Mechanical braking system for exercise machines

Abstract

A mechanical braking system for a high-incline treadmill utilizing a mechanical brake which may be used on its own or in combination with a traditional motor brake. The mechanical brake is generally mountable on a treadmill between or around the belt motor and the flywheel. Upon engagement of the brake, typically the brake engages the flywheel, the motor, or the axle in a way that effectively locks the axle, and thus the belt, in a fixed position.

Claims

1. A method for braking moving components of an exercise machine, the method comprising: providing a treadmill including: a running deck having a belt roller disposed at one end thereof and a continuous belt disposed around said running deck and belt roller; an electric belt motor comprising a stator and rotor, said electric belt motor operatively coupled to said belt roller via a motor axle; a flywheel disposed on said motor axle; a mechanical brake which is an electromagnetic brake comprising: a brake mount sized and shaped to mount to said electric motor, said brake mount mounting said mechanical brake to said stator; an armature movable between a braking position and a non-braking position and biased to said braking position by a biasing means; a brake pad disposed between said brake mount and said armature; and a brake coil; and a main circuit board; supplying said electric belt motor with electricity; operating said electric belt motor with said electricity, said operating turning said belt roller to move said continuous belt around said running deck; supplying said mechanical brake with electricity to energize said brake coil, said energized brake coil moving said armature from said braking position to said non-braking position; said main circuit board: accessing an amount of incline of said running deck; detecting a stopping event; and instructing a brake controller to brake and hold said continuous belt with said mechanical brake only if said amount of incline is above a predefined threshold when said stopping event is detected, by removing said electricity supply from said mechanical brake, said removing said electricity supply de-energizing said brake coil such that said biasing means moves said armature to said braking position.

2. The method of claim 1 wherein said stopping event comprises removing said electricity supply from said electric belt motor.

3. The method of claim 2 wherein said removing said electricity supply from said electric belt motor and said removing said electricity supply from said mechanical brake occur at about the same time.

4. The method of claim 1 wherein said supplying said electric belt motor with electricity and said mechanical brake with electricity occur at about the same time.

5. The method of claim 1 wherein said stopping event comprises a power failure.

6. The method of claim 1 wherein said stopping event comprises removing of a safety key from said treadmill.

7. The method of claim 1 wherein said stopping event comprises completing or pausing a pre-programmed workout routine.

8. The method of claim 1 wherein said biasing means comprises one or more springs.

9. The method of claim 1 wherein said predefined threshold is selected from the group consisting of: 15%, 18%, 20%, 25%, 30%, and 35%.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIGS. 1A, 1B, and 1C provide a typical embodiment of a treadmill exercise machine that may utilize braking systems as contemplated herein.

(2) FIGS. 2A, 2B, 2C, and 2D depict an embodiment of a mechanical brake according to the present disclosure.

(3) FIG. 3 depicts sectional view of an embodiment of the mechanical brake of FIGS. 2A-2D attached to a treadmill motor.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

(4) The following detailed description and disclosure illustrates by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the disclosed systems and methods, and describes several embodiments, adaptations, variations, alternatives and uses of the disclosed systems and methods. As various changes could be made in the above constructions without departing from the scope of the disclosures, it is intended that all matter contained in the description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

(5) Described herein, among other things, is a mechanical braking system (103) for a high-incline treadmill (101) utilizing a mechanical brake (103) which may be used on its own or in combination with a traditional motor brake. For purposes of this disclosure, the term high-incline treadmill means any treadmill where the running deck or belt is capable of adjusting to a position at least 15% from horizontal. It may also mean a treadmill wherein such adjusting is greater than 18%, 20%, 25%, 30% or 40% from horizontal and specifically includes all treadmills described or contemplated in U.S. Pat. No. 9,764,184, issued Sep. 19, 2017, and in pending U.S. Utility patent application Ser. No. 15/860,164, filed Jan. 2, 2018. The entire disclosures of both of which documents are incorporated herein by reference in their entirety.

(6) In a conventional treadmill (101), the treadmill (101) comprises a running deck (121) surrounded by a continuous belt (111). The belt (111) is driven by one or more belt rollers (107) attached to a belt motor (105). The belt motor (105) is controlled and operated via a main circuit board (117) or computer system (117), which is connected to a user interface. The user interface may be as simple as dials or buttons, or may be more complex, including touch-activated screens and other computer-like interface features. When a user pushes buttons on the interface or the screen, electrical signals are sent to the motor (105) by the main circuit board (117), causing the motor (105) to turn the belt (111) at various running paces. Additionally, an incline motor, attached to an incline system, causes the incline angle of the deck to elevate or lower in response to user input via the interface. A high-incline treadmill (101) is generally of similar mechanical construction to a conventional treadmill. However, the deck (121) and belt (111) are capable of being rotated to an angle above those of a conventional treadmill. This often means that motor components and the structural supports may be positioned differently to allow for such motion.

(7) The mechanical brake (103) is generally mountable on a treadmill (101) at a position disposed between or around the belt motor (105) and the flywheel (109). In the depicted embodiment, the distance between the motor (105) and the flywheel (109) is larger than in prior designs to facilitate positioning of the brake (103). Upon engagement of the brake (103), the typical operation will result in the brake (103) engaging either the flywheel (109), the motor (105), or the axle between them in a way that effectively locks the axle, and thus the belt (111) in a fixed position. This may be through a variety of mechanisms, but may be through having an extremely high frictional engagement between the brake (103) and the flywheel (109) or by having a particularly high frictional engagement between the brake (103) and rotational components of the motor (105). In the depicted embodiment, the motor (105) will have attached thereto a brake mount (201) with which a brake pad (203) will engage to halt the rotor (108) in the motor. FIG. 3 shows an embodiment of a mechanical brake (103) mounted to the electric motor (105) of a treadmill (101).

(8) As would be understand by one of ordinary skill in the art, a mechanical brake (103), such as that depicted in FIGS. 2A-2D may be used to carry out this activation. The brake depicted in FIGS. 2A-2D is of the type commonly called an electrically-released spring-set brake. While this general design is preferred for simplicity, pneumatic or hydraulic-set brakes may also be used in alternative embodiments. The brake (103) as depicted assembled in FIG. 2D primarily comprises a brake mount (201) (shown in FIG. 2C), a brake pad (203) (shown in FIG. 2B), an armature (207), and a brake coil (205) (shown in FIG. 2A). The brake mount (201) is a structure sized and shaped to mount the mechanical brake (103) to the treadmill motor (105) (or another motor, if used with a device other than a treadmill). Attachment of the brake mount (201) to the motor (105) is typically done using hardware, such as bolts, but other means for such mounting will be familiar to one of ordinary skill in the art.

(9) Generally, the brake mount (201) will be rigidly mounted to a non-moving component of the motor such as the stator and will allow for rotational components (the rotor (108)) of the motor (105) to turn through it. In an embodiment the brake mount (201) will mount to the stator coil or housing of the motor (105) and allow access to at least a portion of the rotor coil of the motor (105). In an alternative embodiment, the brake mount (201) will be mounted to an alternative static component.

(10) The brake pad (203) is generally a structure known to be used in braking systems. The brake pad (203) causes the braking action by the brake pad (203) which is attached to the rotor (108) being pressed against a braking surface to be stopped. In the embodiment of FIGS. 2A-2D, the brake pad (203) will be pushed toward the brake mount (201) by the armature (207) sandwiching the brake pad (203) between the brake mount (201) and the armature (207). The brake pad (203) will typically have a surface made of a material having an extremely high coefficient of friction so that contact of the brake pad (203) to the brake mount (201) and armature (207) will result in dramatic loss of energy from the rotor (108) which is engaged in the center of the brake pad (203) in a non-relative-rotational fashion (that is, the rotor (108) and the brake pad (203) rotate together). The kinetic energy of the rotor (108) is converted by brake pad (203) to heat. This will quickly slow or stop the rotor (108) of the motor (105). In the embodiment of FIGS. 2A-2D, the brake pad (203) is a disc designed to connect to the rotor (108).

(11) To alternatively engage and disengage the brake pad (203) there is an armature (207) which is attached in a constrained relationship to the brake coil (205). Specifically, the armature (207) will be allowed a constrained movement toward and away from the brake coil (205). In the depicted embodiment of FIGS. 2A-2D, the movement is constrained by the presence of bolts (209) which provide that the armature (207) can only move generally linearly toward and away from the brake coil (205) and the distance of that movement is constrained by the brake coil (205) itself on one side, and the bolt (209) head on the other.

(12) In order to provide for braking, the armature (207) will be biased via a biasing mechanism, which are springs (211) in the brake (103) of FIGS. 2A-2D, away from the brake coil (205) and at the extreme distance of throw toward the brake mount (201). This will cause the brake pad (203) to be sandwiched between the brake mount (201) and the armature (207) to frictionally resist the movement of the brake pad (203) and thus rotation of the rotor (108) in the motor (105). In order to allow for free motor (105) movement, power is provided to the brake coil (205) which will be energized and act as an electromagnet pulling the armature (207) toward the brake coil (205) against the biasing of the springs (211). This will release the brake pad (203) from the sandwiching arrangement and allow it to turn.

(13) As should be apparent from the above, the mechanical brake (103) is in braking position when unpowered. That is, the flow of electrical energy through the mechanical brake (103) causes the brake coil (205) to withdraw the armature (207) from the brake pad (203) thus permitting rotary motion of the motor (105). When power is disengaged, the lack of electricity through the brake coil (205) ceases the magnetic force being generated in the brake coil (205) and causes the armature (207) to move toward the brake pad (203) engaging the brake.

(14) For use in a treadmill (101), the arrangement of powered and unpowered operation is particularly important. If the power is cut for any reason, the mechanical brake of FIGS. 2A-2D will immediately respond by the springs (211) pushing the armature (207) toward the brake pad (203), causing the brake pad (203) to be sandwiched slowing or stopping rotor (108) rotation. Further, the armature (207) cannot be withdrawn until power is restored. This prevents the treadmill from freewheeling in the event of a loss of power, improving user safety as the brake pad (203) is engaged unless it is actively unengaged

(15) In a treadmill (101), the primary concern for safety is typically a fall of the user who is running or walking on the treadmill (101). Should such an event occur, having the belt (111) and other moving components very quickly come to a halt eliminates much of the risk of these moving components presenting a pinch hazard and can dramatically reduce danger from the machine. Treadmills (101) have traditionally utilized a safety key which, when pulled, disconnects all power to all components of the treadmill (101). The safety key is designed to be pulled and disconnect power by a simple circuit breaker when a user has moved sufficiently away from the controller (113) panel to indicate the start of a fall. Thus, the belt (111) and other moving components are designed to have stopped prior to the fall actually completing and the user falling on the belt (111) or other motorized components. The safety key has now become ubiquitous, and is actually required on some treadmills (101) due to regulations.

(16) As discussed above, the problem with traditional motor braking in a treadmill (101) when the safety key is pulled is that while the power disconnection is effective at stopping the belt (111) motion on a flat surface, it is not effective at maintaining the belt (111) in a stopped position after the power is disconnected, as the belt (111) can freewheel once the magnetic fields in the motor (105) have dissipated. Further, the induced field in the motor (105) may not be sufficient to stop the belt at a high incline, particularly at high speed.

(17) The depicted mechanical brake (103) serves to not only assist in rapidly stopping the motor (105), but remains engaged unless and until power is restored. Thus, the brake (103) serves to keep the motor (105), and thus the belt (111) and other components, from freewheeling or otherwise moving even after dissipation of the induced fields. Thus, the mechanical brake (103) provides for additional safety in treadmill (101) operation, particularly in a high-incline treadmill (101).

(18) It is recognized that the amount of brake force which is ideally applied may depend on the braking situation presented, as well as the angle of the belt (111), speed of the motor (105), and the mass of the user. For example, a much more rapid and stronger brake force is generally preferred when the safety key is pulled for a heavy user on a high incline at high speed. A lower braking force will generally be preferred when the treadmill (101) is manually stopped at a level incline and lower speed as would be typical of a user finishing their workout.

(19) In order to provide for differing brake force to be applied in different circumstances, the brake (103) may be connected to various sensors or switches to assist in the brake application. In an embodiment, the depicted brake (103) may be connected to a tilt switch and sensor which causes the brake (103) to activate only if the incline of the treadmill (101) is above a certain predefined angle. By way of example, and not limitation, the brake (103) may activate only if the incline is detected to be 15% or greater, 18% or greater, 20% or greater, 25% or greater, 30% or greater, or 35% or greater. The specific incline at which the tilt switch feature will actuate will depend upon the particular design of a specific high-incline treadmill (101). Some designs, for example, may have sufficient friction of the belt (111) to slow the user without the assistance of a brake (103) at lower inclines than others. This may be desirable as the force of the mechanical brake engaging can be sudden and may cause a user to pitch forward if they are not expecting it. A similar switch and/or sensor may be used to trigger the mechanical brake only at certain belt speeds.

(20) As the mechanical brake (103) engages should the power be disconnected, in the event of a power outage, the sudden engagement of the brake (103) when it is not really needed to avoid freewheeling after a fall, could actually produce a dangerous situation where the sudden braking could cause a user to pitch forward into the control panel (117). As should be apparent, such risk can be reduced by only having the mechanical brake (103) be armed to engage when the benefit outweighs any potential risk. This can be carried out by having the control panel (117) include circuitry to determine if a secondary power system should be supplied to the mechanical brake (103) or other sensors or systems should be engaged to control mechanical brake (103) operation.

(21) In a still further embodiment, the brake (103) may actually be built to engage as a secondary brake mechanism. For example, the sudden reversing of magnetic field in the motor (105) may act to initially slow and stop the motor, then the mechanical brake (103) engages once these have begun to dissipate. This can occur within fractions of a second of the power disconnect and may be carried out, for example, by including capacitor or other power storage systems which cut power to the brake coil (205) at a time later than to the motor (105) when the safety key is disconnected. These types of multi-tier or stepped control mechanisms can also be used to engage the mechanical brake (103) once the motor (105) has effectively stopped to hold the motor (105) in the stopped position in any arrangement.

(22) In the depicted embodiment, the braking system (103) further comprises a controller (113) in electrical communication (115) with the brake. The controller (113) comprises electrical components and circuitry configured to operate the brake (103). The controller (113) is also in electrical communication (115) with a primary circuit board (117) of the high-incline treadmill (101). This circuit board (117) operates the incline system of the treadmill (101), and thus has access to the current incline setting of the treadmill (101). This information may then be relayed to the brake controller (113), which will then control the brake (103). By way of example, and not limitation, if the main circuit board (117) determines that the incline is at or above the tilt switch threshold, and a stopping event is detected, then the main circuit board (117) will send a signal to the brake controller (113) indicating that the brake (103) should be operated. The controller (113) will then cause the brake (103) to actuate at a speed to appropriately slow the treadmill (101).

(23) In the depicted embodiment, the brake (103) may be actuated upon the occurrence of any number of braking events. These may include, without limitation: the safety key is pulled; a pre-programmed workout routine has been completed or paused; the stop button has been pushed; or the machine loses power. The specific actuation of the mechanical brake (103) may also be different in the different scenarios both in the timing of the actuation of the brake (103), the specific brake force provided, and the speed at which the force is provided. Generally, the mechanical brake (105) will be designed to operate in a brake safe arrangement where any situation which results in stoppage of the treadmill belt (111) will engage the mechanical brake (105) either immediately or after traditional braking systems in some fashion.

(24) While the invention has been disclosed in conjunction with a description of certain embodiments, including those that are currently believed to be the preferred embodiments, the detailed description is intended to be illustrative and should not be understood to limit the scope of the present disclosure. As would be understood by one of ordinary skill in the art, embodiments other than those described in detail herein are encompassed by the present invention. Modifications and variations of the described embodiments may be made without departing from the spirit and scope of the invention.