A motor assembly for use with a power tool includes a motor housing, a brushless electric motor disposed at least partially in the motor housing, and a PCB assembly coupled to the motor housing. The PCB assembly includes a heat sink, a power PCB coupled to a first side of the heat sink, and a position sensor PCB coupled to a second side of the heat sink opposite the first side and in facing relationship with the motor.

A brushless electric motor includes a stator and a rotor. The stator includes a core defining a plurality of stator teeth, a first end cap proximate a first end of the core, a second end cap proximate a second end of the core, and a plurality of coils disposed on the respective stator teeth. The stator also includes a plurality of coil contact plates overmolded within one of the first end cap or the second end cap that short-circuit diagonally opposite coils on the stator.

A brushless electric motor includes a stator and a rotor. The stator includes a core defining a plurality of stator teeth, a first end cap proximate a first end of the core, a second end cap proximate a second end of the core, and a plurality of coils disposed on the respective stator teeth. The stator also includes a plurality of coil contact plates overmolded within one of the first end cap or the second end cap that short-circuit diagonally opposite coils on the stator.

A brushless electric motor includes a stator and a rotor. The stator includes a core defining a plurality of stator teeth, a first end cap proximate a first end of the core, a second end cap proximate a second end of the core, and a plurality of coils disposed on the respective stator teeth. The stator also includes a plurality of coil contact plates overmolded within one of the first end cap or the second end cap that short-circuit diagonally opposite coils on the stator.

A motor assembly for use with a power tool includes a motor housing, a brushless electric motor disposed at least partially in the motor housing, and a PCB assembly coupled to the motor housing. The PCB assembly includes a heat sink, a power PCB coupled to a first side of the heat sink, and a position sensor PCB coupled to a second side of the heat sink opposite the first side and in facing relationship with the motor.

A method of manufacturing a brushless electric motor including providing a stator that includes a core defining a plurality of stator teeth, positioning a rotor within the stator, coupling a stator end cap to an end of the core, winding a plurality of coils on the plurality of stator teeth, and overmolding a plurality of coil contact plates within the stator end cap. The coil contact plates short-circuit diagonally opposite coils on the stator.

A brushless electric motor includes a stator and a rotor. The stator includes a core defining a plurality of stator teeth, a first end cap proximate a first end of the core, a second end cap proximate a second end of the core, and a plurality of coils disposed on the respective stator teeth. The stator also includes a plurality of coil contact plates overmolded within one of the first end cap or the second end cap that short-circuit diagonally opposite coils on the stator.

A brush-commutated direct-current motor comprises a stator which is fitted with a plurality of field poles, a rotor which can rotate in relation to the stator about a rotation axis and which has a plurality of pole teeth, a plurality of windings, wherein a plurality of windings are arranged on each pole tooth, a commutator which is arranged on the rotor and has a plurality of lamellas, wherein each winding is connected to one of the lamellas by means of a first winding arm and is connected to another of the lamellas by means of a second winding arm, and a plurality of short-circuiting links which each electrically connect two windings to one another and to this end are each arranged on at least two lamellas of the commutator. The plurality of windings of the plurality of pole teeth are formed by a plurality of wire turns.

A method of manufacturing a brushless electric motor including providing a stator that includes a core defining a plurality of stator teeth, positioning a rotor within the stator, coupling a stator end cap to an end of the core, winding a plurality of coils on the plurality of stator teeth, and overmolding a plurality of coil contact plates within the stator end cap. The coil contact plates short-circuit diagonally opposite coils on the stator.

A power tool including a brushless electric motor having a rotor coupled to a shaft that defines a rotational axis, a stator in which the rotor is received, the stator including a core having a plurality of stator teeth, the core defining an outer circumference, an end cap provided adjacent an end of the core, and a plurality of terminals mounted on the end cap, each terminal of the plurality of terminals includes an angled portion provided at a non-parallel angle to the rotational axis and extending outside the outer circumference of the core. The power tool includes one or more coils wound around respective stator teeth and the end cap to form coil windings. A portion of the coils is routed by at least one of the terminals to form an electrical connection between at least one of the coil windings and the at least one of the terminals.