Cordless treadmill

A cordless treadmill including a frame, a belt system, and a drop-in cartridge is disclosed. The cartridge includes a plurality of staggered rollers configured to provide tactile feedback to the user. The frame is adapted to receive the belt system and the cartridge as they are lowered into the frame, and the frame is adapted to place the belt of the belt system into tension as the belt system is lowered into the frame. An integrated flywheel generator system provides smooth operation of the treadmill and generates electricity to power additional systems.

BACKGROUND

Field

The present inventions relate to exercise equipment, such as treadmills.

Description of the Related Art

Conventional cordless treadmills are bulky and difficult to assemble. Additionally, it can be difficult for lightweight users to start and stop the belt of a conventional cordless treadmill.

SUMMARY

For purposes of summarizing the disclosure, certain aspects, advantages and novel features of the inventions have been described herein. It is to be understood that not necessarily all such advantages can be achieved in accordance with any particular embodiment of the inventions disclosed herein. Thus, the inventions disclosed herein can be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught or suggested herein without necessarily achieving others.

Embodiments described herein include a self-propelled treadmill having smooth starting and stopping features. For example, an integrated flywheel generator and gearing system and sensors configured to detect an amount of deflection of a treadmill deck may be capable of providing a smooth starting operation of the treadmill belt, regardless of the weight of the user. In various embodiments, the treadmill may also include a variable impact absorption system that may include sensors and absorption components to measure and maintain the deflection of the treadmill deck while a user walks or runs on the treadmill.

In one embodiment, a cordless treadmill includes a frame, comprising a first side surface, a second side surface opposite the first side surface, and a bottom surface, the first side surface and the second side surface generally orthogonal to the bottom surface such that the first side surface, second surface and bottom surface define a U-shaped channel extending generally lengthwise of the treadmill, the frame further comprising a plurality of openings in the side surfaces; a belt system, comprising a forward roller configured to roll on a forward axle and a rear roller configured to roll on a rear axle, the forward and rear axles extending laterally from the forward and rear rollers, respectively, such that the forward and rear axles support and allow rotation of the forward and rear rollers in the frame, and a belt placed around the forward and rear rollers; and a cartridge, comprising a first roller having a longitudinal axis that extends along a width of the frame and a second roller adjacent to and laterally spaced apart from the first roller, wherein a longitudinal axis of the second roller extends along the width of the frame, and wherein the longitudinal axis of the first roller and the longitudinal axis of the second roller are offset from each other by a predetermined distance, the cartridge further comprising a first collinear roller and a second collinear roller, wherein the first and second collinear rollers extend along a width of the frame and each of the first and second collinear rollers are adjacent to the first and second rollers such that the first collinear roller is on an opposite side of the first and second rollers than the second collinear roller, the cartridge further comprising at least one connecting member mounted to each of the first and second rollers and the first and second collinear rollers such that a first tab and a second tab extend laterally from each side of the mounted rollers, the cartridge configured such that the endless belt of the belt system rotates over and is supported by the cartridge; wherein the frame is adapted to receive the belt system and the cartridge as they are lowered into the frame, and wherein the frame is adapted to place the belt of the belt system into tension as the belt system is lowered into the frame. In some embodiments, at least one of the openings in the side surfaces of the frame has an arcuate shape that extends in an arcuate path through the side surface of the frame such that the belt of the belt system is placed into tension as the belt system is lowered into the at opening in the side surface of the frame system.

In another embodiment, a cordless treadmill includes a frame, comprising a first side surface, a second side surface opposite the first side surface, and a bottom surface, the first side surface and the second side surface generally orthogonal to the bottom surface such that the first side surface, second surface and bottom surface define a U-shaped channel extending generally lengthwise of the treadmill, the frame further comprising a plurality of openings in the side surfaces; a belt system, comprising a forward roller configured to roll on a forward axis and a rear roller configured to roll on a rear axis, the forward and rear axles extending laterally from the forward and rear rollers, respectively, such that the forward and rear axles support and allow rotation of the forward and rear rollers in the frame, and a belt placed around the forward and rear rollers; a cartridge, comprising a first roller having a longitudinal axis that extends along a width of the frame and a second roller adjacent to and laterally spaced apart from the first roller, wherein a longitudinal axis of the second roller extends along the width of the frame, and wherein the longitudinal axis of the first roller and the longitudinal axis of the second roller are offset from each other by a predetermined distance, the cartridge further comprising a first collinear roller and a second collinear roller, wherein the first and second collinear rollers extend along a width of the frame and each of the first and second collinear rollers are adjacent to the first and second rollers such that the first collinear roller is on an opposite side of the first and second rollers than the second collinear roller, the cartridge further comprising at least one connecting member mounted to each of the first and second rollers and the first and second collinear rollers such that a first tab and a second tab extend laterally from each side of the mounted rollers, the cartridge configured such that the endless belt of the belt system rotates over and is supported by the cartridge; and a flywheel generator system rotatably connected to the forward roller such that rotation of the forward roller rotates a gearing assembly of the flywheel generator system to generate electricity and control an initial rotational resistance of the front roller; wherein the frame is adapted to receive the belt system and the cartridge as they are lowered into the frame, and wherein the frame is adapted to place the belt of the belt system into tension as the belt system is lowered into the frame.

In yet another embodiment, a cordless treadmill includes a frame, comprising a first side surface, a second side surface opposite the first side surface, and a bottom surface, the first side surface and the second side surface generally orthogonal to the bottom surface such that the first side surface, second surface and bottom surface define a U-shaped channel extending generally lengthwise of the treadmill, the frame further comprising a plurality of openings in the side surfaces; a belt system, comprising a forward roller configured to roll on a forward axis and a rear roller configured to roll on a rear axis, the forward and rear axles extending laterally from the forward and rear rollers, respectively, such that the forward and rear axles support and allow rotation of the forward and rear rollers in the frame, and a belt placed around the forward and rear rollers; a cartridge, comprising a first roller having a longitudinal axis that extends along a width of the frame and a second roller adjacent to and laterally spaced apart from the first roller, wherein a longitudinal axis of the second roller extends along the width of the frame, and wherein the longitudinal axis of the first roller and the longitudinal axis of the second roller are offset from each other by a predetermined distance, the cartridge further comprising a first collinear roller and a second collinear roller, wherein the first and second collinear rollers extend along a width of the frame and each of the first and second collinear rollers are adjacent to the first and second rollers such that the first collinear roller is on an opposite side of the first and second rollers than the second collinear roller, the cartridge further comprising at least one connecting member mounted to each of the first and second rollers and the first and second collinear rollers such that a first tab and a second tab extend laterally from each side of the mounted rollers, the cartridge configured such that the endless belt of the belt system rotates over and is supported by the cartridge; and a flywheel generator system rotatably connected to the forward roller such that rotation of the forward roller rotates a generator configured with the forward roller to generate electricity and control an initial rotational resistance of the front roller; wherein the frame is adapted to receive the belt system and the cartridge as they are lowered into the frame, and wherein the frame is adapted to place the belt of the belt system into tension as the belt system is lowered into the frame.

In some embodiments, the treadmill further includes a variable impact absorption system for a treadmill, the variable impact system including at least one shock absorbing members mounted to a walking surface of the treadmill; at least one sensor mounted to the walking surface of the treadmill, the at least one sensor configured to measure an amount of deflection of the walking surface of the treadmill; and a control system connected to the at least one shock absorbing member and the at least one sensor such that an amount of shock absorption may be adjusted due to the amount of deflection of the walking surface of the treadmill.

In some embodiments, the treadmill further includes an automatic stopping system, the automatic stopping system comprising at least one sensor and a control system, wherein the control system is configured to slow or stop the treadmill belt when a predetermined percentage of the body weight of a user has shifted a predetermined distance from an expected use position.

In some embodiments, the treadmill further includes a visual feedback system, the visual feedback system comprising a plurality of lights for displaying visual feedback to a user, at least one sensor, and a control system, wherein the control system is configured to receive at least one signal from the at least one sensor indicating a duration or amount of pressure on the treadmill belt, determining whether the duration or amount of pressure falls within a predetermined desired or undesired range, and trigger at least one of the plurality of lights to illuminate and indicate whether the detected duration or pressure is within a desired or undesired range.

In some embodiments, the frame has a wedge-shape such that a front portion is at a higher elevation than a rear portion. In some embodiments, the treadmill further includes a lift actuator and a plurality of springs, wherein the springs and the lift actuator are configured to provide a lift force to raise the treadmill to a desired incline. In some embodiments, the springs are gas springs.

In some embodiments, the treadmill further includes a plurality of step detection sensors connected to the frame to measure the position of a user's steps on the belt system of the treadmill, wherein the weight of a user transitions from a forward portion of the belt to a rear portion of the belt as the treadmill belt rotates and wherein, if one or more of the plurality of step detection sensors detects a step that does not originate in the front portion of the belt, a control system slows and stops the treadmill belt to prevent user injury.

In another embodiment, a variable impact absorption system for a treadmill, includes at least one shock absorbing members mounted to a walking surface of the treadmill; at least one sensor mounted to the walking surface of the treadmill, the at least one sensor configured to measure an amount of deflection of the walking surface of the treadmill; and a control system connected to the at least one shock absorbing member and the at least one sensor such that an amount of shock absorption may be adjusted due to the amount of deflection of the walking surface of the treadmill.

In yet another embodiment, a treadmill includes a frame, the frame comprising a first side surface, a second side surface, and a bottom surface extending at least partially between the first and second side surfaces, wherein the first and second side surfaces and bottom surface define a U-shaped channel, wherein the first side surface comprises a first opening extending from an upper edge of the first side surface towards the bottom surface and wherein the second side surface comprises a second opening extending from an upper edge of the second surface towards the bottom surface; and an axle, the axle extending at least from the first opening to the second opening, wherein the first and side surfaces are adapted to receive and secure the axle as it is lowered into the first and second openings.

In another embodiment, a treadmill includes a frame; a cartridge coupled to the frame, the cartridge including a first roller, wherein a longitudinal axis of the first roller extends along a width of the frame; a second roller adjacent to and laterally spaced apart from the first roller, wherein a longitudinal axis of the second roller extends along the width of the frame, wherein the longitudinal axis of the first roller and the longitudinal axis of the second roller are offset from each other by a predetermined distance. In some embodiments, the predetermined distance is half of a diameter of the first roller. In some embodiments, the predetermined distance is one quarter of a diameter of the first roller.

In yet another embodiment, a method of controlling treadmill belt rotation, includes determining a weight of a treadmill user; determining an available torque based upon the weight of the treadmill user and one or more treadmill settings; determining a required torque based upon the weight of the treadmill user, wherein the required torque corresponds to an amount of torque used to initiate movement of a treadmill belt in response to movement of the user; and setting a gear ratio of a flywheel generator based upon the available torque and the required torque. In some embodiments, determining the weight of the treadmill user includes determining a deflection of a treadmill deck after the user steps onto the treadmill deck. In some embodiments, the one or more treadmill settings includes an incline of a treadmill deck. In some embodiments, determining the available torque is further based upon friction associated with one or more treadmill components.

DETAILED DESCRIPTION

Various embodiments will be described hereinafter with reference to the accompanying drawings. These embodiments are illustrated and described by example only, and are not intended to be limiting.

Embodiments may be implemented in hardware, software, firmware, or any combination thereof. Those of skill in the art will understand that information and signals may be represented using any of a variety of different technologies and techniques. For example, data, instructions, commands, information, signals, bits, symbols, and chips that may be referenced throughout the above description may be represented by voltages, currents, electromagnetic waves, magnetic fields or particles, optical fields or particles, or any combination thereof.

In the following description, specific details are given to provide a thorough understanding of the examples. However, it will be understood by one of ordinary skill in the art that the examples may be practiced without these specific details. For example, electrical components/devices may be shown in block diagrams in order not to obscure the examples in unnecessary detail. In other instances, such components, other structures and techniques may be shown in detail to further explain the examples.

Overview

A cordless treadmill according to some embodiments discussed below includes a geared flywheel and generator system to improve the starting and stopping action of the treadmill belt. The treadmill includes a belt that passes over a front roller connected to the flywheel and generator system and a rear roller, and the speed and movement of the belt changes in response to the user increasing or decreasing the speed of his or her stride on the belt. The treadmill is further adapted to generate electrical energy in response to the rotation of the treadmill belt (and thus rotation of the flywheel and generator system) that occurs due to the user's steps. A treadmill according to some embodiments includes a “drop-in” frame design in which the various components of the treadmill may be adapted to couple to the frame via slotted openings. The frame may be constructed as a single metal or composite member. The drop-in frame design improves the ease of assembly, maintenance and serviceability of the treadmill. In some embodiments, a treadmill includes a cartridge adapted to support the treadmill belt. The cartridge includes roller channels extending the length of the treadmill. The roller channels are staggered such that the center of each roller is not aligned with center of adjacent rollers, producing a staggered roller section of the cartridge. For example, the longitudinal axes of adjacent sets of rollers may be offset a predetermined distance. In some embodiments, a section of staggered rollers is flanked by a channel of collinear rollers such that one channel of collinear rollers is on one side of the section of staggered rollers and a second channel of collinear rollers is on the opposite side of the section of staggered rollers. The collinear rollers are not aligned with the centers of the plurality of staggered rollers such that when a user steps on the collinear rollers, the user will experience a “bumpy” feel. Stepping on the collinear rollers provides instant feedback to the user that his feet have drifted from a target area of the belt, and help guide the user's steps back to the staggered roller section of the cartridge.

In some embodiments, the treadmill includes a variable impact absorption system (VIAS) adapted to measure deflection of the treadmill deck or cartridge during use. The variable impact absorption system is adapted to interface and communicate with the flywheel generator system to minimize deck deflection and maximize energy transfer to the generator system.

In some embodiments, the treadmill incorporates an automatic stop feature to slow or stop the rotation of the treadmill belt when the user has stepped off the treadmill. In some embodiments, the automatic stop feature may slow or stop the treadmill belt if the user is too close to the front or rear of the treadmill, as detected by sensors incorporated into the VIAS system. In some embodiments, additional sensors and/or the sensor used by the VIAS system may detect whether a user steps on a front portion or a rear portion of the treadmill deck. If the user's step is detected in an undesirable, unexpected, or unsafe position, the treadmill can be slowed or stopped to prevent injury to the user.

Some embodiments of the treadmill incorporate a visual feedback system. The visual feedback system desirably indicates to the user whether the impact (e.g., force, pressure, shock, etc.) of each foot is more or less than a desired amount. Additionally, in some embodiments, the visual feedback system may also indicate to the user whether the left and right strides are in line or out of line, allowing the user to learn to take more efficient or properly placed strides which may be helpful during physical therapy and/or patient rehabilitation.

Some embodiments of the treadmill incorporate a multifaceted method of speed control using one or more of eddy current braking, resistive braking, and frictional braking to control the speed of the treadmill belt within a user-defined desired speed. Each of the methods of speed control may be used individually or in combination to obtain the desired treadmill belt speed. Factors such as the user's weight, desired speed, treadmill incline position, and/or speed of rotation of the flywheel, as determined by various sensors located in the treadmill, as described below, may be used to determine which speed control method or methods to use to obtain the desired speed setting and improve safe performance of the treadmill.

Other embodiments of the treadmill may include a wedge-shaped frame design. A wedge-shaped frame allows the rear section to be at a lower elevation than the front section without compromising performance of the treadmill, as discussed in greater detail below.

Additional embodiments of the treadmill incorporate a supplemental lift assist system to assist the lift motor in achieving a treadmill incline position.

A treadmill having some or all of the embodiments discussed above, including a “drop-in” and “snap-in” frame design in which gravity is the primary force used to retain the components, is shown inFIGS. 1Aand B. The frame is a single piece of metal or composite having multiple slots and openings that align with corresponding laterally extending pieces of a cartridge that. The cartridge, along with the treadmill belt, provides a semi-flexible surface upon which the user can walk or run. Similarly, the treadmill's front and rear rollers also slide into slots positioned at the front and back portions of the frame. Gravity and the weight of the user secure the cartridge in the frame.

The self-powered treadmill100according to the embodiment shown inFIG. 1Aand the partial exploded view ofFIG. 1Bincludes a deck assembly102and a display assembly150. The deck assembly102includes a belt110that rotates around two rollers, a front roller assembly120and a rear roller assembly140. The front roller assembly120and rear roller assembly140are supported by a frame104that is designed such that the roller assemblies may be dropped or slotted into the frame104for easy assembly. The belt110is supported by a cartridge that is supported by the frame104. The cartridge supports the weight of the user, as discussed in greater detail below. The deck assembly102provides a stable surface for running or walking. Side rails, such as side rail106, may be attached to either side of the frame104to provide additional support for the frame104and to conceal and protect other treadmill components, such as a cushioning system described in further detail below. In some embodiments, the treadmill100may also include an incline adjustment assembly that may include a lever112that is rotatably connected at one end to the frame104. The opposite end of the lever112may include a wheel114such that the wheeled end of lever112can easily roll towards the frame104of the treadmill100to incline the front end of the treadmill100such that the front end of the treadmill100is at a higher elevation than the rear end of the treadmill100. Additional supports may be included to provide additional support for the treadmill100and to level the treadmill100on a surface.

As illustrated, the treadmill100does not include railings or arm supports. However, in other embodiments, railings and/or arm supports may be provided, e.g., for users with balance issues.

As shown inFIGS. 1Aand B, the treadmill100also includes a display assembly150. The display assembly150may include a pedestal152that extends upward from the front end of the treadmill100. The pedestal152may be used to support user controls for the treadmill and/or a display console including a video screen, LED light display, or other display device to display information to the user. Such information may include belt speed, treadmill incline, the user's lateral position on the belt, the impact force of a user's feet on the treadmill, etc. Additionally, in some embodiments, the display means may be powered by electrical energy created by the rotational movement of the treadmill belt110or by a battery. The energy capture and generation may be accomplished with an integrated flywheel and generator system connected to rotation of the front or rear roller, as described in further detail below.

In one embodiment, the front roller assembly120and the rear roller assembly140are configured such that operation of the belt110is smooth and controlled for all users. For example, to start operation of the treadmill100, the user begins walking on the belt110. A conventional cordless treadmill will require a large amount of force to overcome the resistance and friction of the roller assemblies, etc. to initiate operation of the belt110. Such conventional cordless treadmills are therefore uncomfortable and difficult to use. In the illustrated embodiment, the treadmill100is configured such that the front roller assembly120and/or the rear roller assembly140allow the user to initiate operation of the belt110using reduced force. Preferably, a user weighing, for example, 100 lbs., can initiate movement of the belt110as easily as a user weighing, for example, 250 lbs. Therefore, in a preferred embodiment, a gearing or transmission system as described below may be configured to determine a user's weight and adjust an initial gear position within the transmission to allow a smooth initial operation of the treadmill for both a lighter weight user and a heavier user. Additionally, a multifaceted speed control system may be used to control the speed of the treadmill to improve safe operation, as described in greater detail below.

In some embodiments, including the illustrated embodiments, the treadmill100includes an impact absorption system, as described in further detail below. The impact absorption system provides shock absorption as the user walks or runs on the treadmill100. In some embodiments, the impact absorption system includes a plurality of sensors connected to a control system to measure deflection of the treadmill deck due to the user's weight or impact on the belt during walking or running. In some embodiments, the gearing and transmission system may be adjusted based on the amount of deck deflection measured by the impact absorption system.

As mentioned above and discussed in greater detail below, the treadmill100may also include an energy capture mechanism that can capture the rotational energy of the treadmill belt110and convent the rotational energy to electrical energy using, for example, an electrical generator. In some embodiments, the impact absorption system may work with the energy capture mechanism to maintain a constant amount of deck deflection during use to increase the efficient of the energy capture and conversion to electrical energy by reducing the amount of energy loss due to deck flexion.

Another embodiment of a treadmill100is illustrated inFIG. 14. Similar to the treadmill100described above with respect toFIG. 1, the treadmill100illustrated inFIG. 14includes a deck assembly102and a display assembly150. The deck assembly102includes a movable treadmill belt110that can rotate around a front and rear roller in response to the force of a user's steps on the belt110. The display assembly150may, in some embodiments, include a pair of arm members160that extend to either side of the belt110to provide a stable surface for the user's hands during treadmill use.

As in the embodiment discussed above with respect toFIGS. 1A and 1B, the treadmill illustrated inFIG. 14may, in some embodiments, also include an impact absorption system, as described in further detail below. Additionally, in some embodiments, the treadmill100illustrated inFIG. 14may include an energy capture mechanism that can capture the rotational energy of the treadmill belt110and convent the rotational energy to electrical energy using, for example, an electrical generator.

Yet another embodiment of a treadmill2100is illustrated inFIG. 19. Similar to the treadmill100described above with respect toFIGS. 1Aand B andFIG. 14, the treadmill2100includes a deck assembly2102and a display assembly2150. The deck assembly2102includes a movable treadmill belt (not shown) that can rotate around a front and rear roller in response to the force of a user's steps on the belt. The display assembly2150may, in some embodiments, include a pair of arm members2160that extend to either side of the belt to provide a stable surface for the user's hands during treadmill use.

The treadmill2150may, in some embodiments, include a wedge-frame design, as described in further detail below, to reduce the step up height such that the rear portion of the treadmill is at a lower elevation than the forward portion of the treadmill. Additionally, the treadmill2100may include an energy capture mechanism to convert the rotation energy produced by a user walking or running on the treadmill to electrical energy. In some embodiments, the treadmill2100may include one or more of an impact absorption system, an automatic stop feature, a drop-in assembly, or any combination of other features discussed below with reference to the treadmills shown inFIGS. 1A and 1BandFIG. 14.

Frame

In some embodiments, as illustrated inFIG. 2, the treadmill100may be constructed on an easy to assemble frame, such as frame104. In one embodiment, the frame104is U-shaped with the side surfaces running the length of the treadmill. The side surfaces form a channel into which various components of the treadmill100, such as the front roller assembly120and the rear roller assembly140, may be inserted. Additionally, the frame104includes a plurality of cutouts or openings that are configured to receive a cartridge assembly such as that discussed below. Due to gravity, minimal securing means such as mechanical fasteners, etc. are used to secure the components of the treadmill100to the frame104.

The bottom of the channel is formed from bottom surface208. A plurality of openings220,222,224,226,228,228, and230may be formed in the bottom surface208to reduce the weight of the frame104. The sides of the U-shaped channel are formed from the left frame side205and the right frame side209. The left frame side205and the right frame side209each form an inverted channel to provide additional rigidity to the frame104. A left horizontal flange204and a left vertical flange202form an inverted U-shaped channel with the left frame side205. Similarly, a right horizontal flange212and a right vertical flange214form an inverted U-shaped channel with the right frame side209. A plurality of openings may be formed in the horizontal flanges and the frame sides such that the openings allow treadmill components, such as the treadmill motion assembly components300, shown inFIG. 3, to be dropped from a vertical position above the frame104through the horizontal flanges204,212and supported by the frame sides205,209. In some embodiments, openings on the left side205and through the left horizontal flange204are paired with symmetrical openings in the right side209and through the right horizontal flange212.

At the front of the frame104, a U-shaped opening246is illustrated in the left frame side205. While only partially shown inFIG. 2, a symmetric U-shaped opening is also formed in the right frame side209. The U-shaped opening246is formed by a curved surface248in the left frame side205. The opening246is configured to allow a connection between the integrated flywheel generator assembly discussed in further detail below and the front roller assembly120shown inFIG. 1. A slotted opening242is formed in the left horizontal flange204and the left side205. The slotted opening242is preferably wide enough to allow a front roller axis to fit within the slotted opening242. Preferably, the slotted opening242is angled such that the end of the slotted opening242closest to the bottom surface208of the frame104is closer to the rear of the frame204than the end of the slotted opening242formed in the left horizontal flange204. In some embodiments, the slotted opening242is angled back towards the rear of the frame204at an angle of approximately 30 degrees with the axis defined by the left side205. In other embodiments, the slotted opening242may be angled either forward or backward at an angle between 15 degrees and 60 degrees. A symmetric slotted opening250is formed in the right horizontal flange212and the right side209. The slotted opening250has a similar width and orientation as the slotted opening242to allow the front roller axle to pass through the opening250. Desirably, the front roller axis is supported by the ends of the slotted openings242,150such that the front roller can rotate freely within the frame104without contacting either of the frame sides205,209or the bottom surface208, as illustrated inFIG. 4.

With continued reference toFIG. 2, curved openings232and258are formed in the left frame side205and the right frame side209, respectively. The curved opening232may be formed with a rectangular opening in the left horizontal flange204that opens into a narrow curved opening in the left side205formed by the curve234. The curve234narrows the curved opening232into an opening wide enough to securely fit the rear roller axis. The curved opening232allows the rear roller to be dropped from a vertical position above the frame104into a tensioned position in the frame104. As the rear roller axis is dropped into the curved openings232,258, the rear roller axis is forced into the rearward position of the opening232,258by the curve234. The dimensions and placement of the openings232,248, along with the corresponding slotted openings242,250at the front end of the frame104, allow the treadmill belt to be tensioned by exact placement of the front and rear rollers, around which the treadmill belt rotates. Desirably, no external tensioning of the treadmill belt is required once the front and rear roller assemblies and the treadmill belt have been dropped into place within the openings232,258,242, and250, as illustrated inFIG. 4.

FIG. 2also illustrates that a number of rectangular openings236,238,240may be formed in the left horizontal flange204and the left side205. Similar symmetric openings252,254,256may be formed in the right horizontal flange212and the right side209. In some embodiments, the openings236,238,240,252,254,256are configured to accept support slats that support and configure the cartridge deck of the treadmill100, as discussed in greater detail below.

The frame104may also include a plurality of openings260formed in the left and right sides205,209to secure other treadmill components, such as the VIAS system shock absorbing components, to the frame104.

Some of the treadmill motion assembly and variable impact absorption system components are illustrated inFIG. 3with the frame104removed to more clearly illustrate the components. The components are shown installed in the frame104inFIG. 4.

A front roller304has a front roller axis306passing therethrough. Similarly, a rear roller344has a rear roller axis346passing therethrough. As discussed above, the front roller axis306preferably extends outwards from each end of the front roller304such that the front roller axis306can fit within the slotted openings242and250in the frame104(FIG. 4). Similarly, the rear roller axis346preferably extends outwards from each end of the rear roller344such that the rear roller axis346can fit within the curved openings232,258in the frame104(FIG. 4). The front roller304and the rear roller344are preferably configured such that a treadmill belt can fit around both the front roller304and the rear roller344. Desirably, when the treadmill belt is fitted around both the front roller304and the rear roller344, and the rollers and belt are dropped into the frame104, as shown inFIG. 6, the treadmill belt is properly tensioned without the need for additional tensioning of the treadmill belt.

With continued reference toFIG. 3, additional treadmill components used for impact absorption, deck deflection, and treadmill motion control are illustrated. The integrated flywheel generator302includes a gearing system that compensates for the measured weight of the user to set an initial gearing of the front roller assembly120such that the treadmill belt has an initial resistance that allows the belt to rotate smoothly and easily for users of different weights. Additional details of the flywheel generator are discussed below.

In some embodiments the frame may have a wedge or inclined shape, such as the frame2104shown inFIG. 20. In this configuration, the back or rear end of the treadmill is at a lower elevation than the front or forward end of the treadmill. This allows the same diameter front roller and other front drive components as used with the frame shown inFIGS. 2 and 3to be used with the frame shown inFIG. 20. The frame2104may include all of the slotted openings, cutouts, and features discussed above with respect to frame104to allow for easy drop-in of treadmill components as described above. Additional advantages of the wedge-frame2104include reducing the step up height for a user to step onto the treadmill belt. This allows the treadmill to be more easily used by those users who may have difficulty stepping up onto the treadmill deck. Furthermore, the lower rear height of the treadmill reduces the distance to the ground to potentially reduce the risk of injury should a user fall off the rear of the treadmill during operation.

An additional advantage of the wedge-shaped frame2104is the assistance the slight incline provides in initiating motion of the treadmill belt. As the user will be walking up a slight incline from the first step on the treadmill, it will be easier for the user to initiate motion of the treadmill belt using the initial steps on the belt.

The wedge-frame2104allows use of the same diameter front roller120as discussed above such that performance of the treadmill is not impacted. In some embodiments, a smaller diameter rear roller may be used without impacting the feel and performance of the treadmill.

In some configurations, a linear actuator or lift motor can be used to raise the front of the treadmill to the desired incline. However, a linear actuator or lift motor consumes a lot of power and is the largest consumer of power for the self-propelled treadmill disclosed herein. When the treadmill is not operating, that is, when a user is not walking or running on the treadmill to generate electricity, the lift motor will require power from the battery to move the treadmill to the desired incline. To achieve the desired treadmill elevation, the lift motor needs to be powerful enough to overcome the user's weight as well as the weight of the treadmill frame and components. To reduce power consumption, some embodiments of the self-propelled treadmill include a lift assist system as shown inFIGS. 22 and 23. The lift assist system can include a pair of gas springs2810that can provide leverage assistance and reduce the amount of power consumed by the lift motor by reducing the amount of work required of the lift motor. In a normal incline operation, the lift motor can lift around 10 or 20 lbs. However, in some embodiments, the lift motor can lift 30, 40, 50, 60, 70 80 or 100 lbs. In some embodiments, the lift motor can lift up to 150 lbs. In some embodiments, the gas springs2810can lift 10, 20, 30, 40, 50, 60, 70, 80, 90, or 100 lbs. In some embodiments, each of the gas springs2810can lift up to 150 lbs. The gas springs2810may be connected to a stationary portion of the support structure and to the frame on opposite sides of the treadmill deck at the front of the treadmill. When a user desires an elevation change, the gas springs2810provide additional force to lift the treadmill frame, therefore reducing the power consumption of the lift motor. In some embodiments, the lift motor provides specific control to achieve the desired incline, that is, the lift motor controls the demanded lift provided by the gas springs2810.

Variable Impact Absorption System

One embodiment of a variable impact absorption system includes one or more adjustable dampers (hydraulic or air cylinders or any other type of damping system), one or more infrared sensors, and a control system. The infrared sensors desirably measure the deflection of the treadmill deck for each user and based on the deflection the control system adjusts the stiffness such that the deflection of the treadmill deck is consistent whether the user weighs 90 lbs or 350 lbs, or any other weight.

The treadmill motion assembly300also includes components that may be used for variable impact absorption. The term “variable impact absorption” is a broad term having its ordinary meaning. In some embodiments, variable impact absorption or a variable impact absorption system refers to components that can measure the amount of deflection of the cartridge or deck due to a user's weight or the force of impact of a user's foot while running or walking on the treadmill and adjust an amount of absorption to reduce or control the amount of deck deflection, provide a desired cushioning or feel, and/or calculate a user's weight or force of impact for use in other treadmill functions, such as calculations of calories burned, etc. The variable impact absorption system includes a plurality of impact absorption members, actuators, and sensors connected to a control system that measure the amount of deflection of the treadmill deck as the user walks or runs on the treadmill. Additionally, the variable impact absorption system, via the control system, can communicate with an energy generation system including the integrated flywheel generator discussed below to establish an initial gearing ratio of the transmission of the treadmill such that users of different weights can start and stop the motion of the treadmill belt with equal force such that the resultant initial motion of the belt is smooth and controlled.

As illustrated inFIG. 3, six impact absorption members310,318,322,326,332,340may be used with the treadmill100, with three impact absorption members on each side of the treadmill belt110and equally distributed along the length of the treadmill belt110. Each impact absorption member may include a pair of spring members308,316,320,324,330,338. The spring members308,316,320,324,330,338may be formed from an elastomeric polymer and may be attached to a mounting member309,317,321,325,331,339using any type of mechanical fastener including screws, nails, brads, etc. In other embodiments, the spring members may be hydraulic dampers, compressed air dampers, or any other type of damper. In some embodiments, the spring members308,316,320,324,330,338may include one or more sets of dampeners (e.g., gbr dampeners, or other type of dampeners). The dampeners may be characterized by a force over travel ratio. One of the sets of dampeners may be mounted lower than the mounting height of the cartridge. One set of the dampeners is preferably always engaged when a user is on the treadmill. The set of dampeners mounted lower will engage when more force is applied to running or walking surface of the treadmill. As force is applied, the second (lower) set of dampeners engages, changing the dampening effect.

Additionally, a pair of variable impact absorption members314,328may be used with the treadmill100. Variable impact absorption member314may be located on the right side of the treadmill belt110while the other variable impact absorption member328may be located on the left side of the treadmill belt110. The variable impact absorption members314,328may be air operated cylinders to provide adjustable absorption of impact on the treadmill due to the force of the user's steps while walking or running. Each of the variable impact absorption members314,328may be placed underneath an impact support member312,342. The impact support members312,342may be rectangular support members that are supported on each end by an impact absorption member. As illustrated inFIG. 3, the variable impact absorption members314,328are desirably centered underneath the impact support members312,342. The variable impact absorption system may also include additional actuators334,336to provide additional impact absorption.

FIG. 4illustrates the treadmill components300discussed above in their relative positions when installed in the frame104. As discussed above, the front roller304is slotted into the front of the frame104in the slotted openings242,250. The axis of the rear roller344fits within the openings232,258in the frame104. The six impact absorption members310,318,322,326,332,340are desirably equally distributed on either side of the frame104outside of the channel formed by the frame104. Desirably, each of the six impact absorption members310,318,322,326,332,340is aligned with one of the openings236,238,240,252,254,256. Preferably, the openings236,238,240,252,254,256are configured such that cartridge support members702,704,706(FIG. 7) fit within the openings236,238,240,252,254,256and each end of the cartridge support members702,704,706is supported by one of the six impact absorption members310,318,322,326,332,340. In some embodiments, as shown inFIG. 5, side support members105a,105bmay be connected to the frame104such that the variable impact absorption system components are enclosed and protected. A fully assembled treadmill deck with front and rear rollers, frame104, and side support members105a,105benclosing the variable impact absorption system components is shown inFIG. 6.FIG. 16illustrates a side view of another embodiment of a cordless treadmill100including dampeners308,316,320that may be arranged as discussed above to provide variable impact absorption.

Cartridge

The treadmill may include a cartridge assembly composed of staggered and non-staggered rollers that may be dropped into the frame104. A cartridge assembly (e.g., instead of a standard treadmill deck) can desirably be dropped into the frame104during assembly, reducing assembly time. The cartridge assembly illustrated inFIG. 7incorporates a staggered pattern of wheels (sometimes referred to as mini-wheels) or rollers assembled with bearings. As illustrated inFIG. 7, the cartridge assembly700includes six staggered roller sets714,716,718,720,722, and724. The staggered roller sets714,716,718,720,722, and724may each be identical and include a plurality of rollers set in a common trough or channel. One example of a single channel of a set of staggered rollers is shown inFIG. 8. Multiple troughs of the rollers shown inFIG. 8may be offset and placed side by side on the center portion or deck of the treadmill100to form the main running or walking surface of the treadmill100as illustrated inFIG. 7. The staggered wheels or roller sets714,716,718,720,722, and724are located on the center portion of the cartridge and preferably extend approximately 18″ of the total width of the cartridge assembly700. The staggered wheel pattern allows the user to have a constant surface contact underfoot while using the treadmill.

In one embodiment, as shown inFIG. 7, the cartridge assembly700further includes a first collinear roller channel710and a second collinear roller channel712located on the outside of or flanking the staggered roller sets714,716,718,720,722, and724. One example of a single channel of collinear rollers is shown inFIG. 9. The two outer channels of collinear rollers710,712provide a bumpy, or vibration-feel experience for the user to guide the user to center their strides over the staggered wheel portion of the cartridge assembly700. As illustrated inFIG. 6, a traditional treadmill belt travels around the outside of the cartridge assembly700to provide the running or walking surface. In some embodiments, each of the staggered wheels or rollers that make up the staggered roller sets714,716,718,720,722, and724have a diameter between 1″-1.5″.

The cartridge assembly700can provide feedback to the user to guide the user to center the running or walking strides on the center, staggered wheel portion of the cartridge assembly700. For example, as the user walks or runs on the treadmill100, the user will desirably place each step on the staggered wheel sets714,716,718,720,722, and724of the cartridge assembly700. Due to the staggered design, the user will not feel any bumpiness or roughness to the surface. If the user steps too far to the right or left, the user will place his or her foot on the collinear roller channels710,712. The collinear design of the roller channels710,712will create a bumpy feel to the user. This will inform the user that the walking or running strides are not centered on the treadmill belt110or the cartridge assembly700and the user will therefore desirably alter his or her stride accordingly. A closer view of another embodiment of the cartridge assembly700is shown inFIG. 18. As illustrated, the staggered rollers714,716,718,720are configured such that the centers of each roller are offset from the adjacent rollers. As discussed above, this provides a smooth surface for the user. Additionally, the collinear rollers710and712are configured such that they flank the sets of staggered rollers such that the collinear rollers710,712extend longitudinally at the exterior side edges of the treadmill deck. As illustrated, the collinear roller sets710,712may be formed from one roller or from two or more rollers that are configured such that their centers are aligned (see rollers712). In the illustrated embodiment, the collinear rollers710,712are arranged such that the centers of the collinear rollers710,712are not aligned with the centers of the adjacent staggered rollers, as illustrated inFIG. 18.

An additional benefit provided by the cartridge assembly700shown inFIG. 7is a reduced loss of energy. The cartridge assembly700with the pattern of staggered roller sets714,716,718,720,722, and724provide constant contact with the treadmill belt110as the belt100rotates around the cartridge assembly700during use. The constant contact between the treadmill belt110and the cartridge assembly700allows for more efficient energy transfer to the energy generation system discussed below due to reduced energy losses in addition to the smooth and comfortable feel of the treadmill to the user.

As further illustrated inFIG. 7and discussed above with respect toFIGS. 5 and 6, the cartridge assembly700also includes a plurality of laterally extending support members702,704,706. Each of the support members is connected to the channels of the roller sets710,712,714,716,718,720,722,724by any type of mechanical fastener. The support members702,704,706extend laterally beyond the edges of each of the collinear roller channels710,712such that the ends of each of the support members702,704,706may slot into the openings236,238,240,252,254,256of the frame104(FIG. 5). To illustrate, the cartridge assembly700shown inFIG. 7can drop into the frame104, shown inFIGS. 5 and 6, and due to gravity and the weight of the cartridge assembly700, requires minimal or no securing devices to hold it together. The laterally-extending tabs of the cartridge slide into the tab receptacles on each side of the frame, securing the cartridge from forward and backward motion. As discussed above, each of the ends of the support members702,704,706rest on one of the six impact absorption members310,318,322,326,332,340such that movement of the cartridge assembly700due to the force of impact of a user's foot during walking or running is damped by the absorption members310,318,322,326,332,340.

In another embodiment of a user-propelled treadmill, as illustrated inFIG. 15, the cartridge assembly700comprising a plurality of sets of staggered rollers flanked on either side by a set of collinear rollers may be configured to move together with the front roller assembly120and rear roller assembly140. All three of the components (cartridge assembly700, front roller assembly120, and rear roller assembly140) may drop into the frame component104as discussed above for ease of assembly. Additionally, as the user is using the treadmill, the cartridge assembly700and front and rear roller assemblies120,140move together left and right. In other embodiments, as shown inFIGS. 4-7, the cartridge assembly700may be independent with the front roller assembly120fixed in position. Allowing the cartridge assembly700, front roller assembly120, and rear roller assembly140to move together provides the additional advantage of increasing the safety of the treadmill by improving the treadmill belt110tracking over the cartridge assembly700, front roller assembly120, and rear roller assembly140.

Another embodiment of a user-propelled treadmill is illustrated inFIG. 19. Similar to the treadmill shown inFIGS. 1-7and discussed above, the treadmill2100includes a cartridge assembly2700comprising a plurality of sets of staggered rollers. In the embodiment illustrated inFIG. 19, the sets of rollers are staggered such that the longitudinal axes of the rollers of the first and third columns (as measured from the left side of the treadmill when viewing the treadmill from behind) are aligned and the longitudinal axes of the second and fourth columns of rollers are also aligned but the longitudinal axes of the first and third columns and the second and fourth columns are staggered or offset. This assembly provides advantages in manufacturing and assembly while retaining the user feedback advantages identified above. In some embodiments, the cartridge assembly2700provides an additional benefit to the user in the form of foot therapy. As the user strides on the belt passing above the cartridge assembly, the motion of the rollers and treadmill belt cause a slight vibration that passes through the user's foot, stimulating the nerves on the bottom of the user's foot. This vibration simulates a more natural feeling under foot that is more similar to what a user would feel when walking on grass, gravel, etc. This vibration or sensation acts to stimulate the user's brain in a way that a traditional treadmill cannot, as the traditional treadmill provides a more static experience due to a belt passing over a solid deck. This awareness may reduce boredom and increase the user's awareness of sensations sensed by the foot, which may provide additional benefits for therapy users.

Integrated Flywheel Generator

Unlike an electric treadmill that has a motor to turn the treadmill's belt, the belt of a cordless treadmill moves under the force of the user's gait. More force is required to start moving the cordless treadmill's belt than to maintain it in motion. The flywheel generator compensates for these different force requirements by initially decreasing resistance and subsequently increasing resistance once the treadmill's belt is in motion. This provides the user a smooth, controlled experience, similar to what would be experienced by using an electric treadmill.

The flywheel generator (FG) includes a gear system (a transmission) that can control the amount of resistance used to control the treadmill's belt's speed. Initially, the FG measures the user's weight and determines the appropriate gear ratio (i.e., which gear to engage) based upon the user's weight. The user's weight can be determined by any of a variety of techniques, including by using a scale, a resistor, a piston, a “variable impact absorption system” (as described below) or any other weight measurement technique.

The FG's initial gear selection assures that the user is able to smoothly initiate belt movement by walking on the belt, regardless of the user's weight. Without such dynamic gear selection, a heavier person may feel very little resistance, and the belt could possibly move too quickly and injure the user. Similarly, without such dynamic gear selection, a lighter person may feel too much resistance and it may be difficult or uncomfortable for the user to initiate belt rotation.

The integrated flywheel generator is a mechanism for powering the treadmill without requiring electricity. The integrated flywheel generator, along with the variable impact absorption system discussed above, incorporates a sensor (preferably an infrared sensor) to measure a user's weight (e.g., by measuring displacement of the variable impact absorption system or the deflection of the cartridge), select an appropriate “stiffness” of the variable impact absorption system and assign an appropriate gear ratio of the flywheel based on the measured weight so that the effort needed to start and maintain the rotation of the treadmill belt by the user is similar regardless of the user's weight. The treadmill provides the same feel and comfort, and works the same way for an individual regardless of his or her weight. For example, the treadmill will start and stop as responsively for a 90 lb. person as it would for a 350 lb. person.

The integrated flywheel generator includes an electrical generator for generating electricity from the rotational motion of the treadmill and a flywheel for storing the converted energy. In one embodiment, the integrated flywheel generator is preferably rotatably connected to the front roller304via a gearing system. As shown inFIG. 10, the integrated flywheel generator800includes a magnetic housing802enclosing a rotor804. A rotor gear806is attached to the rotor804such that the rotor gear806rotates due to rotation of the front roller304caused by a user walking or running on the treadmill belt110.FIG. 11illustrates the front roller304rotatably connected to the flywheel generator800through a system of gears including, in one embodiment, an 84 tooth gear included in the front roller drive.

In some embodiments, the integrated flywheel generator further includes a 3 speed gear box. Gear ratios for the three speed gear box may be 1:1, 1.25:1, 1.375:1 in one embodiment. In one embodiment, the main driven gear806may be a 38-tooth gear. When the treadmill transmission is in first gear the overall fixed gear ratio is approximately 2.2:1. When the treadmill transmission is in second gear the overall fixed gear ratio is approximately 2.75:1 and when the treadmill transmission is in third gear the overall fixed gear ratio is approximately 3.0:1. In some embodiments, sufficient electricity may be generated by the generator and the flywheel effect such that a separate transmission to increase the rpm and change the rotational speed of the generator may not be needed.

In general, the larger the outer diameter of the flywheel generator, the more efficiently the generator can generate electricity. While, in some embodiments having a wedge frame, such as the embodiment shown inFIGS. 19 and 20, a reduced diameter rear roller may be used, the reduction in diameter of the rear roller does not significantly affect the performance and feel of the treadmill. For a self-propelled treadmill, in order to achieve smooth performance and operation, a large diameter, heavy front roller is needed. Furthermore, the heavy front roller is needed to spin the flywheel generate to maximize the efficiency of energy generation. Therefore, the rotating front roller and flywheel generator are rotating masses used to assist with the feel and operation of the treadmill. In some embodiments, the performance and feel of the treadmill having a wedge-frame can be similar to the feel of a treadmill having a front and rear roller with the same diameter. In some embodiments, the flywheel is a 5 lb flywheel having a 7 inch outer diameter (OD) that is used in conjunction with a 22 lb front roller having a 7.75 inch OD and a transmission having a gear ratio between 4:1 and 6:1. In other embodiments, the OD of the flywheel can be between 6 and 8 inches and can weigh 3 to 7 lbs. In other embodiments, the front roller can weigh between 20 and 25 lbs with an OD between 6 and 9 inches, and the transmission can have a gear ratio between 3:1 and 9:1.

In some embodiments, the integrated flywheel generator desirably provides a variable flywheel effect based on the difference between the available torque and the required torque. The available torque may be defined as a variable amount of torque produced by the treadmill depending on the incline setting of the treadmill and the user's weight, minus friction. The required torque may be defined as the energy needed to rotate the treadmill belt and begin operation of the treadmill. To achieve a smooth, consistent feel of operation for all users, incline settings, speed settings and weights, the flywheel effect may be varied depending on the selected gear ratio. The speed reduction of the generator may be electronically controlled to slow the treadmill speed. Additionally, in some embodiments, the generator may generate sufficient electricity to power the treadmill, including a display unit, such as the display unit162shown inFIG. 14.

In some embodiments, including the embodiment illustrated inFIGS. 14-17, the generator may be integrated inside the front roller assembly120. Integration of the generator within the front roller assembly120may provide the additional benefits of improved ease of assembly and may eliminate the requirement for a separate gearing and gear box assembly.

Additionally, the front roller of the front roller assembly120may be configured with a predetermined weight and configuration to act as a flywheel itself. By allowing the front roller to act as a flywheel, the design may be simplified by eliminating the need for a separate flywheel while still achieving the desired flywheel effect.

Control of the variable flywheel effect is automatic. Sensors within the variable impact absorption system discussed above measure the amount of deck deflection which translates into a weight or impact on the treadmill. The control system, which desirably includes a processor, working memory, and memory containing processor-executable instructions or modules, can determine the amount of available torque and the required torque to operate the treadmill belt from the calculated weight. After obtaining the required weight, the control system can select the appropriate gear ratio for the treadmill.

The integrated flywheel generator can work with the variable impact absorption system to provide a smooth and consistent treadmill operation without loss of energy due to an overly stiff or overly soft treadmill deck, as determined by the treadmill deck deflection. The infrared sensors of the variable impact absorption system can measure the user's weight by measuring displacement of the treadmill deck. Based on the measured deflection, the incline setting of the treadmill, the speed of the belt rotation, and a calculated friction, the control system selects an appropriate “stiffness” of the variable impact absorption system and an appropriate gear ratio of the flywheel such that the effort needed to start and maintain rotation of the belt is consistent regardless of the user's weight. In some embodiments, an energy storage unit (e.g., a battery, capacitor, etc.) may be provided with any of the treadmills described herein to store electrical energy generated by the flywheel generator.

To maintain a constant rate of desired speed, some embodiments of the self-propelled treadmill incorporate a multifaceted method of speed control. In some embodiments, speed control of the treadmill can include eddy current braking. An eddy current system, such as the system2800shown inFIG. 22, like a conventional friction brake, is a device used to slow or stop a moving object by dissipating its kinetic energy as heat. However, unlike electro-mechanical brakes, in which the drag force used to stop the moving object is provided by friction between two surfaces pressed together, the drag force in an eddy current brake is an electromagnetic force between a magnet and a nearby conductive object in relative motion, due to eddy currents induced in the conductor through electromagnetic induction.

A conductive surface moving past a stationary magnet will have circular electric currents called eddy currents induced in it by the magnetic field. The circulating currents will create their own magnetic field which opposes the field of the magnet. Thus the moving conductor will experience a drag force from the magnet that opposes its motion, proportional to its velocity. The electrical energy of the eddy currents is dissipated as heat due to the electrical resistance of the conductor.

Another advantage of eddy current braking is that since the brake does not work by friction, there are no brake shoe surfaces to wear out, necessitating replacement, as with friction brakes. A disadvantage of eddy current braking is that since the braking force is proportional to velocity, the brake has no holding force when the moving object is stationary, as is provided by static friction in a friction brake. An eddy current brake can be used to stop rotation of the treadmill belt quickly when power is turned off or another indication is received by the control system to stop the treadmill (such as detecting a user in an area outside the main running surface, etc.). However, when the treadmill is stationary, other speed control methods, such as resistive braking and frictional braking, described below, may be used.

The selection of the material of the flywheel has a strong relationship to the efficiency of the eddy current braking system. For example, a flywheel made of a more conductive material such as a copper, aluminum, or steel rotating at a high speed with high input voltage can improve the performance of the eddy current braking. However, at low speeds very little electrical energy is generated by the flywheel generator and the eddy current braking system may not be sufficient to control the speed of the treadmill belt.

In cases where eddy current braking is insufficient to control the speed of the treadmill, other types of control may be used. In some embodiments, resistive braking using high power resistors in line with the output of the generator can be used to control the treadmill speed. The resistors “resist” the energy flow of the generator causing a slowing effect of the generator that in turn slows the speed of the treadmill. To increase the speed of the generator, resistance is removed or decreased.

In cases where both resistive and eddy current braking are insufficient to slow the treadmill, or at other times when treadmill speed control is desired, such as in response to an automatic stop command, friction braking may be used along with one or more of eddy current and resistive braking or in lieu of one or more of the other control methods. Mechanical friction may be applied to slow or stop rotation of the front roller or flywheel through the application of hydraulic pressure via brake pads to a hard steel disc, as shown inFIG. 23. The frictional brake2820acts on the wheel2830in response to an instruction received from the control system to slow or stop the treadmill. Any type of frictional or mechanical brake may be used, including mountain bike disc brakes, etc. The brake pad2820may be made from any material such as ceramic, steep, bimetal, or in combination thereof.

Flywheel Generator System Overview

FIG. 12illustrates one example of a control system900configured to operate a cordless treadmill with electricity generated by the operation of the treadmill by a user. The illustrated embodiment is not meant to be limiting, but is rather illustrative of certain components in some embodiments. System900may include a variety of other components for other functions which are not shown for clarity of the illustrated components.

The system900may include a flywheel generator910, a plurality of variable impact absorption system (VIAS) sensors911, and an electronic display930. Certain embodiments of electronic display930may be any flat panel display technology, for example an LED, LCD, plasma, or projection screen. Electronic display930may be coupled to the processor920for receiving information for visual display to a user. Such information may include, but is not limited to, visual representations of files stored in a memory location, software applications installed on the processor920, user interfaces, and network-accessible content objects.

The system900may include may employ one or a combination of sensors911, such as infrared sensors. The system900can further include a processor920in communication with the sensors911and the flywheel generator910. A working memory935, electronic display930, and program memory940are also in communication with processor920.

In some embodiments, the processor920is specially designed for treadmill operations. As shown, the processor920is in data communication with, program memory940and a working memory935. In some embodiments, the working memory935may be incorporated in the processor920, for example, cache memory. The working memory935may also be a component separate from the processor920and coupled to the processor920, for example, one or more RAM or DRAM components. In other words, althoughFIG. 12illustrates two memory components, including memory component940comprising several modules and a separate memory935comprising a working memory, one with skill in the art would recognize several embodiments utilizing different memory architectures. For example, a design may utilize ROM or static RAM memory for the storage of processor instructions implementing the modules contained in memory940. The processor instructions may then be loaded into RAM to facilitate execution by the processor. For example, working memory935may be a RAM memory, with instructions loaded into working memory935before execution by the processor920.

In the illustrated embodiment, the program memory940includes a deck deflection measurement module945, a weight calculation module950, a torque calculation module955, operating system965, and a user interface module970. These modules may include instructions that configure the processor920to perform various processing and device management tasks. Program memory940can be any suitable computer-readable storage medium, for example a non-transitory storage medium. Working memory935may be used by processor920to store a working set of processor instructions contained in the modules of memory940. Alternatively, working memory935may also be used by processor920to store dynamic data created during the operation of treadmill system900.

As mentioned above, the processor920may be configured by several modules stored in the memory940. In other words, the process920can execute instructions stored in modules in the memory940. Deck deflection module945may include instructions that configure the processor920to obtain deck deflection measurements from the VIAS sensors911. Therefore, processor920, along with deck deflection module945, VIAS sensors911, and working memory935, represent one technique for obtaining deck deflection data.

Still referring toFIG. 12, memory940may also contain weight calculation module950. The weight calculation module950may include instructions that configure the processor920to calculate a weight of a user based on the measured deck deflection. Therefore, processor920, along with weight calculation module950, and working memory935, represents one means for calculating a treadmill user's weight.

Memory140may also contain torque calculation module955. The torque calculation module955may include instructions that configure the processor920to calculate the available torque and required torque of the treadmill from the weight calculation determined from the measured deck deflection. For example, the processor920may be instructed by the torque calculation module955to calculate the available torque and the required torque and store the calculated torques in the working memory935or storage device925. Therefore, processor920, along with weight calculation module950, torque calculation module955, and working memory935represent one means for calculating and storing torque calculations.

Memory940may also contain user interface module970. The user interface module970illustrated inFIG. 12may include instructions that configure the processor920to provide a collection of on-display objects and soft controls that allow the user to interact with the device. The user interface module970also allows applications to interact with the rest of the system. An operating system module965may also reside in memory940and operate with processor920to manage the memory and processing resources of the system900. For example, operating system965may include device drivers to manage hardware resources for example the electronic display930or sensors911. In some embodiments, instructions contained in the deck deflection module945, weight calculation module950and torque calculation module955may not interact with these hardware resources directly, but instead interact through standard subroutines or APIs located in operating system965. Instructions within operating system965may then interact directly with these hardware components.

Processor920may write data to storage module925. Storage module925may include either a disk-based storage device or one of several other types of storage mediums, including a memory disk, USB drive, flash drive, remotely connected storage medium, virtual disk driver, or the like.

AlthoughFIG. 12depicts a device comprising separate components to include a processor, sensors, electronic display, and memory, one skilled in the art would recognize that these separate components may be combined in a variety of ways to achieve particular design objectives. For example, in an alternative embodiment, the memory components may be combined with processor components to save cost and improve performance.

Additionally, althoughFIG. 12illustrates two memory components, including memory component940comprising several modules and a separate memory935comprising a working memory, one with skill in the art would recognize several embodiments utilizing different memory architectures. For example, a design may utilize ROM or static RAM memory for the storage of processor instructions implementing the modules contained in memory940. Alternatively, processor instructions may be read at system startup from a disk storage device that is integrated into system100or connected via an external device port. The processor instructions may then be loaded into RAM to facilitate execution by the processor. For example, working memory935may be a RAM memory, with instructions loaded into working memory935before execution by the processor920.

Gear Ratio Control Process

FIG. 13illustrates one example of an embodiment of a process500to configure a cordless treadmill to have a smooth and consistent operation for users having different weights. Specifically, the process illustrated inFIG. 13preferably allows users of different weights to smoothly start and maintain rotation of the treadmill belt. In some examples, the process500may be run on a processor, for example, processor920(FIG. 12), and on other components illustrated inFIG. 12that are stored in memory940or that are incorporated in other hardware or software.

The process as illustrated inFIG. 13determines the weight of a user, which may be determined by directly weighing the user, by measuring deck deflection of the treadmill, or through other means, and uses the determined weight to determine both the torque available to rotate the treadmill belt and the torque required to rotate the treadmill belt. The process500begins at start block502and transitions to block504wherein a processor, for example, processor920, is instructed to measure an amount of deck deflection due to a user's weight and based on the amount of deck deflection, determine the user's weight. The process500then transitions to block506, wherein the processor is instructed to determine the available torque based on settings of the treadmill such as the amount of incline and the user's weight and speed of movement on the treadmill. As noted above, the available torque is the variable amount of torque available due to the user's weight and treadmill settings such as the incline setting of the treadmill deck minus a predetermined friction of the treadmill components, such as the treadmill belt, front and rear rollers, and flywheel/gear system. Once the available torque has been determined, process500transitions to block508. In block508, the processor is instructed to determine the required torque, which is the amount of torque necessary to initiate rotation of the belt. After determining the required torque, the process500transitions to block510wherein the processor is instructed to determine the appropriate gear ratio for the flywheel generator system, based on the calculated available and required torque, to achieve smooth operation of the treadmill based on the user's weight. Once the appropriate gear ratio has been determined, the process500transitions to block512wherein the processor is instructed to set the appropriate gear ratio for the flywheel generator system such that smooth and efficient operation of the treadmill is achieved. The process500then transitions to block514and ends.

In some embodiments, setting the appropriate gear on the flywheel generator system may further include the stop of determining what braking or speed control method to use, such as resistive braking, eddy current braking, and/or frictional braking, as discussed above.

Automatic Stop

In some embodiments, the treadmill discussed above can include an automatic stop feature that can slow or stop the treadmill belt when a predetermined percentage of the body weight of the user has shifted a predetermined distance from an expected use position. The automatic stop feature works with at least one sensor, such as an infrared (IR) sensor or pressure sensor (or other sensor), and a control system, such as the variable impact absorption system discussed above. The automatic stop preferably provides an automatic safety mechanism for a treadmill belt that is not dependent on any user action, such as clipping on a safety leash.

For example, as a user walks or runs on the treadmill, typically the user's weight is evenly distributed between an area immediately left and right of the centerline of the treadmill belt, which corresponds to the expected path of the user's left and right feet. If, for example, at least 75% of the user's weight has shifted to a far right or far left edge of the treadmill, as determined by the sensor, the control system will act to stop the treadmill belt. Similarly, if more than a predetermined percentage of a user's weight is distributed too far forward or too far behind an expected use position, the control system will act to stop the treadmill belt. The predetermined percentage of the user's weight, or a predetermined weight shift percentage can be selected (e.g., by the user) to control the treadmill sensitivity to changes in user weight shift during use. In some embodiments, the predetermined percentage is 5%, 10%, 25%, 50%, 75% or 90%

In some embodiments, the treadmill may include a sensor controlled emergency stopping system (SCESS). The SCESS uses sensors that may or may not be the same sensors used as part of the VIAS system discussed above to detect where the user's feet are on the deck with relationship to the running surface. The treadmill deck can be divided into a front portion117and a rear portion119, as indicated by line111shown onFIG. 1A. During normal operation, as the user walks or runs on the treadmill, the user steps in the front portion117with one foot while the other foot lifts away from the rear portion119. The user's weight then continuously alternates between the front portion117and the rear portion119as the user strides. For example, if a user steps with their right foot into the front portion117, it is expected that the weight will transfer to the rear portion119as the treadmill belt rolls. If sensors, such as the sensors911, shown as part of the VIAS system illustrated inFIG. 12, or the sensors2911shown inFIG. 21, detect that the user's next step is a step that is not in the expected area (that is, in some embodiments, in the front portion117) or in an undesirable or unsafe area, a signal is sent to the control system to stop the treadmill belt. With continued reference to the above example, if the user's next step with their left foot is not in the front portion117, a control signal can be sent to the control system to stop the treadmill belt. This can prevent a user from being thrown off the back of the treadmill due to failure of the belt to stop rotating when the user is falling or in an unexpected position on the treadmill belt. While a partial set of sensors2911is shown inFIG. 21on one side of the treadmill, additional sensors2911may be located on the other side of the treadmill deck to provide additional indication of the position of the user on the treadmill.

Visual Feedback System

In some embodiments, a real-time, visual feedback system is provided with the treadmill described above or any other fitness machine. The visual feedback system can indicate, for example, impact or duration differences between the user's left leg and right leg, based on sensors (such as pressure or time sensors) located on or below the treadmill deck or cartridge.

The visual feedback system can display these values (e.g., pressure from each foot-impact on deck, time of contact between foot and deck, timing of right and left impact onto deck, changes in such vales, etc.) as a series of lights grading from red to yellow to green to yellow to red. A separate series of lights could be provided for each leg or arm. To indicate that the user has a limp, for example, the lights corresponding to sensors measuring the user's right side could light up in the first red area to indicate that the right leg has a step of a very short duration or very light pressure. The lights corresponding to sensors measuring the user's left side could light up in the second red area to indicate that the left leg has a step of a very long duration or very heavy pressure. Ideally, the user's steps would fall in the green area to indicate light and even impact and duration between the left and right legs.

This feedback system would provide information to aid the user in improving balance. However, the feedback system is not limited to use with a treadmill but could be used for any fitness machine to indicate strength disparities. The feedback system may also be used for physical therapy or to rehabilitate a person recovering from surgery or an injury.

Benefits and Advantages

A treadmill having one or more of the features discussed above has several advantages over a conventional, cordless treadmill. Most notably, a treadmill including the integrated flywheel generator system discussed above will have a smoother start and stop operation with decreased initial startup resistance as compared to a conventional cordless treadmill. Additionally, the treadmill will also generate electricity that may be used to power a control console, illuminate a visual feedback system, or for other purposes.

The treadmill as discussed above will also be easy to assemble due to the “drop in” frame design discussed above. The cartridge design including a pattern of staggered rollers centered on the treadmill running or walking surface desirably provides a smooth and consistent surface for the user. Constant contact between the belt and the rollers reduces energy losses and improves energy transfer to the electrical generator.

Increased safety and user features are desirably provided by the automatic stop and visual feedback systems, which may be particularly useful for use in a rehabilitation context.

Clarifications Regarding Terminology

Embodiments have been described in connection with the accompanying drawings. However, it should be understood that the figures are not drawn to scale. Distances, angles, etc. are merely illustrative and do not necessarily bear an exact relationship to actual dimensions and layout of the devices illustrated. In addition, the foregoing embodiments have been described at a level of detail to allow one of ordinary skill in the art to make and use the devices, systems, etc. described herein. A wide variety of variation is possible. Components, elements, and/or steps can be altered, added, removed, or rearranged. While certain embodiments have been explicitly described, other embodiments will become apparent to those of ordinary skill in the art based on this disclosure.

Depending on the embodiment, certain acts, events, or functions of any of the methods described herein can be performed in a different sequence, can be added, merged, or left out altogether (e.g., not all described acts or events are necessary for the practice of the method). Moreover, in certain embodiments, acts or events can be performed concurrently, e.g., through multi-threaded processing, interrupt processing, or multiple processors or processor cores, rather than sequentially.