US010617903B2

(12) United States Patent (10 ) Patent No.: US 10,617,903 B2

Orady et al. (45 ) Date of Patent: Apr. 14 , 2020
( 54 ) EXERCISE MACHINE DIFFERENTIAL ( 2013.01); A63B 2220/51 (2013.01); A63B
2220/54 (2013.01 ); A63B 2220/58 (2013.01 );
(71 ) Applicant: Tonal Systems, Inc., San Francisco , A63B 2220/72 ( 2013.01); A63B 2220/80
CA (US ) ( 2013.01) ; A63B 2220/805 (2013.01 );
(Continued )
(72 ) Inventors: Aly E. Orady, San Francisco , CA (US); (58 ) Field of Classification Search
Michael Valente , San Francisco , CA CPC A63B 21/00058 ; A63B 21/00069; A63B
(US); Darryl Weatherspoon , Oakland , 21/00076 ; A63B 21/00178 ; A63B
CA (US ); Bret G. Stott, Menlo Park , 21/00181; A63B 21/002 ; A63B 21/0023 ;
CA (US ) A63B 21/005; A63B 21/0058; A63B
21/0059 , A63B 21/15 ; A63B 21/151;
(73 ) Assignee : Tonal Systems, Inc., San Francisco , A63B 21/152; A63B 21/153; A63B
CA (US ) 21/154 ; A63B 21/155 ; A63B 21/156 ;
A63B 21/4027 ; A63B 21/4033; A63B
( * ) Notice: Subject to any disclaimer, the term of this 21/4034 ; A63B 21/4035 , A63B 21/4041;
patent is extended or adjusted under 35 A63B 21/4043; A63B 21/4045; A63B
U.S.C. 154 (b ) by 91 days . 24/0087 ; A63B 71/0054 ; A63B
2071/0063 ; A63B 2071/0072 ; A63B
( 21 ) Appl. No.: 15 /722,739 2071/0081; A63B 2071/009; A63B
2225/09 ; A63B 2225/093
(22) Filed : Oct. 2 , 2017 See application file for complete search history.
(65 ) Prior Publication Data (56 ) References Cited
US 2019/0099633 A1 Apr. 4 , 2019 U.S. PATENT DOCUMENTS
(51) Int. CI. 3,465,592 A 9/1969 Perrine
A63B 21/005 ( 2006.01 ) 4,616,823 A 10/1986 Yang
A63B 21/00 ( 2006.01) (Continued )
(Continued ) FOREIGN PATENT DOCUMENTS
( 52 ) U.S. CI.
CPC A63B 21/0058 (2013.01); A63B 21/15 EP 3202465 8/2017
(2013.01 ); A63B 21/153 ( 2013.01); A63B Primary Examiner Gary D Urbiel Goldner
21/154 (2013.01); A63B 21/156 ( 2013.01 );
A63B 21/169 (2015.10 ) ; A63B 21/4043 (74 ) Attorney, Agent, or Firm — Van Pelt , Yi & James
(2015.10 ); A63B 23/03541 (2013.01 ); A63B LLP
23/12 ( 2013.01 ); A63B 24/0087 (2013.01 ); ( 57 ) ABSTRACT
A63B 71/0054 (2013.01 ); A63B 21/4035
(2015.10 ); A63B 21/4045 (2015.10 ); A63B An exercise machine comprises a motor, a gearbox coupled
2024/0093 ( 2013.01); A63B 2071/0072 to the motor, a spool coupled to the gearbox , and a cable
( 2013.01) ; A63B 2071/0081 (2013.01); A63B wound about the spool. The gearbox comprises bevel gears .
2210/50 (2013.01); A63B 2220/13 (2013.01) ;
A63B 2220/36 (2013.01 ); A63B 2220/40 22 Claims, 41 Drawing Sheets
201

SC 001
203
202
2015

296

210
 US 10,617,903 B2
Page 2

(51) Int. Ci. 2007/0142187 A1 6/2007 Kolomeir

A63B 24/00 (2006.01 ) 2007/0173384 Al 7/2007 Sechrest
A63B 71/00 ( 2006.01) 2007/0259759 A1 * 11/2007 Sumners A61H 23/0263
482/92
A63B 23/12 (2006.01 ) 2008/0051263 A1 2/2008 Rasmussen
A63B 21/16 ( 2006.01 ) 2008/0248926 A1 10/2008 Cole
A63B 23/035 ( 2006.01 ) 2008/0300116 Al 12/2008 Eder
2009/0023561 A1 * 1/2009 Ross A63B 21/055
(52) U.S. CI. 482/92
CPC A63B 2220/833 ( 2013.01) ; A63B 2220/89 2009/0029835 Al 1/2009 Ellis
( 2013.01 ); A63B 2225/09 (2013.01); A63B 2009/0036277 A1 2/2009 Ish , III
22257093 (2013.01); A63B 2225/50 (2013.01); 2009/0114892 A1 * 5/2009 Lesko B66D 1/22
A63B 2225/54 ( 2013.01 ) 254/342
2009/0170675 A1 7/2009 Giannelli
( 56 ) References Cited 2010/0144496 Al 6/2010 Schmidt
2010/0311552 A1 * 12/2010 Sumners A61H 23/0263
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2011/0172058 A1 * 7/2011 Deaconu A63B 22/0012
4,898,381 A 2/1990 Gordon 482/5
5,117,170 A 5/1992 Keane 2011/0183816 A1 7/2011 Giannelli
5,265,589 A * 11/1993 Wang A63B 23/00 2011/0294630 Al 12/2011 Reyes
434/258 2012/0053014 A1 3/2012 Zhu
5,588,938 A 12/1996 Schneider 2012/0088634 A1 * 4/2012 Heidecke A63B 21/0053
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5,697,869 A 12/1997 Ehrenfried 482/5
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482/99 182/19
6,227,047 B1 5/2001 Livingston 2013/0289452 A1 * 10/2013 Smith B25J 9/0006
6,280,361 B1 * 8/2001 Harvey A63B 21/025 601/33
482/101 2013/0331239 Al 12/2013 Richards
6,547,702 B1 * 4/2003 Heidecke A63B 21/0053 2014/0038777 A1 2/2014 Bird
482/57 2014/0113779 A1 * 4/2014 Loach A63B 21/0004
7,695,418 B2 4/2010 Ish , III 482/115
7,909,742 B2 3/2011 Ish , III 2014/0121071 A1 5/2014 Strom
7,998,036 B2 8/2011 Ish , III 2014/0194250 A1 * 7/2014 Reich A63B 24/0062
8,057,367 B2 11/2011 Giannelli 482/5
8,388,499 B1 * 3/2013 Rindfleisch A63B 22/0089 2014/0194251 A1 * 7/2014 Reich A63B 24/0087
482/1 482/6
8,834,328 B1 9/2014 Batca 2014/0226963 A1 * 8/2014 Ryan F16M 11/041
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396/428
A63B 21/0058
8,900,097 B1 * 12/2014 Griggs A63B 21/4029
482/4 74/37
8,900,099 B1 12/2014 Boyette 2015/0133828 A1 5/2015 Hachisuka
8,968,155 B2 3/2015 Bird 2015/0148194 Al 5/2015 Bird
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9,457,220 B2 10/2016 Olson 482/4
9,656,116 B2 5/2017 Giannelli 2015/0367162 Al 12/2015 Mueller
9,700,753 B1 7/2017 Boatwright 2016/0101322 A1 * 4/2016 Potter A63B 24/0087
9,861,856 B1 1/2018 Miller 48276
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9,901,768 B1 2/2018 Wu A63B 21/0058 482/5
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10,143,880 B1 12/2018 Boatwright 2016/0332020 A1 * 11/2016 Chen F16F 3/04
10,220,235 B2 3/2019 Norris 2016/0354638 A1 * 12/2016 Carr A63B 24/0087
10,286,253 B1 5/2019 Johnson 2017/0173396 Al 6/2017 Lu
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2001/0023221 A1 9/2001 Simonson 2017/0246507 Al 8/2017 Kennington
2003/0134722 A1 7/2003 Greenland 2017/0282015 A1 * 10/2017 Wicks GO5G 9/047
2003/0153438 A1 * 8/2003 Gordon A63B 22/02 2017/0319905 Al * 11/2017 O'Connor A63B 24/0087
482/92 2017/0333756 Al 11/2017 Bird
2003/0176261 A1 9/2003 Simonson 2018/0021616 A1 1/2018 Orady
2003/0207734 A1 11/2003 Lastayo 2018/02 14730 A1 * 8/2018 Larose A63B 21/00181
2004/0009848 Al 1/2004 Lee 2018/0326243 A1 * 11/2018 Badi A61H 1/0262
2004/0082438 A1 4/2004 Lastayo 2018/0361200 A1 12/2018 Walker
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482/142 2019/0099632 Al 4/2019 Orady
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2006/0040799 A1 2/2006 Pompile 2019/0099652 A1 * 4/2019 Orady A63B 71/0054
2006/0069336 A1 * 3/2006 Krebs A61H 1/0266 2019/0160324 A1 * 5/2019 Leopoldo Da Camara Filho
602/28 A63B 21/022
2007/0117691 A1 5/2007 Sechrest
2007/0129223 A1 6/2007 Kolomeir * cited by examiner
U.S. Patent Apr. 14, 2020 Sheet 1 of 41 US 10,617,903 B2

1010

actuator
(handle )

1008 1002

cable filter

1006 1004

motor motor controller

FIG . 1A
U.S. Patent Apr. 14, 2020 Sheet 2 of 41 US 10,617,903 B2

303 300 302

301

200
201
202
203 402
400
104
103
102
401
700 100
500

800
C. 500

600

501
801
702

1000

FIG . 1B
U.S. Patent Apr. 14, 2020 Sheet 3 of 41 US 10,617,903 B2

304
300
301

202 302

201
102

103

100

500

600

*
FIG . 1C
U.S. Patent Apr. 14, 2020 Sheet 4 of 41 US 10,617,903 B2

201

202

MO

103

102

he 100

O w

huwingende
FIG . ID
U.S. Patent Apr. 14, 2020 Sheet 5 of 41 US 10,617,903 B2

al 202

201

00

103
102

100

FIG . 1E
U.S. Patent Apr. 14 , 2020 Sheet 6 of 41 US 10,617,903 B2

801
403
402
302

501
201
203 202
FIG
2A
.
301

300

500

303

400 401 800

U.S. Patent Apr. 14 , 2020 Sheet 7 of 41 US 10,617,903 B2

601
403
402 3024
IOS

203
201
202 FIG
2B
.

00S
303

TO
600
U.S. Patent Apr. 14 , 2020 Sheet 8 of 41 US 10,617,903 B2

Contrle 604
Ground
3A
.
FIG

K
U.S. Patent Apr. 14 , 2020 Sheet 9 of 41 US 10,617,903 B2

u start

3002

collect data from

exercise machine
sensors .

3004

analyze sensor
data to determine
whether data is
within spec .

3006

based on analysis
determine whether
to enter error stop
mode .

FIG . 3B
U.S. Patent Apr. 14, 2020 Sheet 10 of 41 US 10,617,903 B2

5B
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FIG
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405
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4
.
U.S. Patent Apr. 14 , 2020 Sheet 11 of 41 US 10,617,903 B2

702

402
722
6
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FIG

423
422

421
431
420
403
U.S. Patent Apr. 14 , 2020 Sheet 12 of 41 US 10,617,903 B2

732
733

722 702
422
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FIG . 7A

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1
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FIG . 7B
U.S. Patent Apr. 14, 2020 Sheet 13 of 41 US 10,617,903 B2

702

501 8B
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402
U.S. Patent Apr. 14 , 2020 Sheet 14 of 41 US 10,617,903 B2

434

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415
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FIG.9B
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402
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U.S. Patent Apr. 14, 2020 Sheet 15 of 41 US 10,617,903 B2

402

9E
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403
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501
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%
U.S. Patent Apr. 14 , 2020 Sheet 16 of 41 US 10,617,903 B2

704

702

732

403

5 400
U.S. Patent Apr. 14, 2020 Sheet 17 of 41 US 10,617,903 B2

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U.S. Patent Apr. 14 , 2020 Sheet 18 of 41 US 10,617,903 B2

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U.S. Patent Apr. 14 , 2020 Sheet 19 of 41 US 10,617,903 B2

B ?

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U.S. Patent Apr. 14 , 2020 Sheet 20 of 41 US 10,617,903 B2

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U.S. Patent Apr. 14 , 2020 Sheet 21 of 41 US 10,617,903 B2

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U.S. Patent Apr. 14, 2020 Sheet 22 of 41 US 10,617,903 B2

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U.S. Patent Apr. 14 , 2020 Sheet 23 of 41 US 10,617,903 B2

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U.S. Patent Apr. 14 , 2020 Sheet 24 of 41 US 10,617,903 B2

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U.S. Patent Apr. 14 , 2020 Sheet 25 of 41 US 10,617,903 B2

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U.S. Patent Apr. 14, 2020 Sheet 26 of 41 US 10,617,903 B2

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U.S. Patent Apr. 14 , 2020 Sheet 27 of 41 US 10,617,903 B2

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U.S. Patent Apr. 14 , 2020 Sheet 28 of 41 US 10,617,903 B2

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U.S. Patent Apr. 14 , 2020 Sheet 30 of 41 US 10,617,903 B2

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U.S. Patent Apr. 14 , 2020 Sheet 31 of 41 US 10,617,903 B2

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U.S. Patent Apr. 14, 2020 Sheet 32 of 41 US 10,617,903 B2

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U.S. Patent Apr. 14, 2020 Sheet 33 of 41 US 10,617,903 B2

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U.S. Patent Apr. 14 , 2020 Sheet 34 of 41 US 10,617,903 B2

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 US 10,617,903 B2
1 2
EXERCISE MACHINE DIFFERENTIAL FIG . 9L is a perspective view of an exercise machine
slider (403), revealing the pin (404) as well as teeth (422 ) for
BACKGROUND OF THE INVENTION an arm vertical pivot.
FIG . 9M is a perspective view of the exercise machine
Strength training , also referred to as resistance training or 5 slider (403 ) in a column/rail (402 ) with revealed teeth (422 ),
weight lifting, is an important part of any exercise routine . with arm (702 ) set at a vertical pivot at a point parallel to the
It promotes the building of muscle, the burning of fat, and horizontal plane.
improvement of a number of metabolic factors including FIG . 9N is a side view section of the exercise machine
insulin sensitivity and lipid levels . Many users seek a more slider (403 ) in a column/rail (402 ), with arm (702 ) set at a
efficient and safe method of strength training. 10 vertical pivot at a point parallel to the horizontal plane .
FIG . 90 is a sectional side view of the exercise machine
BRIEF DESCRIPTION OF THE DRAWINGS slider (403).
FIG . 9P illustrates an exploded perspective view drawing
Various embodiments of the invention are disclosed in the of the exercise machine slider (403 ).
following detailed description and the accompanying draw- 15 FIG . 9Q is a perspective view of a column locking
ings. mechanism for a horizontal pivot .
FIG . 1A is a block diagram illustrating an embodiment of FIG . 9R is a top view of the top member (412 ).
an exercise machine. FIG . 9S is a side view of the column locking mechanism
FIG . 1B illustrates a front view of one embodiment of an for the horizontal pivot.
exercise machine. 20 FIG . 9T illustrates an exploded perspective view drawing
FIG . 1C illustrates a perspective view of the system of of the column locking mechanism including locking mem
FIG . 1B wherein for clarity arms, cables, and belts are ber (415).
omitted . FIG . 9U is a perspective view of a wrist (704 ), showing
FIG . 1D illustrates a front view of the system of FIG . 1B . a spring mechanism that enables access to the interior of the
FIG . 1E illustrates a perspective view of the drivetrain of 25 wrist ( forexample, to the bolts shown in FIGS. 9V and 9W )
FIG . 1B . in order to, for example, service the wrist.
FIG . 2A illustrates a top view of one embodiment of an FIG . 9V is a perspective section of the wrist (704).
exercise machine . FIG . 9W is a side view section of the wrist ( 704 ).
FIG . 2B illustrates a top view of an alternate embodiment FIG . 9X illustrates an exploded perspective view drawing
of an exercise machine. 30 of the wrist (704 ).
FIG . 3A is a circuit diagram of an embodiment of a FIGS. 10A , 10B , and 10C illustrate a stowed configura
voltage stabilizer. tion .
FIG . 3B is a flowchart illustrating an embodiment of a FIG . 11 illustrates the footprint of the dynamic arm
process for a safety loop for an exercise machine. placement.
FIG . 4 is an illustration of arms in one embodiment of an 35 FIGS. 12A , 12B , 12C , and 12D illustrate a differential for
exercise machine . an exercise machine.
FIG . 5A is an illustration of a locked position for an arm . FIG . 12E illustrates an exploded perspective view draw
FIG . 5B is an illustration of an unlocked position for an ing of sprocket ( 201 ) and shaft (210 ) .
arm . FIG . 12F illustrates an exploded perspective view draw
FIG . 6 is an illustration of an embodiment of a vertical 40 ing of planet gears (205 , 207 ), sprocket (201 ) and shaft
pivot locking mechanism . (210 ).
FIGS. 7A and 7B illustrate locking and unlocking for arm FIG . 12G illustrates an exploded perspective view draw
vertical pivoting. ing of a cover for sprocket (201) .
FIGS. 8A and 8B illustrate a top view ofa track that pivots FIG . 12H illustrates an exploded perspective view draw
horizontally . 45 ing of the sun gears (204, 205) respectively bonded to spools
FIG . 9A shows column (402 ) from a side view . (202 , 203) and assembled with sprocket ( 201).
FIG . 9B shows a top view of arm (402 ). FIG . 121 illustrates an exploded perspective view drawing
FIG . 9C shows device locking member (415 ) having been of the assembled differential (200 ) with finishing features.
pulled back from top member (412 ).
FIG . 9D shows a side view of track (402) with cable (501) 50 DETAILED DESCRIPTION
located in the center of track (402 ), and arm (702 ) traveling
down and directly away from the machine. The invention can be implemented in numerous ways ,
FIG . 9E shows the front view , now with arm (702 ) including as a process; an apparatus ; a system ; a composi
traveling down and to the left. tion ofmatter ; a computer program product embodied on a
FIG . 9F is a perspective view of an exercise machine arm 55 computer readable storage medium ; and /or a processor, such
extended upward . as a processor configured to execute instructions stored on
FIG . 9G is a perspective view of an exercise machine arm and /or provided by a memory coupled to the processor . In
extended horizontally . this specification , these implementations, or any other form
FIG . 9H illustrates an exploded perspective view drawing that the invention may take, may be referred to as tech
of an arm (702 ) including its lever (732 ), compression spring 60 niques. In general, the order of the steps of disclosed
(733 ), and locking member (722 ). processes may be altered within the scope of the invention.
FIG . 91 illustrates both an assembled sectioned and non Unless stated otherwise, a component such as a processor or
sectioned perspective view drawing of the arm (702 ). a memory described as being configured to perform a task
FIG . 9J is a side view section of an exercise machine may be implemented as a general component that is tem
slider (403 ) with its locking mechanism and pin locked . 65 porarily configured to perform the task at a given time or a
FIG . 9K is a side view section of an exercise machine specific component that is manufactured to perform the task .
slider (403) with its locking mechanism and pin unlocked . As used herein , the term ' processor ' refers to one or more
 US 10,617,903 B2
3 4
devices , circuits , and /or processing cores configured to THERABAND , pneumatics, and hydraulics. These systems
process data, such as computer program instructions . have various characteristics with their own applied tension
A detailed description of one ormore embodiments of the curve .
invention is provided below along with accompanying fig Electronic Resistance .
ures that illustrate the principles of the invention . The 5 Using electricity to generate tension / resistance may also
invention is described in connection with such embodi be used , for example, as described in co -pending U.S. patent
application Ser . No. 15/655,682 entitled DIGITAL
ments, but the invention is not limited to any embodiment. STRENGTH TRAINING filed Jul. 20, 2017 , which is
The scope of the invention is limited only by the claims and incorporated herein
the invention encompasses numerous alternatives, modifi 10 of electronic resistanceby reference for all purposes. Examples
cations and equivalents. Numerous specific details are set field to generate tensioninclude
/
using an electromagnetic
resistance, using an electronic
forth in the following description in order to provide a motor to generate tension /resistance , and
thorough understanding of the invention . These details are brushless direct -current (BLDC ) motor tousing a three -phase
generate tension/
provided for the purpose of example and the invention may
be practiced according to the claims without some or all of 15 resistance. The techniques discussed within the instant
application are applicable to other traditional exercise
these specific details. For the purpose of clarity, technical machines without limitation , for example exercise machines
material that is known in the technical fields related to the based on pneumatic cylinders , springs, weights , flexing
invention has not been described in detail so that the nylon rods, elastics, pneumatics, hydraulics, and / or friction.
invention is not unnecessarily obscured . Low Profile .
Traditionally, the majority of strength training methods 20 A strength trainer using electricity to generate tension /
and /or apparatuses fall into the following categories : resistance may be smaller and lighter than traditional
Body Weight: Nothing in addition to the gravitational strength training systems such as a weight stack , and thus
force of body weight is used to achieve resistance may be placed , installed , or mounted in more places for
training. Pull-ups are a good example of this. Some example the wall of a small room of a residential home.
systems such as TRX provide props that may help one 25 Thus , low profile systems and components are preferred for
better achieve this ; such a strength trainer. A strength trainer using electricity to
Free weights: A traditional example are dumbbells , which generate tension / resistance may also be versatile by way of
also operate using gravity as a force. The tension electronic and / or digital control. Electronic control enables
experienced by a user throughout a range of motion , the use of software to control and direct tension . By contrast,
termed throughout this specification as an “ applied 30 traditional systems require tension to be changed physically/
tension curve” , varies depending on the angle ofmove manually ; in the case of a weight stack , a pin has to be
ment and / or the direction of gravity . For somemotion , moved by a user from one metal plate to another.
such as a bicep curl, the applied tension curve is Such a digital strength trainer using electricity to generate
particularly variable: for a bicep curl it starts at near tension /resistance is also versatile by way of using dynamic
zero when the arm is at full extension , peaks at 90 35 resistance, such that tension / resistance may be changed
degrees, and reduces until the arm reaches full curl at nearly instantaneously . When tension is coupled to position
near zero again ; of a user against their range of motion , the digital strength
Fixed -track machine: Machines that use weights , for trainer may apply arbitrary applied tension curves, both in
example plates of metal comprising a weight stack , terms of position and in terms of phase of the movement:
coupled by a cable attached to a cam joined to a 40 concentric, eccentric , and /or isometric. Furthermore , the
mechanism running on a pivot and/or track . These often shape of these curves may be changed continuously and /or
have a fixed applied tension curve, though some sys in response to events; the tension may be controlled con
temssuch asNAUTILUS have used oddly shaped cams tinuously as a function of a number of internal and external
in order to achieve non - linear applied tension curves . variables including position and phase , and the resulting
Often a weight setting is selected for a weight stack by 45 applied tension curve may be pre -determined and/or
using a pin inserted associated with a desired plate; and adjusted continuously in real time.
Cable -machines: Also known as gravity -and -metal based FIG . 1A is a block diagram illustrating an embodiment of
cable -machines , these are a cross between free weights an exercise machine . The exercise machine includes the
and fixed track machines . They comprise a weight stack following :
attached to a cable , often via a pulley system which 50 a controller circuit ( 1004 ),which may include a processor,
may be adjustable in height or direction . Fixed -track inverter, pulse -width -modulator, and /or a Variable Fre
machines have historically been criticized by some for quency Drive (VFD ) ;
overly isolating a single muscle. Free weights on the a motor ( 1006 ), for example a three -phase brushless DC
other hand have historically been criticized by some for driven by the controller circuit ;
activating too many small stabilizer muscles, meaning 55 a spoolwith a cable ( 1008 ) wrapped around the spool and
that a user's workout may be limited by these small coupled to the spool. On the other end of the cable an
muscles before the large ones have even gotten a good actuator/handle ( 1010 ) is coupled in order for a user to
workout . Cables do not run on a track , and thus still grip and pull on . The spool is coupled to the motor
require some use of stabilizermuscles, but not asmuch (1006 ) either directly or via a shaft/belt/chain / gear
as free weights because the direction of pull is strictly 60 mechanism . Throughout this specification, a spoolmay
down the cable . The effective applied tension curves be also referred to as a “ hub ” ;
varies if the angle of attack between a user's hand and a filter ( 1002), to digitally control the controller circuit
the cable changes throughout the range of motion . ( 1004 ) based on receiving information from the cable
While gravity is the primary source of tension and/or ( 1008 ) and /or actuator ( 1010 );
resistance in all of the above , tension has also been achieved 65 optionally (not shown in FIG . 1A ) a gearbox between the
using springs and/or flexing nylon rods as with BOWFLEX , motor and spool. Gearboxes multiply torque and /or
elastics comprising rubber bands/ resistance bands as with friction , divide speed , and /or split power to multiple
 US 10,617,903 B2
5 6
spools . Without changing the fundamentals of digital cable (1008 ) spool. In one embodiment, the motor
strength training , a number of combinations of motor ( 1006 ) is coupled to a cable spool via a shaft, gearbox ,
and gearbox may be used to achieve the same end belt, and /or chain , allowing the diameter of the motor
result. A cable -pulley system may be used in place of (1006 ) and the diameter of the spool to be independent,
a gearbox, and /or a dualmotor may be used in place of 5 as well as introducing a stage to add a set -up or
a gearbox ; step - down ratio if desired . Alternatively, the motor
one or more of the following sensors (not shown in FIG . ( 1006 ) is coupled to two spools with an apparatus in
1A ): between to split or share the power between those two
a position encoder ; a sensor to measure position of the spools. Such an apparatus could include a differential
actuator ( 1010 ) or motor ( 100). Examples of position 10 gearbox, or a pulley configuration; and/or
encoders include a hall effect shaft encoder, grey -code an actuator ( 1010 ) such as a handle, a bar, a strap , or other
encoder on the motor/spool/cable ( 1008 ), an acceler accessory connected directly, indirectly, or via a con
ometer in the actuator/handle ( 1010 ), optical sensors , nector such as a carabiner to the cable ( 1008 ).
position measurement sensors/methods built directly In some embodiments, the controller circuit ( 1002, 1004 )
into the motor ( 1006 ), and /or optical encoders. In one 15 is programmed to drive the motor in a direction such that it
embodiment, an optical encoder is used with an encod draws the cable (1008 ) towards the motor ( 1006 ). The user
ing pattern that uses phase to determine direction pulls on the actuator ( 1010 ) coupled to cable ( 1008 ) against
associated with the low resolution encoder. Other the direction of pull of the motor ( 1006 ).
options thatmeasure back -EMF (back electromagnetic One purpose of this setup is to provide an experience to
force ) from the motor ( 1006 ) in order to calculate 20 a user similar to using a traditional cable-based strength
position also exist; training machine , where the cable is attached to a weight
a motor power sensor ; a sensor to measure voltage and /or stack being acted on by gravity . Rather than the user
current being consumed by the motor (1006 ); resisting the pull of gravity, they are instead resisting the pull
a user tension sensor; a torque/tension /strain sensor and /or of the motor ( 1006 ).
gauge to measure how much tension /force is being 25 Note that with a traditional cable -based strength training
applied to the actuator ( 1010 ) by the user. In one machine , a weight stack may be moving in two directions:
embodiment, a tension sensor is built into the cable away from the ground or towards the ground. When a user
( 1008 ). Alternatively, a strain gauge is built into the pulls with sufficient tension , the weight stack rises, and as
motor mount holding the motor ( 1006 ). As the user that user reduces tension , gravity overpowers the user and
pulls on the actuator (1010 ), this translates into strain 30 the weight stack returns to the ground .
on the motor mount which is measured using a strain By contrast in a digital strength trainer , there is no actual
gauge in a Wheatstone bridge configuration . In another weight stack . The notion of the weight stack is one modeled
embodiment, the cable ( 1008 ) is guided through a by the system . The physical embodiment is an actuator
pulley coupled to a load cell . In another embodiment, ( 1010 ) coupled to a cable ( 1008 ) coupled to a motor (1006 ).
a belt coupling the motor (1006 ) and cable spool or 35 A " weight moving” is instead translated into a motor rotat
gearbox ( 1008 ) is guided through a pulley coupled to a ing. As the circumference of the spool is known and how fast
load cell. In another embodiment, the resistance gen it is rotating is known, the linearmotion of the cable may be
erated by the motor ( 1006 ) is characterized based on calculated to provide an equivalency to the linear motion of
the voltage, current, or frequency input to the motor. a weight stack . Each rotation of the spool equals a linear
In one embodiment, a three -phase brushless DC motor 40 motion of one circumference or 2nr for radius r. Likewise ,
( 1006 ) is used with the following: torque of the motor ( 1006 ) may be converted into linear
a controller circuit ( 1004 ) combined with filter (1002 ) force by multiplying it by radius r.
comprising: If the virtual/ perceived “ weight stack ” is moving away
a processor that runs software instructions ; from the ground ,motor (1006 ) rotates in one direction . If the
three pulse width modulators (PWMs), each with two 45 “weight stack ” is moving towards the ground ,motor (1006 )
channels , modulated at 20 kHz; rotates in the opposite direction. Note that the motor (1006 )
six transistors in an H -Bridge configuration coupled to is pulling towards the cable (1008 ) onto the spool. If the
the three PWMs; cable ( 1008 ) is unspooling, it is because a user has over
optionally, two or three ADCs ( Analog to Digital powered the motor ( 1006 ). Thus, note a distinction between
Converters ) monitoring current on the H -Bridge; 50 the direction the motor ( 1006 ) is pulling , and the direction
and / or the motor ( 1006 ) is actually turning.
optionally , two or three ADCs monitoring back - EMF If the controller circuit ( 1002 , 1004) is set to drive the
voltage ; motor ( 1006 ) with , for example , a constant torque in the
the three-phase brushless DC motor ( 1006 ), which may direction that spools the cable, corresponding to the same
include a synchronous-type and/or asynchronous- type 55 direction as a weight stack being pulled towards the ground ,
permanent magnet motor, such that: then this translates to a specific force/ tension on the cable
the motor (1006 ) may be in an “ out-runner configura ( 1008 ) and actuator ( 1010 ). Calling this force “ Target Ten
tion ” as described below ; sion ” , this force may be calculated as a function of torque
the motor ( 1006 ) may have a maximum torque output multiplied by the radius of the spool that the cable ( 1008) is
of at least 60 Nm and a maximum speed of at least 60 wrapped
300 RPMs;
around , accounting for any additional stages such
as gear boxes or belts that may affect the relationship
optionally, with an encoder or othermethod to measure between cable tension and torque . If a user pulls on the
motor position ; actuator (1010 ) with more force than the Target Tension ,
a cable ( 1008 ) wrapped around the body of the motor then that user overcomes the motor ( 1006 ) and the cable
(1006 ) such that entire motor ( 1006 ) rotates, so the 65 ( 1008 ) unspools moving towards that user, being the virtual
body of the motor is being used as a cable spool in one equivalent of the weight stack rising . However, if that user
case. Thus, the motor ( 1006 ) is directly coupled to a applies less tension than the Target Tension , then the motor
 US 10,617,903 B2
7 8
( 1006 ) overcomes the user and the cable (1008 ) spools onto If a motor does not exactly meet the requirements illus
and moves towards the motor (1006 ), being the virtual trated in the table above , the ratio between speed and torque
equivalent of the weight stack returning . may be adjusted by using gears or belts to adjust. A motor
BLDC Motor. coupled to a 9 " sprocket, coupled via a belt to a spool
While many motors exist that run in thousands of revo 5 coupled to a 4.5 " sprocket doubles the speed and halves the
lutions per second , an application such as fitness equipment torque of the motor. Alternately, a 2 :1 gear ratio may be used
designed for strength training has different requirements and to accomplish the same thing. Likewise, the diameter of the
is by comparison a low speed , high torque type application spool may be adjusted to accomplish the same.
suitable for certain kinds of BLDC motors configured for Alternately , a motor with 100x the speed and 100th the
lower speed and higher torque. 10 torque may also be used with a 100 :1 gearbox. As such a
In one embodiment, a requirement of such a motor ( 1006 ) gearbox also multiplies the friction and /or motor inertia by
is that a cable (1008 ) wrapped around a spool of a given 100x, torque control schemes become challenging to design
diameter, directly coupled to a motor (1006 ), behaves like a for fitness equipment/ strength training applications. Friction
200 lbs weight stack , with the user pulling the cable at a may then dominate what a user experiences. In other appli
maximum linear speed of62 inches per second . A number of 15 cations friction may be present, but is low enough that it is
motor parameters may be calculated based on the diameter compensated for , but when it becomes dominant, it is
of the spool. difficult to control for. For these reasons, direct control of
User Requirements
Target Weight 200 lbs
Target Speed 62 inches /sec 1.5748 meters / sec
Requirements by Spool Size
Diameter (inches )
3 5 6 7 8 9

RPM 394.7159 236.82954 197.35795 169.1639572 148.0184625 131.5719667

Torque (Nm ) 67.79 112.9833333 135.58 158.1766667 180.7733333 203.37
Circumference 9.4245 15.7075 18.849 21.9905 25.132 28.2735
(inches )

Thus , a motor with 67.79 Nm of force and a top speed of motor torque is more appropriate for fitness equipment/
395 RPM , coupled to a spool with a 3 inch diameter meets 35 strength training systems. This would normaly lead to the
these requirements. 395 RPM is slower than most motors selection of an induction type motor for which direct control
available, and 68 Nm is more torque than most motors on the
market as well .
of torque is simple. Although BLDC motors are more
Hub motors are three -phase permanent magnet BLDC directly able to control speed and/or motor position rather
than torque , torque control of BLDC motors can be made
direct drivethismotors
throughout in an out" -outrunner
specification -runnermeans
” configuration
that the per: 40 possible with the appropriate methods when used in com
manent magnets are placed outside the stator rather than bination with an appropriate encoder.
inside, as opposed to many motors which have a permanent Reference Design .
magnet rotor placed on the inside of the stator as they are FIG . 1B illustrates a front view of one embodiment of an
designed more for speed than for torque. Out-runners have 45 exercise machine. An exercise machine ( 1000 ) comprising a
the magnets on the outside , allowing for a larger magnet and pancake motor (100 ), a torque controller (600 ) coupled to
pole count and are designed for torque over speed . Another the pancake motor, and a high resolution encoder coupled to
way to describe an out-runner configuration is when the the pancake motor ( 102 ) is disclosed . As described herein , a
shaft is fixed and the body of the motor rotates. “ high resolution " encoder is any encoder with 30 degrees or
Hub motors also tend to be " pancake style ” . As described
herein , pancakemotors are higher in diameter and lower in 50 coupled
greater ofrespectively
electrical angle . Two cables
to actuators (500(801
(800 ) and ) and) on(501
one) end
are
depth than most motors. Pancake style motors are advanta
geous for a wall mount, subfloor mount, and /or floor mount of the cables . The two cables (500 ) and (501) are coupled
application where maintaining a low depth is desirable , such irectly or indirectly on the opposite end to the motor ( 100 ) .
as a piece of fitness equipment to be mounted in a consum While an induction motor may be used for motor (100 ), a
er's home or in an exercise facility /area . As described 55 BLDC motor is a preferred embodiment for its cost , size ,
herein , a pancake motor is a motor that has a diameter higher weight, and performance . A BLDC motor is more challeng
than twice its depth . As described herein , a pancake motor ing than an induction motor to control torque and so a high
is between 15 and 60 centimeters in diameter, for example resolution encoder assists the system to determine position
22 centimeters in diameter, with a depth between 6 and 15 of the BLDC motor.
centimeters , for example a depth of 6.7 centimeters . 60 Sliders (401 ) and (403 ) may be respectively used to guide
Motors may also be " direct drive ” , meaning that the motor the cable (500 ) and (501) respectively along rails (400 ) and
does not incorporate or require a gear box stage. Many (402). The exercise machine in FIG . 1B translates motor
motors are inherently high speed low torque but incorporate torque into cable tension . As a user pulls on actuators ( 800 )
an internal gearbox to gear down the motor to a lower speed and /or (801 ), the machine creates/maintains tension on cable
with higher torque and may be called gear motors. Direct 65 (500 ) and /or (501). The actuators (800, 801) and /or cables
drivemotors may be explicitly called as such to indicate that (500 , 501 ) may be actuated in tandem or independently of
they are not gear motors . one another .
 US 10,617,903 B2
9 10
In one embodiment, electronics bay (600 ) is included and around the spools. The cables (500) and (501) route through
has the necessary electronics to drive the system . In one the system to actuators (800 ) and (801 ), respectively .
embodiment, fan tray (500 ) is included and has fans that The cables (500 ) and (501) are respectively positioned in
cool the electronics bay (600) and/or motor ( 100). part by the use of “ arms” (700 ) and (702 ). The arms ( 700 )
Motor ( 100 ) is coupled by belt (104) to an encoder (102 ), 5 and (702 ) provide a framework for which pulleys and /or
an optionalbelt tensioner (103), and a spool assembly ( 200 ). pivot points may be positioned . The base of arm ( 700 ) is at
Motor (100 ) is preferably an out- runner, such that the shaft arm slider (401 ) and the base of arm ( 702 ) is at arm slider
is fixed and the motor body rotates around that shaft. In one (403 ).
embodiment, motor ( 100 ) generates torque in the counter 10
The cable (500) for a left arm ( 700) is attached at one end
clockwise direction facing the machine, as in the example in to actuator (800 ). The cable routes via arm slider (401 )
FIG . 1B . Motor ( 100 ) has teeth compatible with the belt where it engages a pulley as it changes direction , then routes
integrated into the body of the motor along the outer along the axis of rotation of track (400 ). At the top of track
circumference . Referencing an orientation viewing the front (400 ), fixed to the frame rather than the track is pulley ( 303 )
of the system , the left side of the belt (104 ) is under tension , 15 that orients the cable in the direction of pulley (300), that
while the right side of the belt is slack . The belt tensioner further orients the cable (500 ) in the direction of spool ( 202 ),
( 103 ) takes up any slack in the belt. An optical rotary wherein the cable (500 ) is wound around spool ( 202 ) and
encoder ( 102 ) coupled to the tensioned side of the belt ( 104 ) attached to spool ( 202 ) at the other end.
captures all motor movement, with significant accuracy Similarly, the cable (501 ) for a right arm (702 ) is attached
because of the belt tension . In one embodiment, the optical 20 at one end to actuator (601 ). The cable (501 ) routes via slider
rotary encoder ( 102) is a high resolution encoder. In one (403 ) where it engages a pulley as it changes direction , then
embodiment, a toothed belt (104) is used to reduce belt slip . routes along the axis of rotation of track (402 ). At the top of
The spools rotate counter- clockwise as they are spooling the track (402 ), fixed to the frame rather than the track is
cable /taking cable in , and clockwise as they are unspooling / pulley (302 ) that orients the cable in the direction of pulley
releasing cable out. 25 ( 301 ), that further orients the cable in the direction of spool
Spool assembly (200) comprises a front spool (203 ), rear ( 203 ), wherein the cable (501 ) is wound around spool (203 )
spool (202 ), and belt sprocket (201 ). The spool assembly and attached to spool (203 ) at the other end .
( 200 ) couples the belt ( 104 ) to the belt sprocket (201), and One important use of pulleys (300 , 301 ) is that they
couples the two cables (500 ) and (501) respectively with permit the respective cables (500 , 501) to engage respective
front spool ( 203) and rear spool ( 202 ). Each of these 30 spools ( 202 , 203 ) “ straight on ” rather than at an angle,
components is part of a low profile design . In one embodi wherein “ straight on ” references being within the plane
ment, a dual motor configuration not shown in FIG . 1B is perpendicular to the axis of rotation of the given spool. If the
used drive each cable (500) and (501). In the example given cable were engaged at an angle , that cable may bunch
shown in FIG . 1B , a single motor (100 ) is used as a single up on one side of the given spool rather than being distrib
source of tension , with a plurality of gears configured as a 35 uted evenly along the given spool.
differential are used to allow the two cables /actuators to be In the example shown in FIG . 1B , pulley (301 ) is lower
operated independently or in tandem . In one embodiment, than pulley ( 300 ). This is not necessary for any functional
spools (202 ) and (203 ) are directly adjacent to sprocket reason but demonstrates the flexibility of routing cables. In
( 201), thereby minimizing the profile of the machine in FIG . a preferred embodiment, mounting pulley ( 301) lower
1B . 40 leaves clearance for certain design aesthetic elements that
As shown in FIG . 1B , two arms (700 , 702 ), two cables make the machine appear to be thinner. FIG . 1C illustrates
(500 , 501) and two spools (202 , 203) are useful for users a perspective view of the system of FIG . 1B wherein for
with two hands, and the principles disclosed without limi clarity arms, cables, and belts are omitted . FIG . 1D illus
tation may be extended to three, four, ormore arms (700 ) for trates a front view of the system of FIG . 1B . FIG . 1E
quadrupeds and /or group exercise . In one embodiment, the 45 illustrates a perspective view of the drivetrain of FIG . 1B .
plurality of cables (500 , 501) and spools (202, 203) are FIG . 2A illustrates a top view of one embodiment of an
driven by one sprocket (201), one belt ( 104 ), and one motor exercise machine . In one embodiment, the top of view of
( 100 ), and so the machine (1000 ) combines the pairs of FIG . 2A is that of the system shown in FIG . 1B . As long as
devices associated with each user hand into a single device . motor torque is in the counter-clockwise direction , a cable is
In one embodiment,motor ( 100 ) should provide constant 50 under tension . The amount oftension is directly proportional
tension on cables (500 ) and (501 ) despite the fact that each to the torque generated by the motor, based on a factor that
of cables (500 ) and (501) may move at different speeds. For includes the relative diameters of themotor ( 100 ), sprocket
example, some physical exercises may require use of only (201), and spools ( 202 ) and (203 ). If the force pulling on a
one cable at a time. For another example, a user may be cable overcomes the tension , the respective spool will
stronger on one side of their body than another side, causing 55 unspool releasing cable , and hence the spool will rotate
differential speed of movement between cables (500) and clockwise . If the force is below the tension , then the respec
(501). In one embodiment, a device combining dual cables tive spool will spool take in cable, and hence the spool will
(500 ) and (501 ) for single belt ( 104 ) and sprocket (201), rotate counter - clockwise .
should retain a low profile , in order to maintain the compact When the motor is being back -driven by the user, that is
nature of the machine, which can be mounted on a wall. 60 when the user is retracting the cable, but the motor is
In one embodiment, pancake style motor(s) (100 ), sprock resisting , and the motor is generating power. This additional
et (s) (201) and spools ( 202 , 203) are manufactured and power may cause the internal voltage of the system to rise .
arranged in such a way that they physically fit together The voltage is stabilized to prevent the voltage rising
within the same space, thereby maximizing functionality indefinitely causing the system to fail or enter an unsafe
while maintaining a low profile. 65 state . In one embodiment, power dissipation is used to
As shown in FIG . 1B , spools (202 ) and (203 ) are respec stabilize voltage , for example to burn additional power as
tively coupled to cables (500 ) and (501) that are wrapped heat.
 US 10,617,903 B2
11 12
FIG . 2B illustrates a top view of an alternate embodiment calculation to calculate the PWM duty cycle , then outputs a
of an exercise machine . As shown in FIG . 2B , pulleys ( 300 ) pulse with a period corresponding to that duty cycle .
and ( 301) may be eliminated by rotating and translating the Safety .
dual-spool assembly. The ideal location of the dual-spool Safety of the user and safety of the equipment is important
assembly would be placed such that the cable route from 5 for an exercise machine. In one embodiment, a safety
both spools to the respective pulleys (302) and ( 303 ) is controller uses one or more models to check system behav
straight-on. Eliminating these pulleys both reduces system ior, and place the system into a safe-stop , also known as an
friction and reduces cost with the tradeoff of making the harm error-stop mode or ESTOP state to prevent or minimize
machine (1000 ) thicker, that is , less shallow from front to 10 may beto athe user and / or the equipment. A safety controller
partof controller (604 )or a separate controller (not
back .
Voltage Stabilization. shown in FIG . 3A ). A safety controller may be implemented
FIG . 3A is a circuit diagram of an embodiment of a redundancy in redundant modules/ controllers/subsystems and /or use
voltage stabilizer. The stabilizer includes a power supply flowchart illustrating to provide additional reliability . FIG . 3B is a
an embodiment of a process for a
(power
603) .with protective element (602 ) that provides system
Such a system may have an intrinsic or by - design
15 safety loop for an exercise machine.
Depending on the severity of the error, recovery from
capacitance (612 ). A motor controller (601 ), which includes ESTOP may be quick and automatic , or require user inter
the motor control circuits as well as a motor that consumes vention or system service .
or generates power is coupled to power supply (603 ). A In step 3002 , data is collected from one or more sensors,
controller circuit (604 ) controls a FET transistor (608 ) 20 examples including :
coupled to a high -wattage resistor (607) as a switch to 1 ) Rotation of the motor ( 100 ) via Hall sensors within the
stabilize system power. A sample value for resistor (607 ) is motor ;
a 300 W resistor/heater. A resistor divider utilizing a resistor 2 ) Rotation of the motor (100 ) via an encoder ( 103)
network (605 ) and (606 ) is arranged such that the potential coupled to the belt ;
at voltage test point (609) is a specific fraction of system 25 3 ) Rotation of each of the two spools (202 , 203) ;
voltage (611 ). When FET (608) is switched on , power is 4 ) Electrical current on each of the phases of the three
burned through resistor (607). The control signal to the gate phase motor ( 100 );
of FET (610 ) switches it on and off. In one embodiment, this 5 ) Accelerometer mounted to the frame;
control signal is pulse width modulated (PWM ) switching 6 ) Accelerometermounted to each of the arms (400, 402 );
on and off at some frequency. By varying the duty cycle 30 7 ) Motor (100) torque ;
and/or percentage of timeon versus off, the amount ofpower 8 ) Motor (100) speed ;
dissipated through the resistor (607 ) may be controlled . 9 ) Motor (100 ) voltage ;
Factors to determine a frequency for the PWM include the 10 ) Motor ( 100 ) acceleration ;
frequency of the motor controller, the capabilities of the 11 ) System voltage (611 ) ;
power supply, and the capabilities of the FET. In one 35 12 ) System current; and /or
embodiment, a value in the range of 15-20 KHz is appro 13 ) One or more temperature sensors mounted in the
priate . system .
Controller (604 ) may be implemented using a micro In step 3004 , a model analyzes sensor data to determine
controller, micro -processor, discrete digital logic , any pro if it is within spec or out of spec , including but not limited
grammable gate array , and/or analog logic , for example 40 to :
analog comparators and triangle wave generators. In one 1) The sum of the current on all three leads of the
embodiment, the samemicrocontroller that is used to imple three -phase motor ( 100 ) should equal zero ;
ment the motor controller (601) is also used to implement 2 ) The current being consumed by the motor ( 100 ) should
voltage stabilization controller (604 ). be directly proportional to the torque being generated
In one embodiment, a 48 Volt power supply (603 ) is used . 45 by the motor ( 100 ). The relationship is defined by the
The system may be thus designed to operate up to a motor's torque constant;
maximum voltage of 60 Volts. In one embodiment, the 3 ) The speed of the motor ( 100) should be directly
Controller (604 ) measures system voltage , and if voltage is proportional to the voltage being applied to the motor
below a minimum threshold of 49 Volts, then the PWM has (100). The relationship is defined by the motor's speed
a duty cycle of 0 % ,meaning that the FET (610 ) is switched 50 constant;
off . If the motor controller (601) generates power, and the 4 ) The resistance of the motor ( 100 ) is fixed and should
capacitance (612 ) charges, causing system voltage (611 ) to not change ;
rise above 49 Volts, then the controller (601) will increase 5 ) The speed of the motor ( 100) as measured by an
the duty cycle of the PWM . If the maximum operating encoder, back EMF voltage, for example zero cross
voltage of the system is 60 Volts , then a simple relationship 55 ings, and Hall sensors should all agree ;
to use is to pick a maximum target voltage below the 60 6 ) The speed of the motor (100 ) should equal the sum of
Volts, such as 59 Volts, so that at 59 Volts, the PWM is set the speeds of the two spools ( 202 , 203 );
to a 100 % duty cycle. Hence , a linear relationship of PWM 7 ) The accelerometer mounted to the frame should report
duty cycle is used such that the duty cycle is 0 % at 49 Volts, little to no movement.Movementmay indicate that the
and 100 % at 59 Volts. Other examples of relationships 60 frame mount has come loose ;
include: a non - linear relationship; a relationship based on 8 ) System voltage (611 ) should be within a safe range , for
coefficients such as one representing the slope of a linear line example as described above, between 48 and 60 Volts;
adjusted by a PID loop ; and /or a PID loop directly in control 9 ) System current should be within a safe range associated
of the duty cycle of the PWM . with the rating of the motor ;
In one embodiment, controller (604 ) is a micro -controller 65 10 ) Temperature sensors should be within a safe range ;
such that 15,000 times per second an analog to digital 11 ) A physics model of the system may calculate a safe
converter (ADC ) measures the system voltage, invokes a amount of torque at a discrete interval in time continu
 US 10,617,903 B2
13 14
ously. Bymeasuring cable speed and tension , the model track (402). This is mirrored on the other side of themachine
may iteratively predict what amount of torque may be with slider (401 ) on track ( 400 ).
measured at the motor ( 100 ). If less torque than As shown in FIG . 1B , slider (401) is at a higher vertical
expected is found at themotor, this is an indication that position than right slider (403 ), so the base of arm (700 ) is
the user has released one or more actuators (800,801); 5 higher than that of arm ( 702). FIGS. 5A and 5B show how
and /or an arm (702 ) can be moved up and down in a vertical
12 ) The accelerometer mounted to the arms (400 , 402 ) direction
FIG .
.
5A is an illustration of a locked position for an arm .
should report little to no movement. Movement would
indicate that an arm has failed in some way, or that the 10 In FIG . 5A , pin (404 ), within slider (403 ), is in a locked
user has unlocked the arm . position . This means that the end of pin (404 ) is located
In step 3006 , if a model has been determined to be within one of a set of track holes (405 ). Pin (404 ) may be set
violated , the system may enter an error stop mode . In such in this position through different means, including manual
an ESTOP mode, depending on the severity , itmay respond pushing , spring contraction , and electrically driven motion .
with one or more of: FIG . 5B is an illustration of an unlocked position for an
15 arm . In FIG . 5B , pin (404) has been retracted for track holes
1 ) Disable all power to the motor; ( 405). This enables slider (403 ) to move up or down track
2 ) Disable the main system power supply , relying on (402 ), which causes arm (702 ) to move up or down. In one
auxiliary supplies to keep the processors running ; embodiment, the user manually moves slider (403 ). In an
3 ) Reduce motor torque and/or cable tension to a maxi alternate embodiment, the motor uses cable tension and
mum safe value, for example the equivalent of torque 20 gravity to move sliders up and down to desired positions.
that would generate 5 lbs of motor tension ; and /or Sliding the slider (403) up and down track (402 ) physi
4 ) Limit maximum motor speed , for example the equiva cally includes the weight of the arm (702 ). The arm (702),
lent of cable being retracted at 5 inches per second . being between 2 and 5 feet long, for example 3 feet long , and
Arms. for example made of steel, may weigh between 6 and 25 lbs,
FIG . 4 is an illustration of arms in one embodiment of an 25 for example 10 lbs. This may be considered heavy by some
exercise machine . An exercise machine may be convenient users to carry directly . In one embodiment, motor ( 100 ) is
and more frequently used when it is small, for example to fit configured to operate in an “ arm cable assist mode by
on a wall in a residential home. As shown in FIG . 4 , an arm generating a tension matching the weight of the arm (702 ) on
( 702 ) provides a way to position a cable (501 ) to provide a the slider (403), for example 10 lbs on cable (501 ), and the
directional resistance for a user's exercise, for example if the 30 user may easily slide the slider (403) up and down the track
arm (702 ) positions the cable user origination point (704) without perceiving the weight of the arms.
near the ground , by pulling up on actuator (801) the user The exercise machine is calibrated such that the tension
may perform a bicep curl exercise or an upright row exer on the cable matches the weight of the slider, so the user
cise. Likewise , if the arm (702) positions cable user origi perceives none of the weight of the arm . Calibration may be
nation point (704 ) above the user , by pulling down on 35 achieved by adjusting cable tension to a level such that the
actuator (801 ) the user may perform a lat pulldown exercise . slider (403) neither rises under the tension of the cable (501 ),
Traditionally , exercise machines utilize one or more arms or falls under the force of gravity. By increasing or reducing
pivoting in the vertical direction to offer adjustability in the motor torque as it compares to that used to balance gravity ,
vertical direction . However, to achieve the full range of the slider may be made to fall lower, or raise higher.
adjustability requires long arms. If a user wishes to have 8 40 Placing the motor ( 100 ) and dual-spool assembly (200 )
feet of adjustment such that the tip of the arm may be above near the top of the machine as shown in FIG . 1B is disclosed .
the user 8 feet off the ground, or at a ground position , then An alternate design may place heavy components near the
a 5 foot arm may be required to be practical . This is bottom of the machine , such that cables (500 ) and (501 ) are ar
inconvenient because it requires more space to pivot the routed from the bottom to the sliders which would conceal
arm , and limits the number of places where such a machine 45 cables and pulleys from the user. By placing heavier com
can be placed . Furthermore, a longer arm undergoes higher ponents near the top of the machine , routing cables from the
lever-arm forces and increases the size and complexity of the top of the machine and columns down to the slider allows
joint in order to handle those larger forces. If arms could be cable tension to offset the effect of gravity. This allows
kept under three feet in length , a machine may be more motor torque to be utilized to generate cable tension that
conveniently placed and lever -arm forces may be more 50 allows the user to not perceive the weight of the arms and
reasonable . slider without an additional set of pulleys to the top of a
FIG . 4 shows arm (702 ) connected to slider (403 ) on track column. This also allows motortorque to be utilized to move
( 402 ). Without limitation , the following discussion is the slider and arms without the intervention of the user .
equally applicable to arm (700 ) connected to slider (401 ) Vertical Pivot.
and track ( 400 ) in FIG . 1B . Note that as shown in FIG . 4 , 55 In addition to translating up and down, the armsmay pivot
cable (501 ) travels within arm (702 ). For clarity , cable (501) up and down, with their bases in fixed position , to provide
is omitted from some of the following figures and discussion a great range of flexibility in positioning the user origination
that concern the arm (702) and its movement. point of a given arm . Keeping arm (702) in a fixed vertically
An arm (702 ) of an exercise machine capable of moving pivoted position may require locking arm ( 702 ) with slider
in different directions and ways is disclosed . Three direc- 60 (403 ).
tions and ways include : 1) translation ; 2 ) vertical pivot; and FIG . 6 is an illustration of an embodiment of a vertical
3 ) horizontal pivot. pivot locking mechanism . In FIG . 6 , slider (403 ) includes a
Translation . part (420 ) that has teeth (422). Teeth (422) match female
In one embodiment, as shown in FIG . 4 , arm (702 ) is locking member (722 ) of arm (702 ).
capable of sliding vertically on track (402 ), wherein track 65 Using trapezoidal teeth for locking is disclosed . The teeth
(402) is between 24 and 60 inches, for example 42 inches in (422 ) and matching female locking member (722 ) use a
height. Arm (702 ) is mounted to slider (403 ) that slides on trapezoidal shape instead of a rectangular shape because a
 US 10,617,903 B2
15 16
rectangular fitting should leave room for the teeth to enter do this , the user simply rotates arm (702 ) left or right, as
the female locking member. Using a rectangular tooth desired . In one embodiment, a mechanism is used to permit
causes “ wiggle ” in the locking joint, and this wiggle is the simultaneous unlocking and locking of top /bottom mem
leveraged at the end of arm (702). A trapezoidal set of teeth bers (412 , 412a ).
(422 ) to enter female locking mechanism ( 722 ) makes it 5 Concentric Path .
simpler for the two members to be tightly coupled , mini In order for cable (501 ) to operate properly, bearing high
mizing joint wiggle . loads of weight, and allow the track to rotate, it should
Using a trapezoidal set of teeth increases the risk of the always remain and travel in the center of track (402 ), no
joint slipping/back -drive while under the stress of high matter which direction arm (702) is pointed or track (402 ) is
loads. Empirically a slope of between 1 and 15 degrees , for 10 rotated . FIGS. 9D and 9E illustrate a concentric path for
example 5 degrees , minimizes joint slippage while maxi cabling
mizing ease of entry and tightening . The slope of the FIG.9D shows a side view of track ( 402) with cable (501)
trapezoid is set such that the amount of back -drive force is located in the center of track (402 ), and arm (702) traveling
lower than the amount of friction of the trapezoidal surfaces down and directly away from the machine . FIG . 9E shows
on one another . 15 the front view , now with arm (702) traveling down and to the
FIGS. 7A and 7B illustrate locking and unlocking for arm left . In both views of FIG . 9D and FIG . 9E , cable (501) is
vertical pivoting. In FIG . 7A , arm (702) is locked into slider directly in the center of track (402 ). The system achieves this
part (420 ). As shown in FIG . 7A , teeth (422 ) and female concentric path of cable (501 ) by off -centering slider (403)
member (722 ) are tightly coupled . This tight coupling is and including pulley (406 ) that rotates horizontally as arm
produced by the force being produced by compressed spring 20 (702 ), slider (403 ), and track (402) rotate.
(733 ). Arm Mechanical Drawings.
In FIG . 7B a user unlocks arm (702). When the user pulls FIGS. 9F -9X illustrate mechanical drawings of the arm
up on lever (732 ) of arm (702 ), this causes spring (733 ) to (700 , 702 ), components coupled to the arm such as the slider
release its compression , thus causing female locking mem (401,403 ), and various features of the arm . FIG . 9F is a
ber (722 ) to pull backward , disengaging from teeth (422 ). 25 perspective view of an exercise machine arm extended
With arm (702 ) thus disengaged , the user is free to pivot arm upward . FIG . 9F is a view from the side of an arm (702 )
(702 ) up or down around hole ( 451 ). To lock arm (702 ) to extended upward on an angle and its associated column
a new vertically pivoted position , the user returns lever ( 732 ) (400 ), with the arm at its highest position along the column
to the flat position of FIG . 7A . (400 ). FIG . 9G is a perspective view of an exercise machine
Horizontal Pivot. 30 arm extended horizontally . FIG . 9G is a view from the side
The arms may pivot horizontally around the sliders to of an arm ( 702 ) extended straight horizontally and its
provide user origination points for actuators (800,802 ) associated column (400 ),with the arm at its highest position
closer or further apart from each other for different exer along the column (400 ). FIG . 9H illustrates an exploded
cises. In one embodiment, track (402 ) pivots , thus allowing perspective view drawing of an arm (702 ) including its lever
arm (702) to pivot. 35 (732) , compression spring (733), and locking member (722 ).
FIGS. 8A and 8B illustrate a top view of a track that pivots FIG . 91 illustrates both an assembled sectioned and non
horizontally . In FIG . 8A, arm (702 ) is positioned straight out sectioned perspective view drawing of the arm (702 ).
from the machine , in a 90 degree orientation to the face of FIG . 9J is a side view section of an exercise machine
the machine . Arm ( 702 )may be locked to slider as shown in slider (403) with its locking mechanism and pin locked . FIG .
FIG . 7A . Further, slider (403) may be locked into track (402) 40 9K is a side view section of an exercisemachine slider (403 )
as shown in FIG . 5A . with its locking mechanism and pin unlocked . FIG . 9L is a
FIG . 8B shows all of track (402 ), slider (403), and arm perspective view of an exercise machine slider (403), reveal
( 702 ) pivoted to the right around hole (432). The usermay ing the pin (404 ) as well as teeth (422 ) for an arm vertical
do this simply by moving the arm left or right when it is in pivot. FIG . 9M is a perspective view of the exercise machine
an unlocked position. 45 slider (403 ) in a column / rail (402 ) with revealed teeth (422 ),
FIGS. 9A , 9B , and 9C illustrate a locking mechanism for with arm (702 ) set at a vertical pivot at a point parallel to the
a horizontal pivot. FIG . 9A shows column (402 ) from a side horizontal plane . FIG . 9N is a side view section of the
view . This view shows top member (412 ). In one embodi exercise machine slider (403) in a column/rail (402 ), with
ment, the bottom of track 402 not shown in FIG . 9A has a arm (702 ) set at a vertical pivot at a point parallel to the
corresponding bottom member (412a , not shown), with the 50 horizontal plane . The female locking member (722) and
same function and operation as top member (412 ). compression spring ( 733 ) are visible within the section of
FIG . 9B shows a top view of arm (402 ). This view shows FIG . 9N . FIG . 90 is a sectional side view of the exercise
that top member (412 ) and corresponding bottom member machine slider (403 ). FIG . 9P illustrates an exploded per
( 412a ) both have teeth (413). Teeth (413) can be placed spective view drawing of the exercise machine slider (403) .
around the entire circumference of top member (412 ), or just 55 FIG . 9Q is a perspective view of a column locking
specific arcs of it corresponding to the maximum rotation or mechanism for a horizontal pivot. FIG . 9Q shows both top
desired positions of track (402 ). member (412 ) interfacing with the device locking member
FIG . 9B shows track ( 402 ) in a locked position as the teeth (415 ). FIG . 9Q shows without limitation a solenoid mecha
(414 ) of a device locking member (415 ) are tightly coupled nism for controlling the device locking member (415 ). FIG .
to teeth (413 ). This tight coupling prevents track (402 ), and 60 9R is a top view of the top member (412 ), and FIG . 9S is a
thus arm (702) from pivoting left or right, horizontally . side view of the column locking mechanism for the hori
FIG . 9C showsdevice locking member (415 ) having been zontal pivot. FIG . 9T illustrates an exploded perspective
pulled back from top member (412 ). In one embodiment, view drawing of the column locking mechanism including
device locking member (415) uses a similar compression locking member (415 ).
spring mechanism as shown in FIGS . 7A and 7B . This, 65 In one embodiment, the user origination point (704 ) is a
together with the pulling back for bottom member (412a ), configurable " wrist” to allow local rotation for guiding the
frees up track (402 ) to rotate freely around cable (501 ). To cable (500, 501 ). FIG . 9U is a perspective view of a wrist
 US 10,617,903 B2
17 18
( 704 ), showing a spring mechanism that enables access to images of one another, the signals from the accelerometer
the interior of the wrist ( for example, to the bolts shown in may be distinguished based at least in part because the
FIGS. 9V and 9W ) in order to , for example , service the accelerometer is upside down/mirrored on one opposing
wrist. This has the benefit of concealing aspects of the wrist arm .
without preventing access to them . FIG . 9V is a perspective 5 Differential.
section of the wrist (704 ). FIG . 9W is a side view section of FIGS. 12A - 12D illustrate a differential for an exercise
the wrist (704 ). FIG . 9X illustrates an exploded perspective machine . FIG . 12A shows a top view of the differential,
view drawing of the wrist ( 704). making reference to the same numbering as in FIG . 1B and
Stowing. FIG . 2 , wherein sprocket (201 ) and spools (202, 203 ) rotate
Stowing arms (700 , 702 ) to provide a most compact form 10 around shaft (210 ).
is disclosed . When arm (702 ) is moved down toward the top FIG . 12B illustrates a cross - sectional view of FIG . 12A .
of the machine as described above , and pivoted vertically In addition to the components shown and discussed for FIG .
until is flush with the machine as described above, the 12A , this figure shows differential configuration of compo
machine is in its stowed configuration which is its most nents embedded within sprocket (201 ) and spools (202 ) and
compact form . FIGS. 10A , 10B , and 10C illustrate a stowed 15 (203). In one embodiment, sun gears (204) and (206 ) are
configuration . FIG . 10A shows this stowed configuration embedded inside of cavities within spools (203 ) and (202 ),
wherein the rails (400, 402 ) may be pivoted horizontally respectively. In one embodiment, planet gear (205 ) is
until the arm is facing the back of the machine (1000 ) and embedded within sprocket ( 201), with the planet gear (205 )
completely out of the view of the user. FIG . 10B illustrates to mesh with sun gears (204 , 206 ) within spools ( 203 , 202 ).
a perspective view mechanical drawing of an arm ( 702 ) 20 This configuration of sun gears (204 , 206 ) and planet gear
stowed behind rail (402 ). ( 205 ) operates as a differential. That is , sun gears (204 , 206 )
FIG . 10C shows that this configuration may be unobtru rotate in a single vertical plane around shaft (210 ), whereas
sive. Mounted on wall (2000 ), machine ( 1000 ) may take no planet gear ( 205 ) rotates both in that vertical plane, but also
more space than a large mirror with ornamental framing or horizontally . As described herein , a differential is a gear box
other such wall hanging. This compact configuration makes 25 with three shafts such that the angular velocity of one shaft
machine ( 1000) attractive as exercise equipment in a resi is the average of the angular velocities of the others, or a
dential or office environment. Typically home exercise fixed multiple of that average . In one embodiment, bevel
equipment consumes a non -trivial amount of floor space , style gears are used rather than spur gears in order to
making them obstacles to foot traffic . Traditionally home promote a more compact configuration.
exercise equipment lacks functionality to allow the equip- 30 The disclosed use of sun gears (204 , 206 ) and planet gear
ment to have a pleasing aesthetic.Machine ( 1000 ),mounted ( 205 ) and /or embedding the gears within other components
on wall ( 2000), causes less of an obstruction and avoids an such as sprocket ( 201) permit a smaller size differential for
offensive aesthetic . dividing motor tension between cables (500 ) and (501) for
Range of Motion . the purposes of strength training.
An exercise machine such as a strength training machine 35 FIG . 12C illustrates a cross -sectional view mechanical
is more useful when it can facilitate a full body workout. An drawing of differential (200 ). FIG . 12C shows an assembled
exercise machine designed to be configurable such that it sprocket (201 ), front spool (202 ), rear spool (203 ) and shaft
can be deployed in a number of positions and orientation to (210 ).
allow the user to access a full body workout is disclosed . In FIG . 12D illustrates a front cross - sectional view of
one embodiment, the exercise machine (1000 ) is adjustable 40 sprocket (201 ). In one embodiment, multiple planet gears
in three degrees of freedom on the left side , and three are used instead of a single gear (205 ) as shown in FIG . 12B .
degrees of freedom on the right side , for a total of six As shown in FIG . 12D , sprocket (201 ) is shown with cavities
degrees of freedom . (211) and (212 ), which house planet gears ( 205 ) and (207).
As described above , each arm (700 , 702 ) may be trans Without limitation , sprocket (201 ) is capable of embedding
lated /moved up or down, pivoted up or down, or pivoted left 45 a plurality of planet gears . More planet gears enable a more
and right. Collectively , this wide range of motion provides balanced operation and a reduced load on their respective
a substantial footprint of workout area relative to the com teeth , but cost a tradeoff of greater friction . Cavities ( 211 )
pact size ofmachine ( 1000 ). FIG . 11 illustrates the footprint and (212 ), together with other cavities within sprocket ( 201)
of the dynamic arm placement. The footprint (2100 ) as and spools (202) and (203 ), collectively form a “ cage” (200 )
shown in FIG . 11 indicates than a compact/unobtrusive 50 in which the sun gears (204 , 206 ) and planet gears (205 , 207)
machine ( 1000 ) may serve any size of human being, who are housed and operate .
vary in “wing spans” . As described herein , a wing span is the As shown in FIG . 12D , planet gears ( 205 ) and (207) are
distance between left and right fingertips when the arms are mounted on shafts (208 ) and ( 209 ), respectively . Thus, these
extended horizontally to the left and right. gears rotate around these shafts in the horizontal direction .
Arm Sensor 55 As noted above, while these gears are rotating around their
Wiring electrical/data connectivity through a movable shafts , they may also rotate around shaft ( 210 ) of FIGS. 12B
arm (700, 702 ) is not trivial as the joint is complex , while and 12D as part of sprocket ( 201).
sensors to measure angle of an arm are useful. In one In one embodiment, each planet and sun gear in the
embodiment, an accelerometer is placed in the arm coupled system has at least two bearings installed within to aid in
to a wireless transmitter, both powered by a battery . The 60 smooth rotation over a shaft , and the sprocket (201) has at
accelerometer measures the angle of gravity, of which least two bearings installed within its center hole to aid in
gravity is a constant acceleration . The wireless transmitter smooth rotation over shaft ( 210 ). Shaft (210 ) may have
sends this information back to the controller, and in one retaining rings to aid in the positioning of the two sun gears
embodiment, the wireless protocol used is Bluetooth . ( 204 , 206 ) on shaft (210 ).
For manufacturing efficiency, one arm is mounted upside 65 In one embodiment, spacers may be installed between the
down from the other arm , so control levers (732 ) in either sun gears (204 , 206 ) and the sprocket (201) on shaft ( 210 )
case are oriented inwards . As the two arms are thus mirror to maintain the position of the sun gears (204, 206 ). The
 US 10,617,903 B2
19 20
position of the planet gears ( 205, 207) may be indexed by the addition , if the system is idle with no cable motion for a
reference surfaces on the cage ( 200) holding the particular pre-determined certain amount of time, for example 60
planet gear ( 205 , 207 ), with the use of either spacers or a seconds, the system will recalibrate its zero point. In one
built in feature. embodiment, the zero point will be determined after each
Differential Mechanical Drawings. 5 arm reconfiguration , for example an arm translation as
FIGS. 12E - 121 illustrate detailed mechanical drawings of described in FIGS. 5A and 5B above.
differential (200 ) and various features of the differential. Cable Length Change .
FIG . 12E illustrates an exploded perspective view drawing In order to determine when a cable is at the zero point, the
of sprocket (201) and shaft (210 ). FIG . 12F illustrates an machine may need to know whether and how much that
exploded perspective view drawing of planet gears ( 205, 10 cable has moved . Keeping track of cable length change is
207), sprocket (201) and shaft (210 ). FIG . 12G illustrates an also important for determining how much of the cable the
exploded perspective view drawing of a cover for sprocket user is pulling . For example, in the process demonstrated in
(201). FIG . 12H illustrates an exploded perspective view FIGS . 5A and 5B , if a user moves slider (403) down 20 cm ,
drawing of the sun gears (204 , 205 ) respectively bonded to then the cable length will have increased by 20 cm . By
spools (202 , 203 ) and assembled with sprocket ( 201). FIG . 15 keeping track of such length change , the machine ( 1000)
121 illustrates an exploded perspective view drawing of the avoids overestimating the length of the user's pull and
assembled differential (200 ) with finishing features . avoids not knowing the ideal cable length at which to drop
Together, the components shown in FIGS. 12A - 121 func cable tension from full tension to nominal tension .
tion as a compact , integrated , pancake style gearbox (200 ). In a preferred embodiment, to keep track of cable length
The teeth (213) of sprocket (201), which mesh with toothed 20 change themachine has a sensor in each of the column holes
belt (104 ), enable the pancake differential/gearbox (200 ) to (405) of FIGS.5A and 5B . When the user retracts pin (404 ),
rotate in specific, pre -measured increments . This may allow the sensor in that hole sends a signal to electronics bay (600 )
electronics bay (600 ) to maintain an accurate account of the that slider ( 403) is about to be moved . Once the user moves
lengths of cables (500 ) and (501 ). slider (403) to a new location and resets pin (404 ), the track
The use of a differential in a fitness application is not 25 hole (405 ) receiving pin (404 ) sends a signal to electronics
trivial as users are sensitive to the feel of cables. Many bay (600 ) of the new location of slider (403 ). This signal
traditional fitness solutions use simple pulleys to divide enables electronics bay (600 ) to compute the distance
tension from one cable to two cables . Using a differential between the former hole and current holes (405 ), and add or
(200 ) with spools may yield a number of benefits and subtract that value to the current recorded length of the
challenges. An alternative to using a differential is to utilize 30 cable . The control signals from holes (405 ) to electronics
twomotor or tension generating methods. This achieves two bay (600 ) concerning pin (404 ) retraction and resetting
cables, but may be less desirable depending on the require travel along physical transmission wires that maintain a
ments of the application . connection regardless of where cable (501) or pin (404 ) are .
One benefit is the ability to spool significantly larger In practice , a user retracts and replaces pin (404) only
amounts of cables. A simple pulley system limits the dis- 35 when the cable is fully retracted since any cable resistance
tance that the cable may be pulled by the user. With a spool above the slider and arm weight matching resistance as
based configuration , the only limitation on the length of the described abovemakes it quite physically difficult to remove
pull is the amount of the cable that may be physically stored the pin .Asthemachine (1000 ) is always maintaining tension
on a spool — which may be increased by using a thinner on the cable in order to offset the weight of the slider plus
cable or a larger spool. 40 arm , as the slider moves up and down, the cable automati
One challenge is the feel of the cable . If a user pulls a cally adjusts its own length . After the pin is re -inserted , the
cable and detects the teeth of the gears passing over one machine re -zeroes the cable length and /or learns where the
another, it may be an unpleasant experience for the user. zero point of the cable is.
Using spherical gears rather than traditional straight teeth In an alternate embodiment, the sensor is in pin (404)
bevel gears is disclosed ,which provides smoother operation . 45 instead of holes (405). In comparison to the preferred
Metal gears may be used , or plastic gears may be used to embodiment, the physical connections between holes (405 )
reduce noise and /or reduce the user feeling of teeth . and electronics bay (600 ) still exist and signals are still
Cable Zero Point. generated to be sent to electronics bay (600 ) once pin (404 )
With configurable arms ( 700 , 702 ), the machine ( 1000 ) is removed or reset . One difference is that the signal is
must remember the position of each cable (500 , 501) cor- 50 initiated by pin (404 ) instead of by the relevant hole (405 ).
responding to a respective actuator (800 , 801 ) being fully This may not be as efficient as the preferred embodiment
retracted . As described herein , this point of full retraction is because holes (405 ) still need to transmit their location to
the “ zero point” . When a cable is at the zero point, the motor electronics bay (600) because of system startup , as if the
( 100 ) should not pull further on that cable with full force . hole (405 ) were not capable of transmitting their location ,
For example , if the weight is set to 50 lbs, the motor ( 100 ) 55 themachine would have no way of knowing where on track
should not pull the fully retracted cable with 50 lbs as that (402) slide (403) is located .
wastes power and generates heat. In one embodiment, using hole sensors (405 ) is used by
In one embodiment, the motor ( 100 ) is driven to reduce the electronics (600 ) to determine arm position and adjust
cable tension instead to a lower amount, for example 5 lbs , torque on the motor (100 ) accordingly. The arm position
whenever the end of the cable is within a range of length 60 may also be used by electronics (600) to check proper
from the zero point, for example 3 cm . Thus when a user exercise , for example that the arm is low for bicep curl and
pulls on the actuator/cable that is at the zero point, they will high for a lat pulldown.
sense 5 lbs ofnominal tension ofresistance for the beginning Cable Safety
3 cm , after which the intended full tension will begin , for When a user has retracted cable (501 ), there is typically
example at 50 lbs. 65 a significant force being applied on slider (403) of FIGS. 5A
In one embodiment, to determine the zero point upon and 5B . This force makes it physically challenging for the
system power-up the cables are retracted until they stop . In user to retract pin (404 ) at this point. After the user retracts
 US 10,617,903 B2
21 22
cable (501 ) to the zero point and the machine resets the a spool coupled to the gearbox ; and
tension at the nominal weight of 5 lbs, the user instead may a cable wound about the spool.
find it easy to retract pin (404 ). 2. The exercise machine of claim 1 , wherein a belt couples
Without a safety protocol, if a user were able to begin the gearbox to the motor.
removing pin (404) while , for example, 50 lbs of force is 5 3. The exercise machine of claim 1, wherein the bevel
being applied to cable (501), a race would ensuebetween the gears are spherical gears.
user fully removing pin (404) and the machine reducing 4. The exercise machine of claim 1 , wherein the bevel
tension weight to 5 lbs . As the outcome of the race is gears are inside a belt sprocket coupled to the motor.
indeterminate, there is a potentially unsafe condition that the 5. The exercise machine of claim 1 , wherein the spool is
pin being removed first would jerk the slider and arm 10 mounted on a gear.
suddenly upwards with 50 lbs of force . In one embodiment,
a safety protocol is configured so that every sensor in holes includes aexercise
6. The machine of claim 1 , wherein the gearbox
planetary gearset.
( 405 ) includes a safety switch that informs the electronics 7. The exercise machine of claim 6 , wherein the planetary
bay (600 ) to reduce motor tension to a safe level such as 5
or 10 lbs. The electrical speed of such a switch being 15 the gearset includes a sun gear and a planet gear, and wherein
spool is mounted on the sun gear.
triggered and motor tension being reduced is much greater
than the speed at which the slider would be pulled upward 8. The exercise machine of claim 1, further comprising a
against gravity . second spool and a second cable , wherein the second spool
In a preferred embodiment, the removal of the locking pin is coupled to the gearbox and the second cable is wound
( 404 ) causes the system to reduce cable tension to the 20 about the second spool.
amount of tension that offsets the weight of the slider and 9. The exercise machine of claim 8 , wherein the differ
arm . This allows the slider and arm to feel weightless . ential comprises a belt sprocket, wherein a belt couples the
Wall Bracket. belt sprocket to the motor.
To make an exercise machine easier to install at home, in 10. The exercise machine of claim 8 , wherein the differ
one embodiment the frame is not mounted directly to the 25 ential comprises a belt sprocket, wherein a toothed belt
wall . Instead , a wall bracket is firstmounted to the wall , and couples the belt sprocket to the motor.
the frame as shown in FIG . 1C is attached to the wall 11. The exercise machine of claim 10 , wherein the bevel
bracket. Using a wall bracket has a benefit of allowing a gears comprise: a planet gear mounted inside the belt
single person to install the system rather than requiring at
least two people . Using a wall bracket also allows the 30 sprocket ; and a sun gear, wherein the spool is mounted on
the sun gear.
mounting hardware such as lag bolts going into wall studs 12. An exercise machine , comprising :
for the bracket to be concealed behind the machine. Alter a motor;
nately, if the machine (1000) were mounted directly, then a gearbox coupled to the motor, wherein the gearbox
mounting hardware would be accessible and visible to allow comprises bevel gears, and wherein the bevel gears are
installation. Using a wall bracket also keeps the machine 35 inside a belt sprocket coupled to the motor;
away from dust created while drilling into the wall and/or a spool coupled to the gearbox ; and
installing the hardware. a cable wound about the spool.
Compactness .
An advantage of using digital strength training is com box13.is The exercise machine of claim 12 , wherein the gear
pactness . The system disclosed includes the design of joints 40 14. The exercise .machine of claim 12 , wherein a belt
a differential
and locking mechanisms to keep the overall system small, couples the gearbox to the motor.
for example the use of a pancake motor (100 ) and differen 15. The exercise machine of claim 12 , wherein the bevel
tial (200 ) to keep the system small , and tracks (400 ) and gears are spherical gears .
sliders (401) to keep arms (700 ) short .
The compact system also allows the use of smaller 45 16. The exercise machine of claim 12 , wherein the spool
is mounted on a gear.
pulleys. As the cable traverses the system , itmust flow over 17. The exercise machine of claim 12 , wherein the gear
several pulleys. Traditionally fitness equipment uses large box includes a planetary gearset.
pulleys, often 3 inches to 5 inches in diameter , because the 18. The exercise machine of claim 17, wherein the plan
large diameter pulleys have a lower friction . The disclosed
system uses many 1 inch pulleys because of the friction 50 etary gearset includes a sun gear and a planet gear, and
compensation abilities of the motor control filters in elec wherein the spool is mounted on the sun gear.
19. The exercise machine of claim 12 , wherein the gear
tronics box (600); the friction is not perceived by the user box is a differential, the exercise machine further comprising
because the system compensates for it. This additional a second spool and a second cable, wherein the second spool
friction also dampens the feeling of gear teeth in the differ is coupled to the gearbox and the second cable is wound
ential (200). 55
about the second spool.
Although the foregoing embodiments have been 20. The exercise machine of claim 19 , wherein the dif
described in some detail for purposes of clarity of under ferential comprises the belt sprocket , wherein a belt couples
standing , the invention is not limited to the details provided . the belt sprocket to the motor.
There are many alternative ways of implementing the inven 21. The exercise machine of claim 19 , wherein the dif
tion . The disclosed embodiments are illustrative and not 60
restrictive. ferential comprises the belt sprocket, wherein a toothed belt
What is claimed is : couples the belt sprocket to the motor.
1. An exercise machine , comprising: 22. The exercise machine of claim 20, wherein the bevel
a motor ; gears comprise : a planet gear mounted inside the belt
sprocket ; and a sun gear; wherein the spool is mounted on
a gearbox coupled to the motor, wherein the gearbox 65 the
comprises bevel gears , and wherein the gearbox is a sun gear.
differential;