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18 Powering Up Your Design Over the past century, power tools have noticeably evolved. Today, they are wireless, light weight, battery-operated, and work hard, so we don't have to. So, what's fueling the evolution of power tools? Besides power-tool enthusiasts, much can be attributed to the many advancements in semiconductor technology, specifically cordless power tools. In the following, we'll cover the key aspects of the cordless, battery-powered variant, including what's propelling the evolution and the challenges along the way. We'll also review how the microprocessor and the brushless DC motor play an instrumental role in transforming the power tools we use today. Additionally, we'll outline how the incorporation of brushless DC motors in power tools provides a competitive edge for manufacturers. Power Tool Main Components The first component of an electric power tool is the power source. All electric-powered tools can be subdivided into corded and cordless. Corded tools—The power source is AC and needs to be plugged into to operate. Cordless or wireless power tools—Rely on the electric energy stored within batteries of different chemistries such as Nickel Cadmium (NiCd), Nickel Metal Hydride (NiMH), and Lithium-Ion (Li-Ion). The Lithium Ion-based battery has become the most prominent because of its increased energy density and resilience to hold a charge. The second component is an actuator or a motor that will transform the electric energy into mechanical energy. This motor can be a universal AC/DC brushed motor, a brushed DC motor, or a brushless DC (BLDC) motor. Many of today's tools have moved to the tri-phase BLDC motor topology. Finally, a switch is employed to control the source-to-motor energy transfer. This component could be as simple as an interrupter, controlling whether there is a current flow. Or it could be something slightly more sophisticated, such as a potentiometer, allowing the user to specify how much energy flows from source to motor. Power Tool Challenges For the first 100 years of electric power tool development, a power source, a motor, and a switch/potentiometer were all that were needed to design and fabricate drills, sanders, grinders, screwdrivers, blowers, saws, etc. However, in the 20th century, the emergence of high-energy-density batteries changed this. Additionally, we saw the emergence of green energy solutions and their integration into all forms of design. Power Tool Design 101: Rev Up Your Knowledge of Brushless DC Motor Functionality Jose Quinones, Senior Applications Engineer – Programmable Power Management