Exercise and Rehabilitation Machine with Autonomous Drive

Abstract

The machine of the present invention can have frame that supports an I-beam in either a vertical or horizontal manner. The I-beam can support a mounting plate and gear racks. A gear box housing is movable with respect to the I-beam under operation of a motor that turns a shaft so that pinion gears engage the gear racks to translate relative to the gear racks. A pivot assembly is fixed with respect to the gear box so that when force is applied to the carriage, it causes a change in torque loading in the gear box that is measurable by a force gauge mounted between the pivot assembly and the gear box housing. The motor is controlled by a controller to be operable to move the carriage and user engagement components carried by the carriage, such as a foot plate and/or manually grasped handles, so as to require user exertion to resist such movement.

Claims

1. An exercise machine comprising: a frame having a base configured to be supported on a floor; a beam supported on the frame; a housing encircling said beam and including a bearing assembly for moveably supporting the housing on the beam for movement of the housing along the length of the beam; a drive assembly, including a drive motor, operably coupled to said housing to move said housing along said beam; a user-engagable component mounted to and movable with the housing for movement with the housing during operation of the drive motor; and a controller operably coupled to the drive motor to operate the drive motor to move the user-engagable component when said component is engaged by the user.

2. The exercise machine of claim 1, wherein the user-engageable component includes at least one arm with at least one handle configured to be manually grasped by the user

3. The exercise machine of claim 1, wherein said frame includes a seat on which the user sits when engaging said user-engageable component.

4. The exercise machine of claim 3, wherein said user-engageable component includes a foot plate arranged to be engaged by the feet of the user when the user is seated on said seat.

5. The exercise machine of claim 3, wherein the user-engageable component includes at least one arm with at least one handle configured and arranged to be manually grasped by the user when the user is seated on the seat.

6. The exercise machine of claim 1, wherein said beam is arranged substantially vertically relative to said base.

7. The exercise machine of claim 1, wherein said beam is arranged substantially horizontally relative to said base.

8. The exercise machine of claim 1, wherein said drive motor is a reversible variable speed motor.

9. The exercise machine of claim 1, further comprising a load cell between the drive motor and the user-engageable component configured to determine the amount of force applied by the user to the user-engageable component.

10. The exercise machine of claim 9, wherein said load cell is engaged by said user-engageable component when the user applies force thereto.

11. The exercise machine of claim 9, wherein said load cell is carried by said housing.

12. The exercise machine of claim 9, wherein: said user-engageable component includes; a vertical beam mounted to said housing; and a foot plate mounted to said vertical beam; and said load cell is mounted between said vertical beam and said foot plate so that force applied to said foot plate applies a force to said load cell.

13. The exercise machine of claim 1, wherein: said beam includes at least one flange and a web perpendicular to said at least one flange; and said bearing assembly includes at least four bearings rotatably engaging said at least one flange and at least four bearings rotatably engaging said web.

14. The exercise machine of claim 1, wherein said drive assembly includes: at least one rack gear mounted to the beam; at least one pinion gear configured for meshed engagement with the at least one gear rack; and a drive motor operably coupled to the at least one pinion gear to rotate the at least one pinion gear along the at least one gear rack.

15. The exercise machine of claim 14, wherein said drive motor is operably coupled to said at least one pinion gear by a gearbox coupled between an output shaft of said drive motor and an axle on which the at least one pinion gear is mounted for rotation with said axle.

16. The exercise machine of claim 15, wherein: said drive motor is carried by said housing with said output shaft of said drive motor extending substantially parallel to said beam; and said axle of said gearbox extends substantially perpendicular to said beam.

17. The exercise machine of claim 1, wherein said drive assembly includes a continuous drive element engaged to said housing and said drive motor engages the continuous drive element to move the drive element.

18. The exercise machine of claim 17, wherein: said continuous drive element is a continuous chain mounted between an idler gear and a drive gear; and said drive motor is coupled to said drive gear to rotate said drive gear.

19. The exercise machine according to claim 1, wherein said user-engageable component includes at least one arm supported on said housing and at least one handle adjustably mounted to said at least one arm for manual engagement by the user.

20. The exercise machine of claim 1, wherein said user-engageable component includes: a vertical beam mounted to said housing; a frame mounted to said vertical beam; at least one arm pivotably mounted at one end thereof to said frame, said at least one arm including a manually graspable handle at an opposite end of said at least one arm, said at least one arm pivotably mounted to pivot about a substantially vertical axis relative to said frame; and a locking device for locking said at least one arm at a pivot location of said at least one arm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] FIG. 1 is a side view of a vertical exercise machine according to one embodiment of the present disclosure.

[0040] FIG. 2 is a rear view of the exercise machine illustrated in FIG. 1.

[0041] FIG. 3 is a cross-sectional view of a gearbox housing and drive assembly of the exercise machine illustrated in FIG. 1.

[0042] FIG. 4 is an enlarged view of a portion of the exercise machine illustrated in FIG. 1.

[0043] FIG. 5 is perspective view of an I-beam, mounting plate, spacers, gear racks and pinions for the gearbox and drive assembly shown in FIG. 3.

[0044] FIG. 6 is an exploded view of components shown in FIG. 5.

[0045] FIG. 7 is a perspective view of a partial assembly of the components shown in FIG. 5.

[0046] FIG. 8 is an enlarged view of the partial assembly of the components shown in FIG. 7.

[0047] FIG. 9 is a side perspective view of the gear box housing mounted on the I-beam of the exercise machine shown in FIG. 1.

[0048] FIG. 10 is a side perspective view of the gear box housing and bearing assemblies of the exercise machine shown in FIG. 1.

[0049] FIG. 11 is an end perspective view of the gear box housing and bearing assemblies illustrated in FIG. 10.

[0050] FIG. 12 is a side view of the bearing assembly illustrated in FIGS. 10-11.

[0051] FIG. 13 is a side schematic view of a horizontally operated machine incorporating common components of the vertical exercise machine shown in FIG. 1.

[0052] FIG. 14 is an enlarged side view of a portion of the horizontally operated machine illustrated in FIG. 13 showing common components.

[0053] FIG. 15 is a side partial cut-away view of the components shown in FIG. 14.

[0054] FIG. 16 is a perspective view of the components shown in FIGS. 14-15.

[0055] FIG. 17 is a diagram of operation of the exercise machine disclosed herein.

[0056] FIG. 18 is an exploded perspective view of a horizontal exercise machine according to one embodiment of the present disclosure, shown with the gearbox and drive assembly removed.

[0057] FIG. 19 is a top view of the exercise machine shown in FIG. 18.

[0058] FIG. 20 is a side partial cut-away view of the exercise machine shown in FIG. 18.

[0059] FIG. 21 is an end view of the exercise machine shown in FIG. 18.

[0060] FIG. 22 is a side partial cross-sectional view showing an alternative load cell integrated into the exercise machine shown in FIG. 18.

[0061] FIG. 23 is a side view of a vertical exercise machine incorporating locking handles according to one aspect of the present disclosure.

[0062] FIG. 24 is a top view of the preferred embodiment of the present invention

[0063] illustrated in FIG. 23.

[0064] FIG. 25 is a perspective view of a carriage for the exercise machine shown in FIGS. 23-24.

[0065] FIG. 26 is an exploded view of two handles, an arm and a portion of the carriage for the exercise machine shown in FIGS. 23-25.

[0066] FIG. 27 is a side view of a horizontal workout machine according to a further embodiment of the present disclosure.

[0067] FIG. 28 is a rear perspective view of a carriage for use with the exercise machine shown in FIG. 27.

[0068] FIG. 29 is a side view of a modified drive system for the exercise machine shown in FIG. 18.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0069] While the invention will be described in connection with one or more preferred embodiments, it will be understood that it is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.

[0070] The present invention relates to an exercise or rehabilitation machine, such as the machine 10 and 510 shown in FIGS. 1-17. Machine 10 is a vertically operable machine, as illustrated in FIGS. 1-4. The machine 10 includes a frame 20 with a base 30 configured to be firmly positioned on the floor of a workout space. A front riser 40 with a monitor arm 50 is connected to the base for supporting a monitor 51, such as a computer or graphics screen. A seat arm 60 can extend from the front riser 40 or directly from the base 30 for supporting a seat 61. The seat 61 is located and arranged so that the user can see the monitor 51 while using the machine, and so that the user can access the working components of the machine. The frame 20 include a central riser 70 projecting vertically upward from the base 30, for use of the machine 10 as a vertically operable machine 10 with motion generally parallel to the longitudinal axis of the central riser. A rear riser 80 can be provided to stabilize and support the central riser 70, particularly during vertical motion of the machine.

[0071] The machine 510 is a horizontally operable machine, as shown in FIGS. 13-16. Machine 510 has a frame 520 with a central beam 580 for supporting the machine on a workout room floor. The subcomponents of machine 510 can be generally the same as the components described below with respect to machine 10, except oriented for horizontal rather than vertical usage. In this regard, they may be shown or described for illustrative purposes for either horizontal or vertical machines, or both.

[0072] Turning back to machine 10, it is seen that the central riser 70 can comprise an I-beam 90. As shown in FIG. 5, I-beam 90 includes opposite flanges 100 and 110 separated by a web 120. Flange 110 defines mounting holes (not shown) therethrough located centrally along the longitudinal axis of the beam, equidistant from the sides of the flange 110. The mounting holes are used to fasten a mounting plate 130 thereon, as best illustrated in FIGS. 5-9. The mounting plate 130 has two sides 131 and 132 and central holes 133 that are aligned along the longitudinal axis of the plate 130 equidistant from the sides 131 and 132, and alignable with the holes in the I-beam 90. Screws or other fasteners can then be used to secure the mounting plate 130 to the I-beam. The center of the mounting plate 130 is preferably geometrically aligned with the center of the I-beam.

[0073] Holes 134, preferably round in shape, are defined along the first side 131 and holes 135, preferably elongated or slot shaped, are defined along the second side 132. There are preferably eight holes 133, 134 and 135 through the mounting plate. A pair of gear racks 170, 180 are mounted to opposite sides of the mounting plate 130, as shown in FIG. 7. Each gear rack 170, 180 has a face with a plurality of teeth 171, 181, as best seen in the enlarged view of FIG. 8. The teeth are generally parallel to each other and are generally perpendicular longitudinal axis. of each rack. Several holes (not shown) are defined in the back of each gear rack for alignment with the respective holes 134, 135. Each gear rack may be provided with a corresponding spacer 160, 161, each spacer having holes therethrough aligned with the holes on the gear rack and on the mounting plate 130. Fasteners (not shown) extend through holes 134, 135 of the mounting plate 130, from underneath the mounting plate, and pass through the aligned holes of the spacers 160, 16 to fasten a corresponding gear rack 160, 180 to the mounting plate.

[0074] A pair of blocks 140, 145 are mounted at opposite ends of side 132 of the mounting plate 130, as shown in FIGS. 7-8. Each block defines a screw hole through which a respective adjustment screw 143, 153 is threaded. The blocks 140 and 145 are preferably welded to the mounting plate at a position offset from the ends of the gear rack 180 positioned on the plate, and more particularly offset by a sufficient distance from the ends of the gear rack so that the gear rack 180 can be moved with its mounting fasteners extending through the elongated slots 135 to permit adjustment of the longitudinal position of the gear rack. In assembly, the gear rack 170 is mounted to the plate at the fixed circular mounting holes so that the rack has a pre-determined position on the mounting plate 130. For smooth operation of the drive mechanism, as described herein, it is important that the teeth 171, 181 of the gear racks are aligned transverse or perpendicular to the longitudinal axis of the I-beam 90. Thus, the second gear rack 180 is initially only loosely connected to the mounting plate by the fasteners passing through the elongated holes 135, through the spacer 161 and engaging the underside of the gear rack 180. The adjustment screws 143, 153 can then be threaded into the receptive block 140, 150 to contact the ends of the gear rack. The adjustment screws can be tightened or loosened in complementary fashion to move the gear rack 180 longitudinally along the mounting plate until the gear teeth 181 are properly aligned with the gear teeth 171 of the fixed position gear rack 170. Once the gear rack 180 is properly positioned, the fasteners can be tightened to fix the gear rack and spacer to the mounting plate 130.

[0075] Turning now to FIGS. 4, 9-11, one embodiment of a gear rack housing 200 is illustrated. The gear rack housing 200, or simply housing, has four side plates 210, 215, 220 and 225, with side plate 210 positioned on the same side of the beam 90 as the gear racks 170 and 180. Side plate 215 is on the opposite side of the beam 90 and side plates 220 and 225 are parallel to each other and straddle the beam 90. Side plate 220 defines a gear shaft hole 221 and preferably two bearing mounting holes 222 on opposite sides of the shaft hole to support a housing bearing 240 as shown in FIG. 4. Side plate 225 has a gear shaft hole 226 and preferably two bearing mounting holes 227 to support a housing bearing 245, similar to the housing bearing 240, as shown in FIG. 23.

[0076] As shown in FIGS. 14-16, a motor 250 and a gear box 260 are carried by the gear rack housing 200. The motor can be a servo motor. The motor 250 can operate under operation of a motion controller 430 with meters 431, as depicted in the diagram of FIG. 17. A CPU 440 is provided along with a controller 450, a servo amp 460 and an encoder 470. The load cell 350 (discussed below) can be incorporated into the meters 431 providing signals to the CPU 440.

[0077] The gear box 260 can be a right-angle gearbox with a gearbox axle 270 supported by the housing bearings 240 and 245. The gear box 260 is rotatable about the shaft (except as limited by the load cell 350, described below). The gear box 260 is operable under operation of the motor, and can cause the shaft to turn one of two ways.

[0078] A pair of pinion gears 280 are mounted on and for rotation with the axle 270, such as by a key and keyway. The pinions 280 include teeth 285 configured to engage the teeth 171, 181 of the racks 170, 180. Rotation of the axle 270 rotates the pinions 280 and 290 which translate relative to the racks 170 and 180 and the I-beam 90. This rotational-to-translational conversion causes the gear rack housing 200 to translate relative to the I-beam as well.

[0079] A pivot assembly 300 is illustrated in FIGS. 14-16. Pivot assembly 300 includes a plate 310 and an L-shaped bracket 320. The plate 310 is secured at one end to the gearbox 260 around the gearbox axle 270. The L-shaped bracket 320 has a first piece 321 that is fastened to the opposite end 311 of the plate 310, and a second piece 322 perpendicular to the first piece. A load cell 350 is fastened to the second piece 322 at one end 351. The load cell is supported at an opposite second end 352 on a tab 236 extending from the gear box housing 200. The load cell 350 can have a generally S-shape and can gauge both tension and compression by strain gauges incorporated into the S-shaped cell. Tension is sensed when a force is present attempting to rotate the pivot assembly 300 away from the gear box housing 200. Compression is sensed when a force is present attempting to rotate the pivot assembly 300 towards the gear box housing 200. The forces are generated by torque reaction of the gearbox housing 200 to the rotation of the axle 270 which rotates the pinions gears 280, 290. In one specific embodiment, the load cell 350 can be the S-Beam load cell, Model LSB350 of Futek Advanced Sensor Technology, Inc. The load cell 350 can be connected to the CPU 440 to provide strain gauge signals to the CPU, which in turn determines the amount of force applied to the load cell.

[0080] The gearbox housing 200 supports four bearing assemblies 360 as illustrated in FIGS. 10-11. Each of these bearing assemblies is preferably identical, each including a base 361 with a protrusion 362, as shown in the detail view of FIG. 12. A first circumferential bearing 365 is rotatably mounted on the perimeter of the protrusion 362. A second bearing 370 extends from the distal end of the protrusion 362 beyond the plane of the first (circumferential) bearing. The bearing assembly 360 has a base that lies in a base plane. The first bearing 365 has a pivot axis that is generally perpendicular to the plane of the base 361. The second (distal) bearing 370 has a pivot axis that is generally parallel to the base plane. Accordingly, the first pivot axis is generally perpendicular to the second pivot axis.

[0081] The four bearing assemblies 360 are mounted to the side plates 220 and 225 of the gear box housing 220 adjacent side plate 215. Two of the bearings assemblies are arranged to be aligned on each side of the I-beam 90, as depicted in FIGS. 15-16. The second distal bearing 370 of each bearing assembly contacts the I-beam web 120. Each of the four bearing assembly's perimeter bearings 365 contact each of the I-beam flanges 110 and 111. In this regard, the four bearing assemblies provide twelve points of contact with the I-beam 90. Each of the bearings 365, 370 are configured for smooth rolling contact with the surface of the I-beam to support the gearbox housing 200 and ensure that the gear box housing 200 moves smoothly relative to the I-beam as the pinions 280 and 290 turn on the racks 170 and 180 under operation of the gear box 260 and motor 250.

[0082] Turning now to FIG. 1, it is seen that a carriage 410 is supported by and rigidly mounted to the gear box housing 200, and particularly to the side plate 215. The carriage supports working components for engagement by the user. In one embodiment of a vertical exercise machine, the carriage 410 supports arms 415 with manually graspable handles 416, or other user-engagable component by which the user can exert a force. The carriage 410 moves as the gear box housing 200 moves under operation of the motor 250.

[0083] The operation of the exercise machine 10 disclosed herein can be explained with reference to FIG. 17. The CPU 440 permits the user to supply various inputs governing the operation of the motor 250 and thereby the resistive force applied to the arms 415 through the gearbox 260 and carriage 400 as they move along the I-beam 90. A non-exhaustive list of inputs can include start distance, stop distance, positive speed, negative speed, reps, and exercise type. The CPU 440 can communicate with a controller 450 to direct a servo amp 460 to power the motor 250, to power the gear box 260, to rotate the axle 270 a sufficient amount of revolutions so that the pinions 280 and 290 can translate along racks 170 and 180 as determined by an encoder 470. It is understood that the bearing assemblies 360 maintain the pinions in meshed engagement with the respective racks. The machine can have pauses between concentric and eccentric strokes (i.e., upward movement and downward movement), which may be the same or different. Further, the concentric and eccentric strokes can be set to different speeds. The motor 250 is therefore a reversible variable speed motor to drive the carriage 400 up or down, depending upon the exercise. The user seated in the seat 61 resists the movement of the arms 415 propelled by the motor and gearbox. The CPU 440 can communicate with the monitor, such as monitor 51, to display data related to the workout, and more particularly to the amount of force being resisted or generated by the user. It is contemplated that the monitor, in addition to displaying information for the use, can operate as a graphical user interface to allow the user to input information to the CPU. In this regard, the monitor can be a touch screen display.

[0084] The system is an autonomous system that passes through its paths regardless of user input. The force gauge 350 operates by measuring the torque supplied by the user upon the carriage 410. As the user pushes and pulls on the carriage 400 through the handles 416 and arms 415, a negative or positive amount of excess torque is developed by the motor 250 and translated through the gear box 260. The rotational force of the pivot assembly 300 towards or away from the gear box housing 200 is measured with the gauge 350 and translated into a force output. The force output can be measured in real time along the entire travel span and can be analyzed.

[0085] It can be appreciated that the same components described in connection with the vertical machine 10 are incorporated into the horizontal machine 510 shown in FIG. 13. In lieu of or in addition to the arms 415 and handles 416, the carriage 400 can support a foot plate 590 that the user pushes with his/her legs.

[0086] A workout machine 700, shown in FIGS. 18-21, includes a frame 712 formed by two lateral elongated oval frames 715, each with an elongated leg 714 adapted to solidly support the machine on a floor. The legs may optionally be provided with feet at the four corners of the frame for increased traction on the workout floor. End plates 716 span between the two lateral frames 714 to from a generally elongated rectangular box structure. Vertical brace beams 718 are provided at opposite ends of the frame 712 to support a center beam 720 that forms part of the drive assembly for the workout machine. The center beam 720 is substantially similar to the I-beam 90 of the machines 10 and 510 described above. The vertical beams may be U-shaped channel or box beams that exhibit high bending and torsional strength. The vertical beams 718 and center beam 720 may be formed of steel as the primary load-bearing components of the frame 712. The lateral frames 714 and end plates 716 may be aluminum in order to reduce the overall weight of the machine.

[0087] The workout machine 700 further includes a seat 725 at the rear of the frame 712. The seat 725 may be mounted to and supported on the center beam 720 or maybe integrated into the rear vertical beam 718. The seat 725 does not need to be adjustable along the longitudinal length of the machine for reasons explained herein. However, the seat 725 may include an adjustable height or adjustable back position feature. The seat may be mounted to the center beam 720 by opposite flanges 726. A top cover plate 727 is mounted to the frame with a slot 728 aligned with the center beam 720. The slot includes an enlarged end 728a to receive the flanges 726 used to mount the seat 725. A pair of side plates 729 are affixed to the sides of the frame 712 to enclose the entire frame structure for the exercise machine 700.

[0088] A controller and display 730 is supported at the opposite front end of the frame 712. The display 730 is mounted to a support beam 731 that is sized to elevate the display 730 so that it can be readily viewed by a person in the seat 725 during a workout cycle. A controller and display 730 includes a microprocessor or computer that implements software and/or firmware controls the operation of the drive assembly and that provides a user interface for selecting, controlling and reviewing the workout, such as the system shown in FIG. 17 as described above. A remote control device (not shown) may be provided for wirelessly controlling the operation of the controller and display as well as for providing an interface for user input to control the operation of the controller. The display itself may be a touchscreen display that allows user input through a touchscreen GUI. Alternatively or in addition, the microprocessor of the controller 730 may be configured to receive and process voice commands in lieu of manual entry through the remote control device or touchscreen.

[0089] The display feature of the controller and display 730 may be optional, in which case the controller feature of the controller and display 730 can be integrated into the frame 712 of the workout machine. The controller can include a computer or microprocessor capable of communicating with a remote device as desired to download data for instance. The remote control device, which may optionally be a hard-wired device, provides the user with direct communication to the controller to select and initiate a workout routine. The remote device maybe configured to provide a visual indication of the selected routine and the progress of the routine.

[0090] A load plate 740 is supported at the opposite front end of the frame 712, with an initial position below the controller and display 730. The load plate 740 may be similar to the plate 590 of the machine 510 described above. In particular, the load plate is sized and configured for the user to place his/her feet on the plate to apply a resistive force against the load plate 740 as it is driven by the motor assembly. The load plate 740 may include optional handle assemblies 742 mountable on both sides of the plate. The handle assemblies include a hand grip that can be selectively oriented by an adjustment mechanism 743. The handle assemblies 742 can be grasped by the user during a leg workout cycle, but is more appropriately used for an upper body workout. The handle assemblies can be removed when the load plate 740 is used exclusively for a leg workout.

[0091] The load plate 740 is mounted to a stiffening frame 752 that is in turn mounted to a vertical beam 750 by a C-shaped bracket 741. The vertical beam and a stiffening angle beam 751 are mounted to a support plate 752. The support plate 752 is driven by a motor assembly, such as the motor 250 and gearbox 260 described above, which in turn drives the load plate 740 toward the user seated in the seat 725. The vertical beam 750 is mounted to a gearbox housing 760 that is similar to the housing 210 described above. The vertical beam 750 extends through the slot 728 in the top cover plate 727.

[0092] As described in more detail above, the housing 760 is supported on the center I-beam 720 by bearing assemblies 761, which can be similar to the bearing assemblies 360 discussed above, to allow the housing, and thus the vertical beam and load plate 740 to translate toward or away from the use seated on the seat 725. The motor assembly for driving the load plate thus includes the racks 170, 180 and pinions 280, with the pinions driven by the gearbox axle 270 which in turn is driven by the motor 250. The motor includes an output shaft (not shown) that meshes with the gearbox to drive the axle 270. In one embodiment, the output shaft of the motor can directly drive a bevel gear that meshes with a ring gear that is either mounted on the pinion axle 270 or fixed to the pinion gears. The pinion gears can include conventional spur gear teeth to mesh with the teeth of the racks 170, 180. It can be appreciated that operation of the drive motor rotates the pinion gears so that the gears travel along the rack toward the user in the seat 725. As the pinion gears travel they propels the load plate 740 toward the user, who resists this movement by exerting his/her own force on the load plate. The configuration of the motor mount, namely the gearbox housing 760 and under-mounted drive motor, in combination with the channeled I-beam center beam 720, ensures stability of the drive mechanism propelling the load plate 740. One problem with prior eccentric load workout machines is that the load plate is unsteady, frequently wobbling laterally as the load plate is driven toward the user. The workout machine 710 of the present disclosure avoids this significant problem and provides a smooth, stable movement of the load plate 740. The use of four rollers 365, two on each side, also avoids the problem of prior workout machines in which the drive mechanism binds on the center rail.

[0093] Hard stops are preferably provided on the center beam 720 to limit the rearward movement (toward the user) and forward movement (toward the controller). The hard stops may be physical stops mounted to the beam to prevent travel of the housing. In this instance, the motor controller would incorporate an overload protection to automatically de-activate the motor when the housing stops moving. In lieu of or in addition to the physical stops, limit switches may be provided at the hard stops to terminate electrical power to the drive motor 250. The hard stops may also be implemented in software/firmware implemented by the controller 730, based on a pre-programmed movement distance or on pre-programmed load limits or changes in load sensed by the load cell 350. The goal of the stops, whether hard or soft, is to protect the user from injury due to continued movement of the use-engageable component.

[0094] It is further contemplated that the controller 730 can generate a soft stop to the forwardmost position of the load plate 740. This soft stop corresponds to the desired starting position for the load plate when the user commences the workout. The soft stop can account for differences in leg length of different users, but can also be used to modify the workout cycle for a given user. The controller can also respond to a panic button on the handheld remote control that immediately stops the load motion of the load plate and orders retraction of the load plate.

[0095] The controller 730 implements software and/or firmware that controls the operation of the drive motor 250 to propel the load plate 740 toward the user or retract the load plate at the end of the workout cycle. The controller thus provides power to the motor based on the software program or firmware instructions implemented by the controller. The motor can be a reversible variable speed servo motor or stepper motor, which increases the variability of the motor operation. For instance, the controller can implement a workout protocol in which the load applied through the load plate 740 changes along the stroke of the carriage, or in which the load plate advances, retracts and advances again during a single workout cycle. The controller can implement a graphical user interface that allows the user to select a pre-programmed workout or to customize the workout.

[0096] A load cell or other force measurement device may be integrated into the drive assembly, such as a load cell 350 mounted to the gearbox housing 760 as described above. Alternatively, the drive motor can be provided with electronics to measure motor torque as an indication of the resistive force being applied by the user as the motor attempts to drive the load plate toward the seated user. The data obtained from these measurements can be translated to an interactive visual indication of the user's applied force on the controller and display 730. In addition, the controller may store data from a particular workout that can be reviewed by the user and/or trainer, or that can be downloaded to another device.

[0097] As an alternative to the load cell 350 mounted to the gearbox housing 760, the machine 700 can incorporate a load cell with the load/foot plate 776. In particular, se shown in FIG. 22, a load cell assembly 770 can include the load cell 771 that is configured like the load cell 350. The load cell 771 is mounted within the vertical beam 750, and particularly within an opening 775 defined in the beam behind the load plate 740 (FIG. 18). The load cell can be mounted by a mounting block 772 to the inside of the vertical beam 750 by a fastener 773. The load cell 771 can also be fastened to the load/foot plate 740 by a recessed fastener 774. The load cell 771 projects outside the vertical beam 750 by a dimension 775 that is sufficient for the S-shaped load cell 771 to deflect as load is applied by way of user pressure on the load/foot plate 750. In one embodiment in which the load cell has a length of about 3.0 in. and the vertical beam has a length of about 3.834 in., a 1.0 in. spacer 772 will produce an offset 775 of about 0.083 in., which is sufficient for the load cell to deflect. In order to permit the deflection, the C-shaped flange 741, which carries the frame 741 and load plate 740, is mounted to the vertical beam 750 in a manner that permits the flange, frame and load plate to pivot slightly to close the gap 775 when load is applied to the load plate 750. Accordingly, the flange 741 is mounted to the vertical beam at a pivot mount 777 (FIG. 20) near the bottom of the flange, whereas the mount 778 near the top of the flange is an elongated slot that allows some play between the flange 741 and the vertical beam 750.

[0098] The workout machine 710 is shown for performing seated leg presses. With the optional handle assembly 742, the machine can be used for arm exercises. For this exercise, the drive assembly is programmed to move the load plate 740 and frame 741, to which the handle assembly 742 is attached, away from the seated user so that the user resists the movement. The same principles can be implemented in a vertical exercise machine for either standing or seated exercises. For instance, the load plate 740 can be arranged above the user for performing leg squats or military press arm exercises.

[0099] Furthermore, in the illustrated embodiments the controllers for the workout machines 10, 510 and 710 can be programmed for providing static or isometric muscle action. It is contemplated that the controller, such as controller 730, can be configured to control the drive motor and thus the load plate 40 (or arms 415) to achieve concentric and eccentric muscle actions. The drive motor can also be controlled to allow the user to resist the load plate moving away from the user, as well as toward the user as described above. In addition, the controller can be programmed to resist movement of the load plate by the user, either toward or away from the user depending on the muscle group being worked.

[0100] A modification of the exercise machine 800 is shown in FIGS. 23-26 in which the vertical exercise machine 800 includes a frame 20, vertical beam 70, base 30, seat 61, monitor 51, and other components identical to the machine 90 described above, including the motor 250, gearbox 200, gearbox housing 210 and bearing assemblies 365 as described above. However, the machine 800 includes a carriage or load plate 850 that differs from the carriage 400 of the machine 90.

[0101] As best seen in FIG. 25, the carriage 850 includes a frame formed by a vertical member 860 separating a first side member 870 and a second side member 910. The first side member 870 and second side member 910 are preferably mirror images of each other. A mount 865 is provided having holes to mount to a base that moves relative to the beam 70. In particular, the mount 865 is fastened to the plate 210 of the gearbox housing 200 in substantially the same manner as the carriage 400 of the machine 10 described above.

[0102] The first side member 870 has a top beam 871, a bottom beam 872 and a side beam 875. The top and bottom beams 871 and 872, respectively, connect the side beam 875 to the vertical member 860. The side beam 875 has a top 876 and a bottom 877, with an upper spacer 880 at or near the top 876 of the side member 875 that supports an upper carriage sleeve 885 offset from the side member 875. A hole 886 is defined through the sleeve for receiving a set screw. A middle spacer 890 at or near the midpoint of the side member 875 supports a middle carriage sleeve 895, which also defines a hole 896 therethrough for receiving a set screw. A lower spacer 900 at or near the bottom 877 of the side member 875 supports a lower carriage sleeve 905 that also defines a hole 906 therethrough for receiving a set screw. The upper carriage sleeve 885, the middle carriage sleeve 895 and the lower carriage sleeve 905 preferably have generally circular profiles and are preferably concentrically aligned along an axis parallel to the side beam 875.

[0103] The second side member 910 is constructed in the same manner as the first side member 870, except as a mirror image, including a top beam 911, a bottom beam 912 and a side beam 915. The side beam 915 includes an upper carriage sleeve 925, a middle carriage sleeve 935 and a lower carriage sleeve 945 that, like their counterparts on the first side member, preferably have generally circular profiles and are concentrically aligned along an axis parallel to the side beam 915.

[0104] Both side members 870, 910 include an indexed pin 950 having opposed ends 951 and 952 and including a shaft 960 having a generally circular cross-sectional profile spans between ends 951 and 952. An upper dimple 965, a middle dimple 966 and a lower dimple 967 are formed into the shaft, are radially aligned and are arranged to coincide or align with the set screw holes 886, 896 and 906, respectively. Index holes 970, 975 are defined in the shaft near a respective end 951 and 952. The index holes 970, 975 are spaced radially around the shaft.

[0105] Two collars 980 and 985 are provided at opposite ends of the indexed pin and beneath the respective top and bottom collars 885, 905. The indexed pin 950 can be received within the carriage sleeves 885, 895 and 905 on the first side member 870, and through the sleeves 925, 935 and 945 on the second side member 910 of the carriage 850. The collars 980 and 985 longitudinally lock the indexed pin relative to the carriage 850. Set screws can be inserted through holes 886,896 and 906 to contact the dimples 965, 966 and 967, respectively, to rotationally lock the indexed pin 950 relative to the carriage 850.

[0106] Arm 1050 has ends 1051 and 1052, as best shown in FIG. 26. An arm mount sleeve 1060 is provided at the first end 1051. A pop pin or fastener 1061 can be secured to the arm mount sleeve 1060 that can be held in a retracted position (preferably by twisting) or can be allowed to extend under force of a spring. It is appreciated that while a pop pin is described, that other fasteners could be used without departing from the broad aspects of the present invention. A distal arm sleeve 1070 is provided at end 1052. A screw hole 1071 is defined through the sleeve 1070 and a D-ring 1072 can be provided extending from the sleeve. It is contemplated that the D-ring 1072 can be used to fasten a strap or a handle strap common in workout equipment.

[0107] The arm 1050 can pivot about the shaft 960 about the longitudinal axis of the shaft when the fastener is unfastened or in an unlocked position. The fastener 1061 can be fastened wherein the pin is inserted into one of the indexing holes 970 to lock the arm is a radial position relative to the carriage 850.

[0108] A handle 1120 is provided having ends 1121 and 1122, with a grip 1130 at end 1122 and a handle sleeve 1135 at end 1121. A fastener 1136, such as a pop pin, is provided at the handle sleeve 1135. The handle 1120 can be concentrically positioned on a shaft 1090 between the distal arm sleeve 1070 and collar 1135. The handle 1120 can pivot about the shaft 1090 when the fastener 1136 is unfastened. The fastener can be inserted into one of the index holes 1105, defined in the shaft 1090, to lock the handle in a radial position relative to the arm 1050. In an alternative embodiment, the pop pin fastener 1136 and index holes 1105 can be replaced with a ratcheting or locking gear mechanism that permits pivoting the handle 1120 relative to the arm 1050 and fixing the handle in different pivot positions.

[0109] A second handle 1140 can also provided that is configured like the handle 1120. The fastener 1146 can engage one of the index holes 1147 near the bottom of the shaft 1090 to fix the handle in position relative to the arm 1050. Both handles 1120 and 1140 can be independently rotated or fixed about a rotation axis extending through the sleeve 1070.

[0110] A second arm 1200 is provided that is similar in function and structure to arm 1050. The first arm 1050 extends or angles upward, while the second arm 1200 extends or angles downward. The second arm can include first and second handles like the handles 1120 and 1140 described above. Additional arms and handles can be provided on the opposite side of the machine for mounting on the second side beam 915.

[0111] It is appreciated that each arm and each handle can be individually locked in a rotational position or remain free to rotate relative to a corresponding shaft so that the machine 800 can be tailored to the workout needs of an individual, as reflected in FIG. 24. In one embodiment, the arms 1050 can pivot from a position generally parallel to the length of the machine 800, inward until the ends of the arms contact, and outward away from the user. In some embodiments, the arms 1050 can pivot to a position behind the seated user, as reflected in FIG. 24. As described above, the arms can be locked in any of these positions. It is also contemplated that each arm includes only one handle, with appropriate modifications to the shaft 1090.

[0112] Assembly of the carriage 850 includes the following steps: [0113] Insert indexed pin 950 for the carriage first side through the upper carriage sleeve 885, through an upper arm 1050 sleeve 1060, through the middle carriage sleeve 895, through a lower arm sleeve, and through the lower carriage sleeve 905. [0114] Place collars 980, 985 on the top and bottom of the shaft 960 to longitudinally lock the indexed pin 950 in place relative to the carriage first side. [0115] Insert set screws (not shown) through the holes 886, 896, 906 in the carriage sleeves 885, 895, 905, respectively, to contact the dimples 965, 966, 967 in the shaft 960 to rotationally lock the indexed pin relative to the carriage. [0116] Repeat steps on second side of the carriage to assemble the upper and lower second carriage side arms. [0117] For the first arm 1050, extend the indexed pin 1090 through the sleeve 1135 of one handle 1120. [0118] Insert the indexed pin 1090 through the distal arm sleeve 1070. [0119] Place the sleeve of a second handle 1140 onto the indexed pin 1090 below the distal arm sleeve. [0120] Use collars 1147 to longitudinally lock the sleeves of the handles onto the indexed pin. [0121] Use set screw to rotationally lock the indexed pin 1090 relative to the distal sleeve 1070. [0122] Repeat handle installation on the second, third and further arms.

[0123] The carriage 800 can be incorporated into a horizontal workout machine 1310, as illustrated in FIGS. 27-28. The machine 1310 has a frame 1320 and other components that are similar to the machine 510 shown in FIG. 13 or the machine 700 shown in FIG. 18. However, in lieu of the carriage 590 of that embodiment, the machine 1310 includes the carriage 1330 that includes a vertical beam 1335 and a brace 1337 mounted to the drive components (i.e., gearbox housing 210) for horizontal movement relative to the frame 1320. The carriage 1330 is substantially similar to the carriage 850 for supporting an arm, such as arm 1200 and any handles associated with the arm. However, in this embodiment, the carriage further includes a foot plate 1340 affixed to the beams of the carriage, in which the foot plate is similar to the foot plate 740 of the machine 700. Since the arms 1200 are at the side beams of the carriage 1330, the arms and associated handles are laterally separated from the foot plate 1340 so that the arms and handles do not interfere with the user's ability to push against the foot plate with leg power. The user can optionally grip the handles on the arms as desired. It is further contemplated that the user can resist movement of the foot plate 1340 toward the user, as driven by the motor (such as motor 250), by leg power, and then resist movement of the carriage 1330 away from the user, again under power of the motor 250, by use of upper body power.

[0124] In the illustrated embodiments, the drive systems for the machines 10, 510, 700 and 800 incorporate the racks 170, 180 and pinion gears 280 driven by the motor 250. An alternative drive system 1400 is shown in FIG. 29 in which the rack and pinion configuration is replaced with a belt or chain drive. In particular, a chain 1402 is supported between an idler gear 1403 at one end and a drive gear 1404 at the opposite end. The drive gear 1404 is driven by a motor 1410 and a gearbox 1412. A carriage 1407 is fastened to the chain 1402 and engaged to the gearbox housing 760 to which the vertical beam 750 is mounted. The length of the chain 1402 essentially acts as a hard stop when the carriage 1407 reaches one end or the other. The motor 1410 is controlled in the same manner as the motor 250 to control the movement of the load plate. It is contemplated that this drive system 1400 can be integrated into the other machine 10, 510 and 800. It is further contemplated that the chain drive can be a belt drive, cable drive or other similar continuous loop drive element.

[0125] The present disclosure should be considered as illustrative and not restrictive in character. It is understood that only certain embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the disclosure are desired to be protected.