In a loaded condition, the controller increases at least one of the conduction band or the advance angle from a baseline value up to a maximum value within a first torque range below a torque threshold to as to maintain the output speed of the motor at a linear speed-torque profile. After the at least one of the conduction band or the advance angle reaches the maximum value, the controller maintains the at least one of the conduction band or the advance angle at the maximum value within a second torque range greater than or equal to the torque threshold so as to maintain the output speed of the motor at a naturally-curved speed-torque profile.

A method of manufacturing a battery pack including the creation of a support board for enabling conversion of the battery pack from providing a first voltage to providing a second voltage. The support board is created by injection molding about a precut set of power traces for coupling a converting element to a plurality of battery cells. The power traces couple the plurality of battery cells to a set of battery pack terminals. The support board may be mechanically coupled to a battery cell holder.

A method of manufacturing a battery pack including the creation of a support board for enabling conversion of the battery pack from providing a first voltage to providing a second voltage. The support board is created by injection molding about a precut set of power traces for coupling a converting element to a plurality of battery cells. The power traces couple the plurality of battery cells to a set of battery pack terminals. The support board may be mechanically coupled to a battery cell holder.

A battery pack and charger system includes a first battery pack having a first set of battery cells and configured to provide only a first operating voltage and a second battery pack having a second set of battery cells and configured to provide the first operating voltage and a second operating voltage that is different from the first operating voltage and a battery pack charger configured to be able to charge the first battery pack and the second battery pack.

A battery pack and charger system includes a first battery pack having a first set of battery cells and configured to provide only a first operating voltage and a second battery pack having a second set of battery cells and configured to provide the first operating voltage and a second operating voltage that is different from the first operating voltage and a battery pack charger configured to be able to charge the first battery pack and the second battery pack.

A multi-voltage battery pack including a converting system for converting the battery pack between a low voltage configuration and a high voltage configuration. The converting system includes a converter element moves between a first position and a second position to configure the battery pack between the low voltage configuration and the high voltage configuration. The converter element includes a set of contacts that mates with a set of contact pads to establish the voltage configuration.

A multi-voltage battery pack including a converting system for converting the battery pack between a low voltage configuration and a high voltage configuration. The converting system includes a converter element moves between a first position and a second position to configure the battery pack between the low voltage configuration and the high voltage configuration. The converter element includes a set of contacts that mates with a set of contact pads to establish the voltage configuration.

A power tool is provided with a multi-phase brushless motor including a rotor and a stator having stator windings corresponding to at least three phases of the motor. A power switch circuit is provided including high-side and low-side power switches. A power supply interface receives alternating-current (AC) power from an AC power supply or battery direct-current (DC) power from one or more battery packs. A rectifier converts the AC power to a rectified DC voltage on a bus line. A capacitor is disposed across the bus line such that, within each half cycle of the AC power voltage waveform, the power switch circuit draws current from the AC power supply within a first time period and from the capacitor within a second time period, the capacitor having a capacitance value such that the first time period is greater than the second time period.

A power tool is provided with a multi-phase brushless motor including a rotor and a stator having stator windings corresponding to at least three phases of the motor. A power switch circuit is provided including high-side and low-side power switches. A power supply interface receives alternating-current (AC) power from an AC power supply or battery direct-current (DC) power from one or more battery packs. A rectifier converts the AC power to a rectified DC voltage on a bus line. A capacitor is disposed across the bus line such that, within each half cycle of the AC power voltage waveform, the power switch circuit draws current from the AC power supply within a first time period and from the capacitor within a second time period, the capacitor having a capacitance value such that the first time period is greater than the second time period.

A power tool is provided including a power supply interface receiving a medium-voltage-rated removable battery pack having a maximum rated voltage in the range of 40 to 80 volts, and a brushless direct current (BLDC) motor. The motor includes a rotor and a stator having at least three stator windings corresponding to at least three phases of the motor, the rotor being moveable by the stator when the stator windings are appropriately energized within the corresponding phases, each phase being characterized by a corresponding voltage waveform energizing the corresponding stator winding. A multi-phase inverter bridge circuit is disposed between the power supply interface and the motor, and a controller is configured to output drive signals to the inverter bridge circuit to control flow of current from the battery pack to the motor such that the motor produces a maximum power output of at least 2500 watts.