Stair exerciser apparatus

The present invention relates to a stair exercise device for simulating stair climbing, the device having a plurality of steps which are activated by the weight of a person walking up them. A stationary platform at the base of the stair exercise device sends a signal to a controller to bring the exercise device to a controlled stop when an operator steps onto the platform. The steps of the exercise device stop in a predetermined location when the exercise device comes to a controlled stop, ensuring proper step location to allow the operator to easily enter and exit the exercise device. Steps have a step platform of a different color than the risers between steps to aid in foot placement.

FIELD OF THE INVENTION

This invention relates to exercise equipment and more particularly to stair exerciser equipment for simulating stair climbing.

SUMMARY OF THE INVENTION

The present invention relates to a stair exerciser involving a downwardly and rearwardly sloping treadmill having a plurality of steps which are activated by the weight of a person “walking” up them.

The stair exerciser includes a frame shaped in the form of a staircase and having a base and necessary support structures. A plurality of movable hinged steps are supported from an inclined track located at each side of the frame extending from an portion of the frame to a lower position just above the base of the frame.

Two pairs of pillow blocks for rotatably supporting upper and lower shafts are secured to the frame below the inclined tracks. A sprocket is mounted on either end of each shaft. A pair of endless chains is supported around the sprockets which are mounted on the ends of the upper and lower shafts. The chains are sealed motorcycle chains designed to keep grit and dirt away from the greased pivot connecting each chain link to the next. A number of connecting links are placed at predetermined locations along each chain and are spaced equidistant from each other.

A series of steps are connected to the connecting links of the pair of endless chains, forming an endless chain conveyor. The steps are made up of normally horizontal tread platforms and normally vertical risers. The connection between the normally horizontal tread platforms and normally vertical risers and the connecting links allow the normally horizontal tread platforms and the normally vertical risers to travel around the sprockets with the endless chains. The tread platforms and riser portions fold to an acute angle when they traverse around a sprocket whereas they are normally at right angles along the straight portion of the chain between sprockets.

A transmission belt connects a first pulley on either the upper shaft or the lower shaft and a second pulley on a speed control mechanism. The speed control mechanism includes a flywheel which is driven by the second pulley on the speed control mechanism and a braking mechanism, such as an eddy current brake (ECB). The rotation of the flywheel is connected by way of the pulleys and transmission belts to cyclical movement of the endless chain conveyor around the upper and lower shafts. The braking mechanism resists the rotation of the flywheel. The braking mechanism is adjustable so that adjusting the amount of braking force performed by the ECB increases and decreases the resistance to the flywheel rotation based upon the setting of the braking mechanism. The braking mechanism is used to increase and decrease the resistance level of the stair exerciser, by controlling the amount of resistance applied to the motion of the endless chain conveyor.

The braking mechanism, in addition to slowing the motion of the endless chain conveyor, may be used to stop the motion of the steps. A locking mechanism is connected to either the upper shaft or the lower shaft. The locking mechanism is engaged to immobilize the endless chain conveyor of the stair exerciser. When the locking mechanism is engaged, an operator of the stair exerciser may step onto the endless chain conveyor or step off of the endless chain conveyor without causing motion of the endless chain conveyor. When the locking mechanism is disengaged, the endless chain conveyor is no longer immobilized and may rotate around the upper shaft and lower shaft, though the rotation is resisted by the braking mechanism.

A position sensor indicates one or more locations of the endless chain conveyor about the upper shaft and lower shaft. The position sensor sends out a position signal to a controller. The controller communicates with the sensor, the braking mechanism, and the locking mechanism. During a controlled stop, the motion of the endless chain conveyor is brought to a stop by the operation of the braking mechanism. The controller engages and disengages the braking mechanism to bring the motion of the endless chain conveyor to a controlled stop at a specific location, and the locking mechanism is engaged to immobilize the endless chain conveyor. The specific location at which the endless chain conveyor is immobilized is chosen to set the lowest tread platform at a position and orientation relative to the ground for ease of ingress and egress by the operator of the stair exerciser.

A console, mounted to the frame at a position above the upper shaft, provides operating, goal-setting, and other health related information.

It is an object of the present invention to provide a stair exercise device including a frame having a base resting on a substantially horizontal support surface, a pair of shafts rotatably mounted to the frame, the pair of shafts including a lower shaft located toward the rear of the apparatus and an upper shaft located above the lower shaft and toward the front of the apparatus, and a pair of chain assemblies configured to revolve about the pair of shafts to constitute an endless chain conveyor. An upper run of the endless chain conveyor is supported by the frame. A number of steps span the endless chain conveyor and are capable of moving cyclically as the steps follow the revolving endless chain conveyor. A braking mechanism in the stair exerciser adjusts and controls the resistance to rotation of at least one of the pair of shafts, and thereby adjusts and controls the downward running speed of the steps.

The stair exerciser also includes a sensor for determining the position of the steps along its cyclical movement, and a locking mechanism for preventing motion of the steps when the locking mechanism is engaged. The stair exercisers has a controller that communicates with the sensor, the locking mechanism, and the braking mechanism, so that the controller can adjust and control the braking mechanism to adjust the resistance of the apparatus. The controller also adjusts and controls the braking mechanism and the locking mechanism to bring the steps to a controlled stop in one or more predetermined locations, so that the controller can stop the steps in a configuration where there is a stair landing position near the lower shaft, positioned in height and orientation to enable easy ingress onto and egress from the stair exerciser.

It is another object of the present invention to provide a stair exercise device with a stationary platform near the base of the frame of the stair exercise device and a switch configured to detect a load applied to the stationary platform. The switch communicates with the controller, and the switch sends a load signal to the controller when a load is applied to the stationary platform. Upon receipt of the load signal from the switch, the controller engages the braking mechanism to bring the steps to a controlled in one or more predetermined locations, so that the controller can stop the steps in a configuration where there is a stair landing position near the lower shaft, positioned in height and orientation to enable easy ingress onto and egress from the stair exerciser.

It is another object of the present invention to provide a stair exercise device with steps that are made up of a typically horizontal step platform that is a first color, and a typically vertical riser that is a different, second color. The color of the step platform is visually differentiated from color of the riser, making it easier for an operator to see where to step.

DETAILED DESCRIPTION OF THE INVENTION

Referring now toFIG. 1, a preferred embodiment of a stair type exercising device100is illustrated having a stationary frame20and a plurality of steps30supported by the frame20and able to move with respect to the frame20. The steps30are pivotally linked together and are attached to a pair of chain assemblies, forming an endless chain conveyor12. The steps30are configured to move in a downward and backward direction as the endless chain conveyor12revolves in a cyclical fashion about an upper shaft18(shown inFIGS. 3-4) and a lower shaft15(shown inFIGS. 3-4).

The stair exerciser100includes a housing50, removable access panels60covering access hatch openings in the housing50, a hand rail90, and pair of handlebars92. Each handlebar92has contact heart rate pulse sensor95built into the handlebar92. In addition, each handlebar92has control buttons97incorporated into the handlebar92. The control buttons97on the handlebar92can include controls such as speed control, resistance control, start, stop, and pause. The frame20includes a base25and a mast98. The mast98supports a console120with a display screen enabled to provide feedback to an operator. The console120may also include input devices to enable an operator to provide information to the stair exerciser100.

Each of the steps30consists of a step platform32and a step riser34. The step platforms32and step risers34are connected to each other by hinge pins so that each step30is pivotally connected to the next step30, and the steps30each have pivots between step platform32and the step riser34. The steps30are connected at the bottom of a step riser34by connecting pins33, and the step platforms32and step risers34are connected to each other at the top of a step riser34by guide pins35. The plurality of steps30are formed by alternating a step platform32, a connecting pin33, a step riser34, a guide pin35, and back to another step platform32. The connecting pins33are connected to the endless chain conveyor12.

The step platform32is a first color. The color could be molded into a plastic part, or the step platform32could be painted, or coated with colored material to make the step platform the first color. The first color might be a dark color like black to hide scuff marks on the step platform32, and to easily identify the step platform32. The step riser34is a second color, different from the first color. The second color would be a color that is easily distinguished from the first color, so in the case where the first color is black, the second color would be a lighter color, such as a light gray. The easily distinguishable colors assist an operator to visually identify each step platform32and to plant a foot firmly situated on the step platform32without kicking the step riser34. To aid in foot placement, the step platform32is approximately 10 inches deep to ensure that there is enough surface area to locate most if not all of the foot on the surface of the step platform32. The step riser34is approximately 9 inches tall so that each step up to the next step platform32is a reasonable distance, similar to steps in a building.

The stair exerciser100is illustrated with a stationary platform70located below and behind the steps30at the entrance to the stair exerciser100. The stationary platform70provides a convenient platform for an operator to stand upon before stepping onto a step30of the stair exerciser100to start exercising. Similarly, the stationary platform70provides a convenient surface upon which an operator can step when exiting the stair exerciser100. The stationary platform70is connected to a switch75(shown inFIG. 6), which may be configured to generate a load signal76to indicate when a load such as the weight of an operator is upon the stationary platform70.

A removable debris tray80is illustrated below the steps30, adjacent to the stationary platform70. As the steps30revolve along with the endless chain conveyor12, dust, dirt and debris is transported along with the steps30until the steps30revolve down and around the lower shaft15. As the steps30revolve around and underneath the lower shaft15, the dust, dirt and debris drop from the steps30and are captured by the debris tray80. The debris tray80may be removed to dispose of the captured debris, whereupon the clean debris tray80is returned to the stair exerciser100for further use. In addition to capturing dry debris, the debris tray is configured to also capture liquids. The housing50includes channels85configured to direct perspiration or other liquids spilled onto the housing50to flow down the channel85toward the debris tray80.

FIG. 1also illustrates a number of other features. Cup holders99are shown mounted to the hand rail90. The base25includes a metal tube wrapping around the periphery of the stair exerciser100to protect the housing50from being accidentally kicked. The base25also includes a front support28, and the front support28includes a transport wheel27on either side of the front support28to assist in moving the stair exerciser100. There are a pair of locking and leveling casters170(shown inFIGS. 3-4) located underneath the stationary platform70that also assist in moving the stair exerciser100.

Referring now toFIG. 2, a side view of the stair exerciser100shows the stair exerciser100resting on a support surface10, such as a floor. The stair exerciser100has a housing50with a second removable access panel60on the left side of the stair exerciser100. The front support28is shown with the previously unseen transport wheel27on the left side of the stair exerciser100. The transport wheels27aid in the transport of the entire stair exerciser100from one location to another.

Referring toFIG. 3, the stair exerciser100is illustrated with the covers removed to reveal internal features. The frame20is shown more clearly. The frame20includes the base25, a front support28, the mast98, an inclined track24for supporting the endless chain conveyor12and the connecting pins33of the steps30, and a guide rail23for supporting the guide pins35of the steps30. A lower shaft15and an upper shaft18are rotatably mounted to the frame20. The lower shaft15is connected to a pair of lower sprockets16, and the upper shaft18is connected to a pair of upper sprockets19. The endless chain conveyor12and the steps30are illustrated to be revolvably mounted about lower shaft15and the upper shaft18.

The endless chain conveyor12is shown to have an upper run14of the endless chain conveyor12configured to position a number of steps30for exercise use, and a lower run13of the endless chain conveyor12configured to be a return path for the endless chain conveyor12. The inclined track24supports and guides the connecting pins33and the upper run14of the endless chain conveyor12as the steps30move downward and backward along the inclined track24. Because the inclined track24supports the connecting pins33and the connecting pins33are connected to the bottom of a step riser34, the inclined track24positions the bottom of each step riser34as it travels along the upper run14of endless chain conveyor12. The guide rail23supports and guides the guide pins35as the steps30move downward and backward along the inclined track24. Because the guide rail23supports the guide pins35and the guide pins35are connected to the top of a step riser34, the guide rail23positions the top of each step riser34as it travels along the upper run14of endless chain conveyor12.

FIG. 3also illustrates a microprocessor or controller125configured to receive electrical input signals from various sources such as a tachometer155, a position sensor130, a load switch75(shown inFIG. 6), or a console120. The controller125is configured to output various control signals to other devices such as a braking mechanism150or a locking mechanism160. The controller125is shown as a separate unit mounted to the frame20, but one skilled in the art will understand that the controller125could be located elsewhere such as embedded inside of the console120.

A tachometer155is shown mounted onto the frame20. The tachometer155measures the speed of the moving steps30and provides a speed signal to the controller125. A position sensor130is shown mounted onto the frame20.

The position sensor130provides position information to the controller125, where the position information informs the controller125of the relative position of the steps30along the cyclical path followed by the steps30and the endless chain conveyor12.

A braking mechanism150is shown mounted onto the frame20next to a flywheel152. The braking mechanism150is controlled by control signals sent by the controller125. The braking mechanism150is adjustable so that the amount of braking force may be increased or decreased by the controller125. The flywheel152is connected by belts and pulleys to the upper shaft18, though the flywheel could easily be connected instead to the lower shaft15. As the steps30of the stair exerciser100are driven downward by an external load, such as the weight of an operator standing upon one or more of the steps30, the endless chain conveyor12revolves about the upper shaft18and the lower shaft15, causing the upper shaft18to rotate. The rotation of the upper shaft18drives the rotation of the flywheel152. As the flywheel152rotates, the braking mechanism150provides an opposing torque to the flywheel152, thereby slowing down the rotation of the flywheel152and the speed of the steps30. The braking mechanism150may be an eddy current brake (ECB), a friction brake, or any other brake that is known in the art.

A locking mechanism160(not shown) is coupled to the upper shaft18. The locking mechanism160is configured to prevent the upper shaft18from rotating and to prevent the steps30from moving when the locking mechanism160is engaged. When the steps30are stationary, the locking mechanism160is engaged by the controller125to ensure the steps30remain stationary. An operator stepping onto the steps30or stepping from the steps30down to the stationary platform70will find the process much easier when the steps30are locked in a stationary position.

The steps30may also be brought to a controlled stop when the steps30are moving. The controller125first engages the braking mechanism150to slow or stop the motion of the steps30. The controller125uses the position information from the position sensor130to slow the motion of the steps30when the steps30are near a predetermined stopping position along the cyclical path followed by the steps30and the endless chain conveyor12. The controller125further engages the braking mechanism150to fully stop the motion of the steps30when the steps30are located at the predetermined stopping position along the cyclical path. The controller125then engages the locking mechanism160to prevent additional movement of the steps30. The controller125is able to consistently bring the steps30to the same predetermined stopping position any time the controller125stops the steps30of the stair exerciser100.

Referring now toFIGS. 3-4, a caster170is located near the back end of the stair exerciser100. The caster170serves much the same purpose as the transport wheel27located on the front support28. The casters170and the transport wheels27allow the stair exerciser100to be rolled from one location to another location. The casters170will be discussed in greater detail whenFIGS. 8-10are discussed.

Referring now toFIG. 4, the lowest step platform32on the upper run14of the endless chain conveyor12is shown at an angle (A) relative to a horizontal line. The step riser34supporting the rear portion of the step platform32has begun to wrap around the lower sprocket16on the lower shaft15, causing the rear portion of the step platform32to drop below the elevation of the front portion of the step platform32. The elevation of the rear portion of the step platform32is at an elevation H relative to the support surface10. The elevation of the front portion of the step platform32is at an elevation (H+h) relative to the support surface10. This difference in elevation (h) between the front portion and rear portion of the step platform32orients the step platform in a plane that is at an angle (A) relative to a horizontal plane. If the depth of the step platform32is a constant depth (d), then the angle (A) of the step platform32is:
Tan(A)=(h/d)
Or
(A)=Arctan(h/d)

It is beneficial to an operator of the stair exerciser100to minimize the step-up height of the stair exerciser100. That is, a lower step-up height makes it easier for an operator to mount the lowest step30of the stair exerciser100from the stationary platform70, and a lower step-up height make it easier for an operator to dismount from the lowest step30of the stair exerciser100to the stationary platform70. One way to lower the step-up height (H) is to increase the difference in elevation (h) between the front portion and rear portion of the step platform32. A lower front portion of the step platform32means a lower step-up height (H). However, increasing the difference in elevation (h) between the front portion and rear portion of the step platform32also increases the angle (A) of the orientation of the step platform32. Therefore, care must be taken to choose a predetermined stopping location for the steps30such that the step-up height (H) is low for the convenient entering and exiting of the stair exerciser100, while keeping the angle (A) of the orientation of the step platform32low enough to ensure that an operator will not slip off the of the step platform32.

The angle (A) for the lowest step platform32may be 0 degrees from the horizontal plane, or 5 degrees, 10 degrees, 15 degrees, 17.5 degrees, 20 degrees, 25 degrees, or 30 degrees. A step platform32at any of these angles (0-30 degrees from the horizontal plane) provides a surface that may easily be stood upon.

The step-up height (H) for the lowest step platform32may be 0 inches above the support surface10or ground, or it may be 5 inches, 10 inches, 12 inches, 13 inches, 14 inches, or 15 inches above the support surface10. A step platform32at any of these step-up heights10or elevations (0-15 inches above the support surface) provides a reasonable step-up height from the support surface10.

The controller125has the ability to bring the steps30to a controlled stop at any position along the cyclical path followed by the steps30and the endless chain conveyor12. In the preferred embodiment, the controller125is configured to bring the steps30to a predetermined controlled stop location that will position the lowest step platform32having a relatively low elevation or step-up height (H) of approximately 13 inches above the support surface10, and having a relatively low orientation angle (A) of approximately 17.5 degrees from a horizontal plane.

Referring now toFIG. 5, a close-up view of the removable debris tray80and the stationary platform70are shown. The stationary platform70has hook features78to connect the stationary platform70to the frame20. The stationary platform70also has a mating feature72to connect to a loop82on the debris tray80. By connecting the debris tray80to the stationary platform70, and by connecting the stationary platform70to the frame20, the stationary platform70and the debris tray80become an integral part of the stair exerciser100, and move with the stair exerciser100as a single unit.

InFIG. 6, the underside of the stationary platform70has a load switch75for sending a load signal76to the controller125. The load switch75detects when an operator is standing on the stationary platform70, and sends the load signal76to the controller125. The controller125then brings the steps30to a controlled stop if the steps30are moving, and the controller125engages the locking mechanism160to prevent any further motion of the steps30. The operator may then easily step up onto the steps30of the stair exerciser100while the steps30are locked into a stationary position.

Referring now toFIG. 7, the removable access panel60is shown. The access panel60has locking tabs68along one side that may be snapped into an access hatch opening in the housing50to quickly attach the one side of the access panel60to the housing50. The access panel60as shown also has two quick locking fasteners65that can be screwed into the housing50. The quick locking fasteners65are configured to remain attached to the access panel60at all times, so the quick locking fasteners65will not fall out and get lost like a typical screw fastener. The quick locking fasteners65shown only require a quarter-turn of the quick locking fastener65to connect the access panel60to the housing50. By using a combination of snap-fit locking tabs68to attach one side of the access panel60and a limited number of quick locking fasteners65to retain the other side of the access panel60, the removable access panel60may be removed from access hatch opening in a matter of seconds, and just as quickly replaced, thereby aiding any maintenance work that may need to be performed within the housing.

Referring now toFIGS. 8-10, the casters170have a caster wheel175much like the transport wheel27(shown inFIGS. 3-4). However, the casters170also have a wheel lock176to prevent rotation of the caster wheel175. By locking the wheel lock176, the stair exerciser100is held in a stationary position, and by unlocking the wheel lock176, the stair exerciser100is able to be rolled about on the two caster wheels175and two transport wheels27for relocation of the stair exerciser100.

FIG. 10shows the caster170pivotally connected to the base25. The caster170is configured to be raised and lowered relative to the base25, allowing the caster170to be used to level the stair exerciser100. A bearing plate179is mounted to the caster170at a distance from a pivot axle178. The pivot axle178pivotally connects the caster170to the base25, such that the caster170may pivot up or down about the pivot axle178. A height adjustment screw180is screwed into a hole in the top of the base25and is driven down until it contacts the bearing plate179of the caster170. The height adjustment screw180prevents the caster170from pivoting up any higher than the point at which the bearing plate179contacts the height adjustment screw180. By adjusting the position of the height adjustment screw180in the base25, the caster170can be lowered relative to the base25so that all four wheels (the two transport wheels27, and the two caster wheels175) are all in contact with the support surface10. When all four wheels are in firm contact with the support surface10, the stair exerciser100is properly leveled.

Whereas the present invention has been described in relation to the drawings attached hereto, it should be understood that other and further modifications, apart from those shown or suggested herein, may be made within the spirit and scope of this invention.