Motor controller for a tool

Abstract

A tool (Fig.1, 100) having a housing (Fig.1, 102), the tool comprising: a motor 106 disposed in the housing and adapted to receive power from a power source. The motor includes: an end cap 122 having opposing first and second surfaces; a power board 128 coupled to the first surface and including position sensors (Fig.5, 138) and switching elements 136; and a control board 130 coupled to the second surface and including a processor. A thermal interface material 140 may be disposed between the power board and the first surface, which may be a thermally conductive pad and thermal paste. A gear assembly may be disposed in the housing, and the motor may have an output shaft 144 that engages the gear assembly. The end cap may be composed of aluminum, magnesium, or carbon steel. The switching elements may be MOSFETs, and the position sensors may be Hall-effect sensors. The motor may have a rotor 126 and a stator 124, and the end cap may be coupled to the stator. Figure 4