Patent Description:
Relevant background information can be found in the following U. patent documents.

<CIT> discloses an exercise machine having a first frame member, a second frame member that is movable with respect to the first frame member, and a locking device configured to retain the second frame member in position which frees the second frame member for movement with respect to the first frame member.

<CIT> and <CIT> disclose exercise bicycles and several mechanisms for permitting a user to adjust the seat on an exercise bicycle. The described mechanisms can be used to adjust the height of the seat or the fore and aft positioning of the seat on an upright-type bicycle.

<CIT> discloses a mechanism mounted on a stationary exercise bicycle including a frame, a rear seat, a front drive mechanism having a pedal at either side, and a numeric display. In one embodiment, the mechanism includes a mounting assembly fixedly mounted at one side of the frame and including upper and lower mounting lugs; and an arm including an upper section secured to the display and a lower section having a distal end releasably secured to the upper section and a proximal end pivotably fastened between the mounting lugs. The display is adapted to dispose in a first position in front of the seat, in a second position at one side of the frame or in a position between the first position and the second position by pivoting about the mounting assembly.

According to the invention, the problem posed is solved by the exercise machine of claim <NUM>.

The present disclosure provides an example of an exercise machine that extends between a front and a rear in a longitudinal direction, between a first side and an opposite, second side in a lateral direction that is perpendicular to the longitudinal direction, and between a top and a bottom in a vertical direction that is perpendicular to the longitudinal direction and perpendicular to the lateral direction, the exercise machine comprising a frame for supporting a user of the exercise machine, a base member, and a console assembly comprising a handlebar for engagement by the user and a display for displaying and/or controlling an operational characteristic of the exercise machine, wherein the console assembly is coupled to and longitudinally movable relative to the frame to facilitate adjustment of the handlebar and the display relative to the user, and a carriage that is longitudinally slidable back and forth relative to the base member, wherein the exercise machine further comprises a locking device configured to lock the console assembly in position relative to the frame, wherein the locking device includes a pivot lever having an elongated body with a first end for manually grasping by the user and an opposite, second end that is pivotable about a pivot shaft, the pivot lever being centered on the console assembly and located forwardly of the handlebar such that pulling the first end of the pivot lever towards the handlebar brings the pivot lever into a raised position and pushing the first end of the pivot lever away from the handlebar brings the pivot lever into a lowered position.

In independent aspects, the console assembly may be longitudinally slidable relative to the frame. The locking device may comprise a cam that causes the locking device to clamp the console assembly to the frame upon pivoting the pivot lever.

In independent aspects, the locking device may be configured to clamp the console assembly in position relative to the frame. The locking device may be manually operable by the user.

In independent aspects, the display may comprise a screen that extends upwardly at an angle relative to the handlebar, wherein said angle remains constant as the console assembly is longitudinally moved relative to the frame.

In independent aspects, the console assembly may further comprise a wireless charger.

In independent aspects, the console assembly may be longitudinally adjustable into and between a forwardmost position relative to the frame and a rearwardmost position relative to the frame and the locking device may be configured to lock the console assembly in place relative to the forwardmost position and the rearwardmost position.

In independent aspects, the handlebar and the display may be coupled to the carriage. The handlebar may be rigidly coupled to the carriage along two planes that are transverse to each other. The display may be rigidly coupled to the carriage along two planes that are transverse to each other. The carriage may comprise a body having a first end and a second end, and wherein the display may be fastened to the first end and separately fastened to the body, and wherein the handlebar may be fastened to the second end and separately fastened to the body. The carriage may be coupled to the base member by opposing slide rails and opposing slide bearings that support sliding of the opposing slide rails. The exercise machine may further comprise a cable assembly for providing power and/or electrical communication to the console assembly, wherein the cable assembly may be disposed in the frame and may be coupled to and move with the carriage relative to the base member.

In independent aspects, a stop device may prevent sliding of the carriage past a forwardmost position relative to the base member and may prevent sliding of the carriage past a rearwardmost position relative to the base member.

The carriage may be coupled to the base member by opposing slide rails and opposing slide bearings supporting sliding of the opposing slide rails, and the stop device may comprise a bumper that operatively engages at least one slide bearing of the opposing slide bearings to prevent sliding of the carriage past the forwardmost position and that operatively engages at least one slide bearing of the opposing slide bearings to prevent sliding of the carriage past the rearwardmost position.

In independent aspects, the locking device may be configured to lock the carriage in position relative to the base member.

The locking device may be configured to clamp the console assembly in position relative to the frame, and the locking device may be manually operable by the user.

The locking device may further comprise a cam block, a cam shaft coupled to a cam and extending through the cam block, the carriage, and the base member, and a clamp head on the cam shaft, wherein pivoting the pivot lever applies a camming force on the clamp head that clamps the carriage between the base member and the clamp head.

Various other features, objects and advantages of the disclosure will be made apparent from the following description taken together with the drawings.

The present disclosure includes the following drawing Figures.

During research and development in the field of exercise machine, the present inventors have identified a need for improved machines having adjustability for accommodating differently sized users. The present inventors have also identified a need for improved assembly methods for such exercise machines which are efficient and effective, including without compromising alignment and long-term reliable functionality of the assembled components. The present disclosure is a result of these efforts.

The following detailed description refers to an example stationary exercise bike shown in the appended drawing figures. However, it should be understood that the present disclosure is applicable to a wide variety of other types and configurations of exercise machines, including but not limited to elliptical machines, treadmills, arc trainers, and/or the like. The present disclosure is also applicable to a wide variety of other types and configurations of exercise bikes, including but not limited to upright bikes and recumbent bikes. The illustrated stationary exercise bike is provided for discussion purposes only and is not intended to limit the scope of this disclosure or the appended claims.

<FIG> depicts an exercise machine, which in the illustrated example is a stationary exercise bike <NUM>. The bike <NUM> extends in three dimensions, including between a front and a rear in a longitudinal direction LO, between a first side and an opposite, second side in a lateral direction LA that is perpendicular to the longitudinal direction LO, and between a top and a bottom in a vertical direction V that is perpendicular to the longitudinal direction LO and perpendicular to the lateral direction LA. The bike <NUM> has a frame <NUM> (see <FIG>), which is cladded by a shroud <NUM> such that only limited portions of the frame <NUM> are visible. The frame <NUM> provides a rigid framework or other structure for supporting components of the bike <NUM> and for supporting a user seated on the bike <NUM> while performing a pedaling exercise motion. A seat post <NUM> and seat <NUM> extend upwardly from the frame <NUM> and are for supporting the user in a seated position. Pedals <NUM> are located on opposite sides of the bike <NUM> and are configured for engagement by the user's feet and performance of the noted pedaling exercise motion. Although not shown in the figures, the pedals <NUM> may be operatively coupled to a resistance mechanism such as a flywheel and/or brake and/or the like, configured to resist rotation the pedals <NUM>. The height of the seat <NUM> may be adjustable relative to the pedals <NUM> to accommodate users of different height, for example according to examples shown the above-referenced patents.

The frame <NUM> has front and rear legs <NUM> that laterally extend from opposite sides of the bottom of the bike <NUM>. The front and rear legs <NUM> are configured to support the bike <NUM> and prevent tipping of the bike <NUM> relative to the ground or other supporting surface. Adjustable feet <NUM> may be provided on the bottom of each of the front and rear legs <NUM> for engaging and leveling the bike <NUM> relative to the ground or supporting surface.

Referring to <FIG>, the frame <NUM> has a support column <NUM>. The support column <NUM> is a rigid elongated member that extends upwardly at the front of the bike <NUM>. The upper end of the support column <NUM> has a pedestal <NUM>. The pedestal <NUM> is provided by a base bracket <NUM> having opposite sides <NUM> that extend upwardly and laterally outwardly relative to the support column <NUM>. A trough <NUM> is defined laterally between the sides <NUM>. The bottom <NUM> of the trough <NUM> defines an opening <NUM> (see <FIG>) to the interior <NUM> of the support column <NUM>. Opposing mounting flanges <NUM> extend laterally outwardly from the angled sides <NUM>. Apertures <NUM> are defined through one of the mounting flanges <NUM>. Each aperture <NUM> is a round hole. Apertures <NUM> are defined through the other mounting flange <NUM>. Each aperture <NUM> is a laterally elongated slot. Alignment holes <NUM> are also defined in the mounting flanges <NUM>.

A base member <NUM> is mounted on the pedestal <NUM>. In the illustrated example, the base member <NUM> is a plate member that extends over the trough <NUM> and has laterally opposite sides <NUM> that are fastened to the mounting flanges <NUM> of the pedestal <NUM>. A centrally raised portion <NUM> protrudes upwardly relative to the opposite sides <NUM> and has a longitudinally elongated slot <NUM> formed therein. Fasteners <NUM> extend through the apertures <NUM> in the mounting flange <NUM> and through corresponding apertures <NUM> in the base member <NUM>. Each fastener <NUM> has a threaded shaft <NUM> and conical head <NUM>, which, as further described herein below, is self-centering relative to the round hole during tightening of the fastener <NUM>. Fasteners <NUM> extend through the apertures <NUM> in the mounting flange <NUM> and through corresponding apertures <NUM> in the base member <NUM>. Each fastener <NUM> has a threaded shaft <NUM> and a hex flat head <NUM>. Alignment pins <NUM> (see <FIG>) protrude from the bottom of the opposite sides <NUM> of the base member <NUM> and are received in the noted alignment holes <NUM> in the mounting flanges <NUM> of the pedestal <NUM> for initially aligning the base member <NUM> on the pedestal <NUM> prior to tightening of fasteners <NUM>, <NUM>, as will be further described herein below. In other examples, the base member <NUM> may be integral with the pedestal <NUM> or coupled to the pedestal <NUM> by other means than what is shown and described.

With continued reference to <FIG>, a console assembly <NUM> is coupled to the frame <NUM> and is advantageously longitudinally movable (i.e., longitudinally adjustable) relative to the frame <NUM> along the noted adjustment axis A shown in <FIG>. The position of the console assembly <NUM> can be adjusted by the user seated on the seat <NUM>. Among other things, console assembly <NUM> includes a handlebar <NUM> for manual engagement by the user and a display <NUM> (see <FIG>) for displaying and/or controlling an operational characteristic of the bike <NUM>. The display <NUM> may include a generally flat liquid crystal and/or any other type of screen <NUM> for displaying operational characteristics of the bike <NUM>. The screen <NUM> may be a conventional touch screen configured to receive touch inputs from the user for input to a computer controller having a processor and/or software for controlling one or more operational characteristics of the bike <NUM>. In other examples, the display <NUM> may include other types and configurations of displays such as more than one screen, more than one touch screen, one or more curved screens, a combination of flat and curved screens, lighted displays, and/or the like. The display <NUM> may further include audio speakers. The handlebar <NUM> and the display <NUM> are each fixed to a carriage <NUM>, which as described herein below is longitudinally slidable back and forth relative to the base member <NUM> along an adjustment axis A (see <FIG>, <FIG>) extending in the longitudinal direction LO. As will be further described herein below, note that the above-described apertures <NUM> comprising round holes are substantially aligned with each other along an axis C (see <FIG>, described herein below) in the longitudinal direction LO, substantially parallel to the adjustment axis A. As will be described below this permits the round holes to provide a reference line (axis C) to ensure that the carriage <NUM> and remainder of the console assembly <NUM>, once installed onto the frame <NUM>, are substantially aligned with and will slide along the desired direction of axis A.

Referring to <FIG>, the carriage <NUM> has a carriage body <NUM> with a rearward end <NUM> and a forward end <NUM> that is longitudinally opposed to the rearward end <NUM>. Slide rails <NUM> longitudinally extend along opposite sides of the carriage body <NUM>. In the illustrated example, the carriage body <NUM> is plate-like member and the slide rails <NUM> are elongated cylindrical members that are integrally formed with the plate-like member. However, the carriage body <NUM> may have another shape, and/or the slide rails <NUM> may be fastened or otherwise attached to the carriage body <NUM> instead of being integrally formed therewith. The slide rails <NUM> protrude downwardly from the carriage body <NUM> such that a channel <NUM> is defined below the carriage body <NUM> and between the slide rails <NUM>. The channel <NUM> is sized to receive the raised portion <NUM> protruding upwardly from the base member <NUM> when the carriage <NUM> is slidably mounted on the base member <NUM>.

The carriage <NUM> is supported on the base member <NUM> by opposing slide bearings, including opposing front slide bearings <NUM> and opposing rear slide bearings <NUM>. The opposing front and rear slide bearings <NUM>, <NUM> are configured to support longitudinal sliding motion of the slide rails <NUM>. The type and configuration of slide bearing can vary from what is shown and described. In the illustrated example, each slide bearing <NUM>, <NUM> has a bearing body <NUM> that defines a bearing passage <NUM> in which one of the slide rails <NUM> is nested and freely longitudinally slidable therein. Each bearing <NUM>, <NUM> has linear bearings <NUM> in the bearing passage <NUM> for engaging and permitting said longitudinal sliding motion of the noted slide rail <NUM> relative to the respective bearing <NUM>, <NUM>. Suitable bearings for use with the illustrated example may be purchased from igus®, linear guide rail, model WJ200UM-<NUM>. Each bearing body <NUM> is fastened to the base member <NUM> and pedestal <NUM> via threaded engagement with respective fasteners <NUM>, <NUM>, such that the opposite sides <NUM> of the base member <NUM> are vertically sandwiched between the mounting flanges <NUM> on the pedestal <NUM> and the slide bearings <NUM>, <NUM>.

Referring to <FIG>, <FIG>, and <FIG>, a stop device <NUM> is configured to prevent forward sliding of the carriage <NUM> past a forwardmost position relative to the base member <NUM>, as shown in <FIG>, and to prevent rearward sliding of the carriage <NUM> past a rearwardmost position relative to the base member <NUM>, as shown in <FIG>. The type and configuration of the stop device <NUM> may vary from what is shown and described. In the illustrated example, the stop device <NUM> includes a bumper <NUM> that laterally extends from one side of the carriage body <NUM> and has front and rear engagement surfaces <NUM>, <NUM> that face and are configured to abut or otherwise engage with the front and rear slide bearings <NUM>, <NUM> on that side of the carriage body <NUM>, respectively. Sliding of the carriage <NUM> forwardly to the forwardmost position brings the front engagement surface <NUM> into engagement with the front slide bearing <NUM> and thus stops further forward movement of the carriage <NUM>. Sliding of the carriage <NUM> rearwardly to the rearwardmost position brings the rear engagement surface <NUM> into engagement with the rear slide bearing <NUM> and thus stops further rearward movement of the carriage <NUM>. The type and configuration of the bumper <NUM> can vary from what is shown and described. In the illustrated example, the bumper <NUM> includes a pair of washers <NUM> made of a resilient material such as soft rubber to provide a low impact engagement with the front and rear bearings <NUM>, <NUM>. The washers <NUM> are coupled to ends of a cylindrical spacer <NUM> by fasteners <NUM> extending there through. A mounting bracket <NUM> couples the cylindrical spacer <NUM> to the carriage body <NUM> via fasteners <NUM>.

Referring to <FIG>, <FIG> and <FIG>, in the illustrated example, the handlebar <NUM> is an elongated and generally U-shaped member having a keypad <NUM> having input buttons, and/or sensors <NUM> for sensing a physical characteristic of the user, such as heart rate. The opposing ends of the handlebar <NUM> provide handles <NUM> for grasping by the user. Additional keypads <NUM> may be provided on the handles <NUM>. It should be understood however that the shape and configuration of the handlebar <NUM> and user options provided by the handlebar <NUM> are exemplary and may widely vary from what is shown and described.

A handlebar mounting bracket <NUM> couples the handlebar <NUM> to the carriage <NUM> along two planes that are transverse to each other. The transverse planes may be perpendicular or non-perpendicular. This advantageously provides a robust mounting connection of the handlebar <NUM> to the carriage <NUM>, which as described above is movable component. In the illustrated example, the two planes are perpendicular. The first plane extends in the lateral direction LA and the longitudinal LO direction. The second plane extends in the lateral LA direction and the vertical V direction. However, this is not limiting, and in other embodiments connections of the handlebar <NUM> along different transversely oriented planes may be employed. To facilitate the two-plane mounting, the handlebar mounting bracket <NUM> has a rear bracket plate <NUM> that is fastened to the rearward end <NUM> of the carriage body <NUM>, particularly via fasteners <NUM> (see <FIG> and <FIG>) longitudinally extending through the rear bracket plate <NUM> and engaged with end bores in the rear ends of slide rails <NUM>, and a top bracket plate <NUM> that is fastened to the top of the carriage body <NUM> via fasteners <NUM> engaged with bores in the carriage body <NUM> and extending through the top bracket plate <NUM>. As such the handlebar <NUM> is rigidly coupled to the carriage <NUM> in the noted two-plane arrangement and configured to move along with the carriage <NUM> relative to the frame <NUM>.

Referring to <FIG>, a display mounting bracket <NUM> couples the display <NUM> to the carriage <NUM> along two planes that are transverse to each other. The planes may be perpendicular or non-perpendicular. This advantageously provides a robust mounting connection of the display <NUM> to the carriage <NUM>. In the illustrated example, the two planes are perpendicular to each other. The first plane extends in the lateral direction LA and the longitudinal LO direction. The second plane extends in the lateral LA direction and the vertical V direction. However, this is not limiting, and other embodiments connections of the display <NUM> along different transversely oriented planes may be employed. In the illustrated example, the display mounting bracket <NUM> has a front bracket mounting plate <NUM> that is fastened to the forward end <NUM> of the carriage body <NUM>, particularly via fasteners <NUM> (see <FIG>) longitudinally extending through the front bracket mounting plate <NUM> and engaged with end bores in the slide rails <NUM>, and a top bracket <NUM> that is fastened to the top of the carriage body <NUM> via fasteners <NUM> vertically extending through the top bracket <NUM> and engaged with bores in the top of the carriage body <NUM>. As such, the display <NUM> is rigidly coupled to the carriage <NUM> and configured to move along with the carriage <NUM> relative to the frame <NUM>.

Referring to <FIG>, a wireless charger <NUM> may be incorporated into the console assembly <NUM> and conveniently located longitudinally between the handlebar <NUM> and the display <NUM>. In the illustrated example the wireless charger <NUM> is located in an "activity zone" defined within the U-shape of the handlebar <NUM>. The wireless charger <NUM> defines a generally flat tray on which the user may set and wirelessly charge their personal wireless device, for example tablet or phone. The type and configuration of the wireless charger <NUM> may vary from what is shown.

Referring now to <FIG>, a cable assembly <NUM> is configured to provide power and/or electrical communication to the keypad <NUM> and/or input buttons <NUM>, and/or sensors <NUM> on the handlebar <NUM>, and/or to the display <NUM>, and/or wireless charger <NUM>, and/or to any other electrical components of the console assembly <NUM>. The cable assembly <NUM> is disposed inside the frame <NUM>, particularly inside the support column <NUM> and is coupled to and moves with the carriage <NUM> relative to the base member <NUM> and relative to the frame <NUM>. The manner of connection of the cable assembly <NUM> to the carriage <NUM> may vary from what is shown and described. In the illustrated example, a connection bracket <NUM> couples the cable assembly <NUM> to the bottom of the carriage <NUM>. The cable assembly <NUM> is advantageously routed along a curved shape <NUM> inside the support column <NUM>. As the carriage <NUM> is moved relative to the frame <NUM> in the longitudinal direction LO, the portion of the cable assembly <NUM> that is attached to the carriage <NUM> via the connection bracket <NUM> will move relative to the portion of the cable assembly <NUM> located in the support column <NUM>. The curved shape <NUM> of the cable assembly <NUM> advantageously will compress or expand (e.g., in the longitudinal direction) upon movement of the carriage <NUM>, which limits movement of the cable assembly <NUM> relative to the interior surfaces of the frame <NUM>, and thus limits chafing that otherwise would occur by dragging the cable assembly <NUM> along the interior surfaces.

Referring to <FIG>, <FIG> and <FIG>, a locking device <NUM> is configured to lock the carriage <NUM> and console assembly <NUM> in position relative to the frame <NUM>. The type and configuration of the locking device <NUM> can vary from what is shown and described. In the illustrated example, the locking device <NUM> includes a pivot lever <NUM> having an elongated body <NUM> with a first end <NUM> for manually grasping by the user and an opposite, second end <NUM> that is pivotable about a pivot shaft <NUM>. The pivot lever <NUM> is pivotable upwardly and downwardly about the pivot shaft <NUM>, as shown by the double-headed arrow in <FIG>. As further described herein below, pivoting the pivot lever <NUM> into the lowered position shown in solid line in <FIG> securely locks the carriage <NUM> and the remainder of the console assembly <NUM> in a longitudinal position relative to the frame <NUM>. Conversely, pivoting the pivot lever <NUM> into the raised position shown in dashed lines in <FIG> frees the carriage <NUM> and remainder of the console assembly <NUM> for longitudinal movement relative to the frame <NUM>, into and anywhere between a forwardmost position shown in <FIG> and a rearwardmost position shown in <FIG>. The pivot lever <NUM> is advantageously centered on the console assembly <NUM> and located just forwardly of the handlebar <NUM> for easy and ergonomic access and operation by the user. A user seated on the seat <NUM> can easily use his or her fingers to grasp and pull the first end <NUM> of the pivot lever <NUM> towards the handlebar <NUM> into the raised position, and conversely can easily use his or her fingers or palm to push the first end <NUM> of the pivot lever <NUM> away from the handlebar <NUM>, into the lowered position.

The locking device <NUM> includes a cam <NUM> that is configured to apply a clamping force on the base member <NUM> and carriage <NUM> which prevents longitudinal movement of the carriage <NUM> relative to the base member <NUM>. The cam <NUM> is provided via camming engagement between an eccentric outer profile <NUM> on the second end <NUM> of the pivot lever <NUM> and a curved laterally elongated recess <NUM> on a cam block <NUM> fixedly coupled to the carriage <NUM>. A cam shaft <NUM> extends through a through-bore <NUM> in the cam block <NUM> and a hole <NUM> in the carriage <NUM>. Between the cam block <NUM> and the carriage <NUM>. the cam shaft <NUM> also extends through the elongated slot <NUM> in the base member <NUM>. As will be further explained herein below, the elongated slot <NUM> is shaped and sized such that the cam shaft <NUM> is free to move along the elongated slot <NUM> during longitudinal adjustment of the carriage <NUM> and remainder of the console assembly <NUM>.

The cam shaft <NUM> has a first end <NUM> extending into the second end <NUM> of the pivot lever <NUM> and fixed to the pivot shaft <NUM>, and a second end <NUM> having a clamp head <NUM> configured to apply an axial clamping force on the bottom of the base member <NUM> when the locking device <NUM> is moved into the locked position. In the illustrated example, the clamp head <NUM> has a friction washer <NUM> for frictionally engaging the bottom of the base member <NUM> and a pair of jam nuts <NUM> that retain the friction washer <NUM> on the cam shaft <NUM>. As shown in <FIG>, the clamp head <NUM> is generally located in a channel <NUM> (see <FIG>) defined by the raised portion <NUM> of the base member <NUM> and the friction washer <NUM> is configured to frictionally engage the inner top wall therein on opposite sides of the elongated slot <NUM>. The type and configuration of the clamp head <NUM> can vary from what is shown and described. An alignment pin <NUM> extends from the pivot shaft <NUM> into a bore <NUM> in the cam block <NUM> and is configured to prevent twisting movement of the pivot lever <NUM> relative to the cam block <NUM>. Cylindrical bearings <NUM> seated in the through-bore <NUM> and bore <NUM> support axial movement of the cam shaft <NUM> and the alignment pin <NUM> during rotation of the pivot lever <NUM> about the pivot shaft <NUM>.

It will thus be understood that the locking device <NUM> is manually operable by a user operating or preparing to operate the bike <NUM> and is configured to rigidly clamp the console assembly <NUM> in position relative to the frame <NUM>, thus accommodating users of different sizes to ergonomically operate the same bike <NUM>. Pivoting of the pivot lever <NUM> into the lowered position shown in solid lines in <FIG> and <FIG> rotates the eccentric outer profile <NUM> at the second end <NUM> of the pivot lever <NUM> and causes the cam <NUM> to raise the clamp head <NUM> into axial and frictional engagement with the base member <NUM>, thereby securely clamping the base member <NUM>, carriage <NUM> and cam block <NUM> between the clamp head <NUM> and the second end <NUM> of the pivot lever <NUM>. The locking device <NUM> is thus configured to facilitate locking of the position of the carriage <NUM> and the remainder of the console assembly <NUM> in any position relative to the forwardmost position and rearward most positions shown in <FIG> and <FIG>. Conversely, pivoting of the pivot lever <NUM> into the raised position shown in dashed lines in <FIG> and <FIG> rotates the eccentric outer profile <NUM> in the opposite direction, which causes the cam <NUM> to lower the clamp head <NUM> out of axial and frictional engagement with the base member <NUM>, thus freeing the carriage <NUM> and the remainder of the console assembly <NUM> into another position. As discussed above, the cam shaft <NUM> is free to move along the elongated slot <NUM> of the base member <NUM> during longitudinal adjustment of the carriage <NUM> and remainder of the console assembly <NUM>. Also as discussed above, the stop device <NUM> prevents forward sliding of the carriage <NUM> past a forwardmost position relative to the base member <NUM>, as shown in <FIG>, and prevents rearward sliding of the carriage <NUM> past a rearwardmost position relative to the base member <NUM>, as shown in <FIG>. The handlebar <NUM> and the display <NUM> are securely and rigidly fixedly coupled to the carriage <NUM> in two planes, thus preventing rattling or misalignment of the assembly during use. Fixing both the handlebar <NUM> and the display <NUM> to the carriage <NUM> advantageously retains the display <NUM> at a constant angle (see <FIG>) relative to the remainder of the console assembly <NUM> during and after adjustment of the position of the console assembly <NUM> relative to the frame <NUM>. Also as discussed above, the cable assembly <NUM> is advantageously coupled to the carriage <NUM> and circuitously routed within the supporting frame <NUM> so that the cable assembly <NUM> efficiently moves within the supporting frame <NUM> during movement of the console assembly <NUM>, both contracting and expanding, thus preventing frictional engagement with the interior of the frame <NUM> and wear of the cables in the cable assembly <NUM> that otherwise would result.

It is also contemplated that the exercise machine may incorporate a sensor arrangement, such as disclosed in detail in the above-referenced <CIT>. As described in that document, the sensor arrangement may be configured to sense movement of the console assembly <NUM> relative to the frame <NUM> for use by a computer controller for the bike <NUM>.

<FIG> depict a method of assembling the bike <NUM> in a manner that ensures secure connection and accurate mounting and alignment of components of the frame <NUM> and console assembly <NUM> components, in particular ensuring secure mounting and accurate alignment of the bearings <NUM>, <NUM> and carriage <NUM> relative to each other and relative to the frame <NUM>, thus improving adjustability of the console assembly <NUM>. In particular, the present inventors determined it would be desirable to provide improved methods of assembling the opposing slide bearings <NUM>, <NUM> and carriage <NUM> onto the pedestal <NUM> so that slide bearings <NUM>, <NUM> define slide bearing axes B1, B2 (see <FIG>, <FIG>) that are substantially parallel to each other and to the adjustment axis A. This includes embodiments like what is illustrated wherein the slide bearing axes B1, B2 are exactly parallel to each other and/or to the adjustment axis A, as well as embodiments like what is illustrated wherein the slide bearing axes B1, B2 are within a range of plus or minus five degrees of parallel to each other and/or to the adjustment axis A, and more preferably are within a range of plus or minus two degrees of parallel to each other and/or the adjustment axis A. With respect to the illustrated embodiment, the present inventors determined that the closer the respective axes are made to exactly parallel, the better the performance. The present inventors determined that applying a predetermined lateral clamping (preload) force on the opposing slide bearings <NUM> and carriage <NUM> prior to their assembly onto the frame <NUM> advantageously ensures that the slide bearings <NUM>, <NUM> are securely engaged with the slide rails <NUM> and also aligns the noted slide bearing axes B1, B2 substantially parallel to each other and substantially parallel to the adjustment axis A. This advantageously provides an assembled console assembly <NUM> having smooth and reliable sliding movement relative to the frame <NUM>.

Referring to <FIG>, the base member <NUM> is initially placed on the pedestal <NUM> such that the alignment pins <NUM> are inserted into the alignment holes <NUM> in the mounting flanges <NUM>. This locates the base member <NUM> in the position shown in <FIG>. Next, the fasteners <NUM> having the conical head <NUM> are loosely inserted into the apertures <NUM> from below the mounting flanges <NUM> and through the corresponding apertures <NUM> in the base member <NUM>, as shown in <FIG>. The opposing slide bearings <NUM>, <NUM> are also longitudinally slid onto the slide rails <NUM> of the carriage <NUM>. Next, the carriage <NUM> is lowered onto the base member <NUM> and the fasteners <NUM>, <NUM> are initially threaded into engagement with the slide bearings <NUM>, <NUM> so the base member <NUM>, slide bearings <NUM> and carriage <NUM> are loosely held in position on the pedestal <NUM> of the frame <NUM>. As shown in <FIG>, the fasteners <NUM> are also inserted through the apertures <NUM> from below the mounting flange <NUM> and through corresponding apertures <NUM> in the base member <NUM> and initially threaded into engagement with the slide bearings <NUM>, <NUM>.

With further reference to <FIG>, a clamp device <NUM> is positioned on the assembly shown in <FIG>. The type and configuration of clamp device <NUM> may vary from what is shown and described. In the illustrated example the clamp device <NUM> is a C-clamp having opposing arms <NUM> and a threaded rod <NUM> that laterally extends through one of the arms <NUM>. The threaded rod <NUM> has a handle <NUM> on one end and one or more clamp heads <NUM> on the other end. An opposing clamp head <NUM> is located on the other arm <NUM>. A compression block assembly <NUM> is disposed laterally between the clamp head(s) <NUM>, <NUM> and the slide bearings <NUM>, <NUM>. Rotation of the handle <NUM> causes the clamp heads <NUM>, <NUM> to apply opposing uniform clamping forces on the compression block assembly <NUM> which in turn applies uniform clamping forces on both sets of front and rear slide bearings <NUM>, <NUM>. Rotating the handle <NUM>, as shown by the arrow in <FIG>, causes laterally inward translation of the threaded rod <NUM> and the clamp head <NUM>, which closes the clamp head <NUM> (such as shown in <FIG>) onto the compression block assembly <NUM> and moves the compression block assembly <NUM> laterally inwardly against the slide bearings <NUM>, <NUM>. The opposing clamp head <NUM> and compression block assembly <NUM> in turn applies a reactive compression force onto the slide bearings <NUM>, <NUM> on the opposite side of the carriage <NUM>. This securely clamps the carriage <NUM> between the slide bearings <NUM>, <NUM> and advantageously substantially aligns and holds the first slide bearing axis B1 and the second slide bearing axis B2 defined by the slide bearings <NUM>, <NUM> substantially parallel to each other.

The present inventors determined that by applying a desired predetermined clamp force or "preload" on the bearings <NUM>, <NUM> it is possible to substantially align the opposing front and rear slide bearings <NUM>, <NUM> relative to each other prior to their mounting to the base member <NUM> and pedestal <NUM>. This facilitates a smooth sliding operation of the slide rails <NUM> along the slide bearings <NUM>, <NUM>. The amount of clamping force or preload force that achieves the best (i.e., most reliably smooth sliding operation) will vary based on the type of bearing and overall configuration of the assembly and can be determined by trial and error and then recorded and thereafter used as a target value.

Referring to <FIG>, with the clamp device <NUM> actuated, the fasteners <NUM> having the conical head <NUM> are further rotated to securely tighten the threaded connection between the fasteners <NUM> and the slide bearings <NUM>, <NUM>, which vertically clamps the illustrated components together. Advantageously, as shown in <FIG>, during tightening of the fasteners <NUM>, the conical heads <NUM> engage with the circular perimeter of the round holes <NUM> which causes the fasteners <NUM> to be laterally and longitudinally centered or to "self-center" in the apertures <NUM>, increasing the precision of alignment between the noted slide bearing axis B1 and the desired sliding axis A for the carriage <NUM>. Referring to <FIG>, thereafter the opposing fasteners <NUM> are rotated to further tighten the threaded connection between the fasteners <NUM> and the opposing slide bearings <NUM>, <NUM>, thus vertically clamping the illustrated components and providing precision of alignment between the noted slide bearing axis B2 and the desired sliding axis A for the carriage <NUM>. Thereafter, referring to <FIG>, rotating the handle <NUM> in the opposite direction opens the clamp device <NUM> (see <FIG>), i.e., relieves the clamping preload force from the bearings <NUM>, <NUM> and carriage <NUM>. The clamp device <NUM> can then be removed from the assembly.

Referring to <FIG>, the handlebar mounting bracket <NUM> and handlebar <NUM> may then be mounted to the carriage <NUM>. The display mounting bracket <NUM> and display <NUM> may then also be mounted to the carriage <NUM>. A next step may include assembling the wireless charger <NUM>, as well as a lower shroud <NUM> for enclosing the carriage <NUM>. It is also possible before or after the above steps to assemble various components of the sensor assembly, as described in the above-referenced provisional patent application.

Thus it will be understood that examples of the method according to the present disclosure may include (a) providing a frame <NUM> for supporting a user of the bike <NUM>, and a base member <NUM> disposed on or integrated with the frame <NUM>, (b) providing a carriage <NUM> that is slidable relative to the base member <NUM> along an adjustment axis A, (c) providing a first slide bearing apparatus (<NUM>, <NUM>) for supporting sliding of a first lateral side of the carriage <NUM> along a first slide bearing axis B1 (see <FIG> and <FIG>), (d) providing a second slide bearing apparatus (<NUM>, <NUM>) for supporting sliding of an opposite, second lateral side of the carriage <NUM> along a second slide bearing axis B1 (See <FIG> and <FIG>), (e) laterally clamping the carriage <NUM> between the first slide bearing apparatus and the second slide bearing apparatus such that the first slide bearing axis B1 and the second slide bearing axis B2 are substantially parallel to each other, (f) rigidly coupling the first slide bearing apparatus to the base member <NUM> such that the first slide bearing axis B1 is fixed substantially parallel to the adjustment axis A, and (g) thereafter fastening the second slide bearing apparatus to the base member <NUM>. As described herein above, steps (e) through (g) are advantageously configured to ensure that the first slide bearing axis B1 is substantially parallel to the second slide bearing axis B2 and also substantially parallel to the adjustment axis A after assembly, such that in use the carriage <NUM> is freely slidable along the adjustment axis A relative to the first slide bearing apparatus and the second slide bearing apparatus.

In the illustrated example, the first slide bearing apparatus comprises a first set of slide bearings <NUM>, <NUM> and the second slide bearing apparatus also comprises a second set of slide bearings <NUM>, <NUM>. The first and second sets of bearings are laterally opposed to each other. The first set of slide bearings comprises a front slide bearing and a rear slide bearing that is spaced apart from and substantially aligned with the front slide bearing, and the second set of slide bearings comprises a front slide bearing and a rear slide bearing that is spaced apart from and substantially aligned with the front slide bearing.

As described above, step (f) may include fixing the first slide bearing apparatus to the base member <NUM> by engaging the fasteners <NUM> in the apertures <NUM> which are aligned substantially parallel to the adjustment axis A. Each aperture <NUM> may be a round hole, and each fastener <NUM> may have a conical head <NUM> that operatively engages and is self-centered respect to the round hole during fastening, thus further improving alignment.

Claim 1:
An exercise machine (<NUM>) that extends between a front and a rear in a longitudinal direction (LO), between a first side and an opposite, second side in a lateral direction (LA) that is perpendicular to the longitudinal direction (LO), and between a top and a bottom in a vertical direction (V) that is perpendicular to the longitudinal direction (LO) and perpendicular to the lateral direction (LA), the exercise machine (<NUM>) comprising:
a frame (<NUM>) for supporting a user of the exercise machine (<NUM>);
a base member (<NUM>); and
a console assembly (<NUM>) comprising:
a handlebar (<NUM>) for engagement by the user and a display (<NUM>) for displaying and/or controlling an operational characteristic of the exercise machine (<NUM>), wherein the console assembly (<NUM>) is coupled to and longitudinally movable relative to the frame (<NUM>) to facilitate adjustment of the handlebar (<NUM>) and the display (<NUM>) relative to the user; and
a carriage (<NUM>) that is longitudinally slidable back and forth relative to the base member (<NUM>);
characterized in that the exercise machine (<NUM>) further comprises a locking device (<NUM>) configured to lock the console assembly (<NUM>) in position relative to the frame (<NUM>), wherein the locking device (<NUM>) includes a pivot lever (<NUM>) having an elongated body (<NUM>) with a first end (<NUM>) for manually grasping by the user and an opposite, second end (<NUM>) that is pivotable about a pivot shaft (<NUM>), the pivot lever (<NUM>) being centered on the console assembly (<NUM>) and located forwardly of the handlebar (<NUM>) such that pulling the first end (<NUM>) of the pivot lever (<NUM>) towards the handlebar (<NUM>) brings the pivot lever (<NUM>) into a raised position and pushing the first end (<NUM>) of the pivot lever (<NUM>) away from the handlebar (<NUM>) brings the pivot lever (<NUM>) into a lowered position.