Abstract:
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.

Description:
FIELD OF THE INVENTION 
       [0001]    This invention relates to exercise equipment and more particularly to stair exerciser equipment for simulating stair climbing. 
       SUMMARY OF THE INVENTION 
       [0002]    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. 
         [0003]    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. 
         [0004]    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. 
         [0005]    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. 
         [0006]    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. 
         [0007]    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 of 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. 
         [0008]    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. 
         [0009]    A console, mounted to the frame at a position above the upper shaft, provides operating, goal-setting, and other health related information. 
         [0010]    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. 
         [0011]    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. 
         [0012]    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. 
         [0013]    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. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0014]      FIG. 1  is a perspective view of a stair exerciser constructed in accordance with the present invention; 
           [0015]      FIG. 2  is a left side elevation of the stair exerciser of  FIG. 1 ; 
           [0016]      FIG. 3  is a left side elevation of the stair exerciser of  FIG. 1  with the housing removed, showing the frame and other internal components; 
           [0017]      FIG. 4  is cut-away view of the left side elevation of  FIG. 3 , showing steps and the endless chain conveyor; 
           [0018]      FIG. 5  is a perspective view of a removable tray and a stationary platform from the stair exerciser of  FIG. 1 ; 
           [0019]      FIG. 6  is a bottom view of the stationary platform of  FIG. 5 ; 
           [0020]      FIG. 7  is a view of an access panel from the stair exerciser of  FIG. 1 ; 
           [0021]      FIG. 8  is a perspective view of a caster from the stair exerciser of  FIG. 3 ; 
           [0022]      FIG. 9  is a left side elevation of the caster shown in  FIG. 8 ; 
           [0023]      FIG. 10  is a close-up view of the caster from the stair exerciser of  FIG. 3  showing the leveling feature of the caster. 
       
    
    
     DETAILED DESCRIPTION  
       [0024]    Referring now to  FIG. 1 , a preferred embodiment of a stair type exercising device  100  is illustrated having a stationary frame  20  and a plurality of steps  30  supported by the frame  20  and able to move with respect to the frame  20 . The steps  30  are pivotally l inked together and are attached to a pair of chain assemblies, forming an endless chain conveyor  12 . The steps  30  are configured to move in a downward and backward direction as the endless chain conveyor  12  revolves in a cyclical fashion about an upper shaft  18  (shown in  FIGS. 3-4 ) and a lower shaft  15  (shown in  FIGS. 3-4 ). 
         [0025]    The stair exerciser  100  includes a housing  50 , removable access panels  60  covering access hatch openings in the housing  50 , a hand rail  90 , and couple of handlebars  92 . Each handlebar  92  has contact heart rate pulse sensor  95  built into the handlebar  92 . In addition, each handlebar  92  has control buttons  97  incorporated into the handlebar  92 . The control buttons  97  on the handlebar  92  can include controls such as speed control, resistance control, start, stop, and pause. The frame  20  includes a base  25  and a mast  98 . The mast  98  supports a console  120  with a display screen enabled to provide feedback to an operator. The console  120  may also include input devices to enable an operator to provide information to the stair exerciser  100 . 
         [0026]    Each of the steps  30  consists of a step platform  32  and a step riser  34 . The step platforms  32  and step risers  34  are connected to each other by hinge pins so that each step  30  is pivotally connected to the next step  30 , and the steps  30  each have pivots between step platform  32  and the step riser  34 . The steps  30  are connected at the bottom of a step riser  34  by connecting pins  33 , and the step platforms  32  and step risers  34  are connected to each other at the top of a step riser  34  by guide pins  35 . The plurality of steps  30  are formed by alternating a step platform  32 , a connecting pin  33 , a step riser  34 , a guide pin  35 , and back to another step platform  32 . The connecting pins  33  are connected to the endless chain conveyor  12 . 
         [0027]    The step platform  32  is a first color. The color could be molded into a plastic part, or the step platform  32  could 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 platform  32 , and to easily identify the step platform  32 . The step riser  34  is 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 platform  32  and to plant a foot firmly situated on the step platform  32  without kicking the step riser  34 . To aid in foot placement, the step platform  32  is 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 platform  32 . The step riser  34  is approximately 9 inches tall so that each step up to the next step platform  32  is a reasonable distance, similar to steps in a building. 
         [0028]    The stair exerciser  100  is illustrated with a stationary platform  70  located below and behind the steps  30  at the entrance to the stair exerciser  100 . The stationary platform  70  provides a convenient platform for an operator to stand upon before stepping onto a step  30  of the stair exerciser  100  to start exercising. Similarly, the stationary platform  70  provides a convenient surface upon which an operator can step when exiting the stair exerciser  100 . The stationary platform  70  is connected to a switch  75  (shown in  FIG. 6 ), which may be configured to generate a load signal  76  to indicate when a load such as the weight of an operator is upon the stationary platform  70 . 
         [0029]    A removable debris tray  80  is illustrated below the steps  30 , adjacent to the stationary platform  70 . As the steps  30  revolve along with the endless chain conveyor  12 , dust, dirt and debris is transported along with the steps  30  until the steps  30  revolve down and around the lower shaft  15 . As the steps  30  revolve around and underneath the lower shaft  15 , the dust, dirt and debris drop from the steps  30  and are captured by the debris tray  80 . The debris tray  80  may be removed to dispose of the captured debris, whereupon the clean debris tray  80  is returned to the stair exerciser  100  for further use. In addition to capturing dry debris, the debris tray is configured to also capture liquids. The housing  50  includes channels  85  configured to direct perspiration or other liquids spilled onto the housing  50  to flow down the channel  85  toward the debris tray  80 . 
         [0030]      FIG. 1  also illustrates a number of other features. Cup holders  99  are shown mounted to the hand rail  90 . The base  25  includes a metal tube wrapping around the periphery of the stair exerciser  100  to protect the housing  50  from being accidentally kicked. The base  25  also includes a front support  28 , and the front support  28  includes a transport wheel  27  on either side of the front support  28  to assist in moving the stair exerciser  100 . There are a pair of locking and leveling casters  170  (shown in  FIGS. 3-4 ) located underneath the stationary platform  70  that also assist in moving the stair exerciser  100 . 
         [0031]    Referring now to  FIG. 2 , a side view of the stair exerciser  100  shows the stair exerciser  100  resting on a support surface  10 , such as a floor. The stair exerciser  100  has a housing  50  with a second removable access panel  60  on the left side of the stair exerciser  100 . The front support  28  is shown with the previously unseen transport wheel  27  on the left side of the stair exerciser  100 . The transport wheels  27  aid in the transport of the entire stair exerciser  100  from one location to another. 
         [0032]    Referring to  FIG. 3 , the stair exerciser  100  is illustrated with the covers removed to reveal internal features. The frame  20  is shown more clearly. The frame  20  includes the base  25 , a front support  28 , the mast  98 , an inclined track  24  for supporting the endless chain conveyor  12  and the connecting pins  33  of the steps  30 , and a guide rail  23  for supporting the guide pins  35  of the steps  30 . A lower shaft  15  and an upper shaft  18  are rotatably mounted to the frame  20 . The lower shaft  15  is connected to a pair of lower sprockets  16 , and the upper shaft  18  is connected to a pair of upper sprockets  19 . The endless chain conveyor  12  and the steps  30  are illustrated to be revolvably mounted about lower shaft  15  and the upper shaft  18 . 
         [0033]    The endless chain conveyor  12  is shown to have an upper run  14  configured to position a number of steps  30  for exercise use, and a lower run  13  configured to be a return path for the endless chain conveyor  12 . The inclined track  24  supports and guides the connecting pins  33  and the upper run  14  of the endless chain conveyor  12  as the steps  30  move downward and backward along the inclined track  24 . Because the inclined track  24  supports the connecting pins  33  and the connecting pins  33  are connected to the bottom of a step riser  34 , the inclined track  24  positions the bottom of each step riser  34  as it travels along the upper run  14  of endless chain conveyor  12 . The guide rail  23  supports and guides the guide pins  35  as the steps  30  move downward and backward along the inclined track  24 . Because the guide rail  23  supports the guide pins  35  and the guide pins  35  are connected to the top of a step riser  34 , the guide rail  23  positions the top of each step riser  34  as it travels along the upper run  14  of endless chain conveyor  12 . 
         [0034]      FIG. 3  also illustrates a microprocessor or controller  125  configured to receive electrical input signals from various sources such as a tachometer  155 , a position sensor  130 , a load switch  75 , or a console  120 . The controller  125  is configured to output various control signals to other devices such as a braking mechanism  150  or a locking mechanism  160 . The controller  125  is shown as a separate unit mounted to the frame  20 , but one skilled in the art will understand that the controller  125  could be located elsewhere such as embedded inside of the console  120 . 
         [0035]    A tachometer  155  is shown mounted onto the frame  20 . The tachometer  155  measures the speed of the moving steps  30  and provides a speed signal to the controller  125 . A position sensor  130  is shown mounted onto the frame  20 . 
         [0036]    The position sensor  130  provides position information  131  to the controller  125 , where the position information  131  informs the controller  125  of the relative position of the steps  30  along the cyclical path followed by the steps  30  and the endless chain conveyor  12 . 
         [0037]    A braking mechanism  150  is shown mounted onto the frame  20  next to a flywheel  152 . The braking mechanism  150  is controlled by control signals sent by the controller  125 . The braking mechanism  150  is adjustable so that the amount of braking force may be increased or decreased by the controller  125 . The flywheel  152  is connected by belts and pulleys to the upper shaft  18 , though the flywheel could easily be connected instead to the lower shaft  15 . As the steps  30  of the stair exerciser  100  are driven downward by an external load, such as the weight of an operator standing upon one or more of the steps  30 , the endless chain conveyor  12  revolves about the upper shaft  18  and the lower shaft  15 , causing the upper shaft  18  to rotate. The rotation of the upper shaft  18  drives the rotation of the flywheel  152 . As the flywheel  152  rotates, the braking mechanism  150  provides an opposing torque to the flywheel  152 , thereby slowing down the rotation of the flywheel  152  and the speed of the steps  30 . The braking mechanism  150  may be an eddy current brake (ECB), a friction brake, or any other brake that is known in the art. 
         [0038]    A locking mechanism  160  (not shown) is coupled to the upper shaft  18 . The locking mechanism  160  is configured to prevent the upper shaft  18  from rotating and to prevent the steps  30  from moving when the locking mechanism  160  is engaged. When the steps  30  are stationary, the locking mechanism  160  is engaged by the controller  125  to ensure the steps  30  remain stationary. An operator stepping onto the steps  30  or stepping from the steps  30  down to the stationary platform  70  will find the process much easier when the steps  30  are locked in a stationary position. 
         [0039]    The steps  30  may also be brought to a controlled stop when the steps  30  are moving. The controller  125  first engages the braking mechanism  150  to slow or stop the motion of the steps  30 . The controller  125  uses the position information  131  from the position sensor  130  to slow the motion of the steps  30  when the steps  30  are near a predetermined stopping position along the cyclical path followed by the steps  30  and the endless chain conveyor  12 . The controller  125  further engages the braking mechanism  150  to fully stop the motion of the steps  30  when the steps  30  are located at the predetermined stopping position along the cyclical path. The controller  125  then engages the locking mechanism  160  to prevent additional movement of the steps  30 . The controller  125  is able to consistently bring the steps  30  to the same predetermined stopping position any time the controller  125  stops the steps  30  of the stair exerciser  100 . 
         [0040]    Referring now to  FIGS. 3-4 , a caster  170  is located near the back end of the stair exerciser  100 . The caster  170  serves much the same purpose as the transport wheel  27  located on the front support  28 . The casters  170  and the transport wheels  27  allow the stair exerciser  100  to be rolled from one location to another location. The casters  170  will be discussed in greater detail when  FIGS. 8-10  are discussed. 
         [0041]    Referring now to  FIG. 4 , the lowest step platform  32  on the upper run  14  of the endless chain conveyor  12  is shown at an angle (A) relative to a horizontal line. The step riser  34  supporting the rear portion of the step platform  32  has begun to wrap around the lower sprocket  16  on the lower shaft  15 , causing the rear portion of the step platform  32  to drop below the elevation of the front portion of the step platform  32 . The elevation of the rear portion of the step platform  32  is at an elevation H relative to the support surface  10 . The elevation of the front portion of the step platform  32  is at an elevation (H+h) relative to the support surface  10 . This difference in elevation (h) between the front portion and rear portion of the step platform  32  orients the step platform in a plane that is at an angle (A) relative to a horizontal plane. If the depth of the step platform  32  is a constant depth (d), then the angle (A) of the step platform  32  is: 
         [0000]      Tan( A )=( h/d ) 
         [0000]      Or 
         [0000]      ( A )=Arctan ( h/d ) 
         [0042]    It is beneficial to an operator of the stair exerciser  100  to minimize the step-up height of the stair exerciser  100 . That is, a lower step-up height makes it easier for an operator to mount the lowest step  30  of the stair exerciser  100  from the stationary platform  70 , and a lower step-up height make it easier for an operator to dismount from the lowest step  30  of the stair exerciser  100  to the stationary platform  70 . 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 platform  32 . A lower front portion of the step platform  32  means a lower step-up height (H). However, increasing the difference in elevation (h) between the front portion and rear portion of the step platform  32  also increases the angle (A) of the orientation of the step platform  32 . Therefore, care must be taken to choose a predetermined stopping location for the steps  30  such that the step-up height (H) is low for the convenient entering and exiting of the stair exerciser  100 , while keeping the angle (A) of the orientation of the step platform  32  low enough to ensure that an operator will not slip off the of the step platform  32 . 
         [0043]    The angle (A) for the lowest step platform  32  may 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 platform  32  at any of these angles (0-30 degrees from the horizontal plane) provides a surface that may easily be stood upon. 
         [0044]    The step-up height (H) for the lowest step platform  32  may be 0 inches above the support surface  10  or ground, or it may be 5 inches, 10 inches, 12 inches, 13 inches, 14 inches, or 15 inches above the support surface  10 . A step platform  32  at any of these step-up heights  10  or elevations (0-15 inches above the support surface) provides a reasonable step-up height from the support surface  10 . 
         [0045]    The controller  125  has the ability to bring the steps  30  to a controlled stop at any position along the cyclical path followed by the steps  30  and the endless chain conveyor  12 . In the preferred embodiment, the controller  125  is configured to bring the steps  30  to a predetermined controlled stop location that will position the lowest step platform  32  having a relatively low elevation or step-up height (H) of approximately 13 inches above the support surface  10 , and having a relatively low orientation angle (A) of approximately 17.5 degrees from a horizontal plane. 
         [0046]    Referring now to  FIG. 5 , a close-up view of the removable debris tray  80  and the stationary platform  70  are shown. The stationary platform  70  has hook features  78  to connect the stationary platform  70  to the frame  20 . The stationary platform  70  also has a mating feature  72  to connect to a loop  82  on the debris tray  80 . By connecting the debris tray  80  to the stationary platform  70 , and by connecting the stationary platform  70  to the frame  20 , the stationary platform  70  and the debris tray  80  become an integral part of the stair exerciser  100 , and move with the stair exerciser  100  as a single unit. 
         [0047]    In  FIG. 6 , the underside of the stationary platform  70  has a load switch  75  for sending a load signal  76  to the controller  125 . The load switch  75  detects when an operator is standing on the stationary platform  70 , and sends the load signal  76  to the controller  125 . The controller  125  then brings the steps  30  to a controlled stop if the steps  30  are moving, and the controller  125  engages the locking mechanism  160  to prevent any further motion of the steps  30 . The operator may then easily step up onto the steps  30  of the stair exerciser  100  while the steps  30  are locked into a stationary position. 
         [0048]    Referring now to  FIG. 7 , the removable access panel  60  is shown. The access panel  60  has locking tabs  68  along one side that may be snapped into an access hatch opening in the housing  50  to quickly attach the one side of the access panel  60  to the housing  50 . The access panel  60  as shown also has two quick locking fasteners  65  that can be screwed into the housing  50 . The quick locking fasteners  65  are configured to remain attached to the access panel  60  at all times, so the quick locking fasteners  65  will not fall out and get lost like a typical screw fastener. The quick locking fasteners  65  shown only require a quarter-turn of the quick locking fastener  65  to connect the access panel  60  to the housing  50 . By using a combination of snap-fit locking tabs  68  to attach one side of the access panel  60  and a limited number of quick locking fasteners  65  to retain the other side of the access panel  60 , the removable access panel  60  may 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. 
         [0049]    Referring now to  FIGS. 8-10 , the casters  170  have a caster wheel  175  much like the transport wheel  27  (shown in  FIGS. 3-4 ). However, the casters  170  also have a wheel lock  176  to prevent rotation of the caster wheel  175 . By locking the wheel lock  176 , the stair exerciser  100  is held in a stationary position, and by unlocking the wheel lock  176 , the stair exerciser  100  is able to be rolled about on the two caster wheels  175  and two transport wheels  27  for relocation of the stair exerciser  100 . 
         [0050]      FIG. 10  shows the caster  170  pivotally connected to the base  25 . The caster  170  is configured to be raised and lowered relative to the base  25 , allowing the caster  170  to be used to level the stair exerciser  100 . A bearing plate  179  is mounted to the caster  170  at a distance from a pivot axle  178 . The pivot axle  178  pivotally connects the caster  170  to the base  25 , such that the caster  170  may pivot up or down about the pivot axle  178 . A height adjustment screw  180  is screwed into a hole in the top of the base  25  and is driven down until it contacts the bearing plate  179  of the caster  170 . The height adjustment screw  180  prevents the caster  170  from pivoting up any higher than the point at which the bearing plate  179  contacts the height adjustment screw  180 . By adjusting the position of the height adjustment screw  180  in the base  25 , the caster  170  can be lowered relative to the base  25  so that all four wheels (the two transport wheels  27 , and the two caster wheels  175 ) are all in contact with the support surface  10 . When all four wheels are in firm contact with the support surface  10 , the stair exerciser  100  is properly leveled. 
         [0051]    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.