plurality of stator teeth,

wherein the motor braking coil is wound around one or more of the plurality of stator windings.

5 . The power tool of claim 4 , wherein:

the motor further includes a fan attached for rotation with an output shaft of the motor; and

the heat generated by the motor braking coil is dissipated by an airflow generated by the fan.

6 . The power tool of claim 1 , wherein the motor braking coil and the braking switch are connected in series.

7 . The power tool of claim 6 , wherein the motor braking coil and the braking switch are connected in parallel to the plurality of switching elements.

8 . The power tool of claim 7 , wherein the plurality of switching elements includes a plurality of pairs of high side switching elements and a plurality of low side switching elements such that motor phase coils of the motor are coupled to nodes between the high side switching elements and low side switching elements, and

wherein the motor controller controls the motor braking switch and the plurality of high side switching elements to close when connecting the motor braking coil to the motor.

9 . The power tool of claim 1 , wherein the braking event includes a releasing of a trigger switch of the power tool.

10 . A method for braking a brushless direct current motor of a power tool, the brushless direct current motor including a stator, a rotor, and a stator lamination stack, the method comprising:

operating, using a motor controller of the power tool, the motor in accordance with a user input;

detecting, using the motor controller, a braking event of the power tool;

connecting, using a braking switch, a motor braking coil to the motor to brake the motor in response to detecting the braking event of the power tool, the motor braking coil and the braking switch electrically connected between a terminal of a power source and a plurality of switching elements and configured to form a current path between the power source and the plurality of switching elements; and

cooling, using a component of the motor, the motor braking coil,

wherein the motor braking coil is wound around a circumference of the stator lamination stack, and wherein the stator lamination stack is configured to absorb heat generated by the motor braking coil.

11 . The method of claim 10 , wherein:

the component of the motor is a stator of the motor;

the motor braking coil is wound around the stator of the motor; and

the stator of the motor is configured to absorb the heat generated by the motor braking coil.

12 . The method of claim 11 , wherein the braking event includes a releasing of a trigger switch connected to the motor.

13 . The method of claim 10 , wherein:

the component of the motor is one or more of a plurality of stator windings of the motor; and

the motor braking coil is wound around one or more of the plurality of stator windings of the motor,

wherein the heat generated by the motor braking coil is dissipated by an airflow generated by a fan attached for rotation with an output shaft of the motor.

14 . The method of claim 10 , wherein the motor braking coil and the braking switch are connected in series, and wherein the motor braking coil and the braking switch are connected in parallel to a plurality of switching elements that are controlled to operate the motor in accordance with the user input.

15 . The method of claim 14 , wherein the plurality of switching elements includes a plurality of pairs of high side switching elements and low side switching elements such that motor phase coils of the motor are coupled to nodes between the high side switching elements and low side switching elements.

16 . The method of claim 15 , further comprising, controlling, using the motor controller, the motor braking switch and the plurality of high side switching elements to turn on when connecting the motor braking coil to the motor.

17 . A power tool comprising:

a housing;

a brushless direct current motor provided in the housing, the brushless direct current motor including a stator, a rotor, and a stator lamination stack;

a power source providing operating power to the motor;

a motor drive circuit coupled between the power source and the motor to drive the motor, the motor drive circuit including:

a plurality of switching elements controllable to drive the motor,

a motor braking coil wound around a circumference of the stator lamination stack, wherein the stator lamination stack is configured to absorb heat generated by the motor braking coil, and

a braking switch connected in series with the motor braking coil, the braking switch configured to selectively connect the motor braking coil to the motor, the motor braking coil and the braking switch are electrically connected in parallel to the plurality of switching elements and configured to form a current path between a terminal of the power source and the plurality of switching elements; and

a motor controller connected to the motor drive circuit and configured to:

control the plurality of switching elements to operate the motor in accordance with a user input,

detect a braking event of the power tool, and

connect, using the braking switch, the motor braking coil to the motor to brake the motor in response to detecting the braking event of the power tool.

18 . The power tool of claim 17 , wherein the braking event includes a releasing of a trigger switch of the power tool, and

wherein the plurality of switching elements includes a plurality of pairs of high side switching elements and a plurality of low side switching elements such that motor phase coils of the motor are coupled to nodes between the high side switching elements and low side switching elements.

Assignments (1)

Continuity (2)

References Cited (86)