Cordless Power Tool Motor Unit

/ Enabling Cordless Mobility

/ Application Considerations

To ensure the highest levels of quality and reliability,  engineers should factor the following application considerations into their motor unit design:

• Motor technology - brushed DC motors and brushless DC motors offer different pros and cons. Brushed versions are cheaper and simpler but less efficient, while brushless ones offer superior power and lifespan.
• Battery type - many products use lithium-ion (Li-Ion) batteries due to their high energy density and long lifespan. Alternatively, nickel metal hydride (NiMH) batteries are more cost-effective but have lower energy density.
• Motor size and power - brushless DC motors are more compact and better-suited for lightweight tools, while brushed DC motors are larger in size to provide the torque required in heavy-duty applications. Finding a balance between size, weight, and power output is essential. 
• Safety features - trigger locks, emergency stop mechanisms, and motor braking can help protect users from accidents and promote safe operation.
• ESD protection - diodes or other safety measures should be in place to address harmful electrostatic discharge.
• Thermal management - because cordless tools generate substantial heat during operation, proper mechanisms, such as heat sinks, proper ventilation channels, and thermal motor cut-off switches, should be in place to prevent overheating.
• Motor unit compatibility - the motor unit must be designed to meet the demands of the specific application while operating efficiently with the battery technology selected.
• Durability - power tools can take a beating, so their construction and components should be durable enough to withstand impact, vibrations, dust, moisture, and extreme temperatures.
• Noise reduction - gears and motors can be designed to reduce noise levels and enhance user safety and comfort.