Patent Description:
<CIT> discloses a tensioning system for articles of footwear and articles of apparel. The tensioning system includes a tensioning member that is tightened or loosened using a motorized tensioning device for winding and unwinding the tensioning member on a spool. The motorized tensioning device includes a torque transmitting system that allows for incremental tightening, incremental loosening and full loosening of the tensioning member.

Devices for automatically tightening an article of footwear have been previously proposed. Liu, in <CIT>, titled "Automatic tightening shoe", provides a first fastener mounted on a shoe's upper portion, and a second fastener connected to a closure member and capable of removable engagement with the first fastener to retain the closure member at a tightened state. Liu teaches a drive unit mounted in the heel portion of the sole. The drive unit includes a housing, a spool rotatably mounted in the housing, a pair of pull strings and a motor unit. Each string has a first end connected to the spool and a second end corresponding to a string hole in the second fastener. The motor unit is coupled to the spool. Liu teaches that the motor unit is operable to drive rotation of the spool in the housing to wind the pull strings on the spool for pulling the second fastener towards the first fastener. Liu also teaches a guide tube unit that the pull strings can extend through.

Some optional features are defined by the dependent claims.

The headings provided herein are merely for convenience and do not necessarily affect the scope or meaning of the terms used.

The concept of self-tightening shoe laces was first widely popularized by the fictitious power-laced Nike® sneakers worn by Marty McFly in the movie Back to the Future II, which was released back in <NUM>. While Nike® has since released at least one version of power-laced sneakers similar in appearance to the movie prop version from Back to the Future II, the internal mechanical systems and surrounding footwear platform employed in these early versions do not necessarily lend themselves to mass production or daily use. Additionally, previous designs for motorized lacing systems comparatively suffered from problems such as high cost of manufacture, complexity, assembly challenges, lack of serviceability, and weak or fragile mechanical mechanisms, to highlight just a few of the many issues. The present inventors have developed a modular footwear platform to accommodate motorized and non-motorized lacing engines that solves some or all of the problems discussed above, among others. The components discussed below provide various benefits including, but not limited to: serviceable components, interchangeable automated lacing engines, robust mechanical design, reliable operation, streamlined assembly processes, and retail-level customization. Various other benefits of the components described below will be evident to persons of skill in the relevant arts.

The motorized lacing engine discussed below was developed from the ground up to provide a robust, serviceable, and inter-changeable component of an automated lacing footwear platform. The lacing engine includes unique design elements that enable retail-level final assembly into a modular footwear platform. The lacing engine design allows for the majority of the footwear assembly process to leverage known assembly technologies, with unique adaptions to standard assembly processes still being able to leverage current assembly resources.

In an example, the modular automated lacing footwear platform includes a mid-sole plate secured to the mid-sole for receiving a lacing engine. The design of the mid-sole plate allows a lacing engine to be dropped into the footwear platform as late as at a point of purchase. The mid-sole plate, and other aspects of the modular automated footwear platform, allow for different types of lacing engines to be used interchangeably. For example, the motorized lacing engine discussed below could be changed out for a human-powered lacing engine. Alternatively, a fully-automatic motorized lacing engine with foot presence sensing or other optional features could be accommodated within the standard mid-sole plate.

The automated footwear platform discussed herein can include a motorized lacing engine to provide automatic (or user activated) tightening of laces within a footwear platform. The motorized lacing engine utilizes custom motor control routines to provide certain lacing tightening functions for the footwear platform.

This initial overview is intended to introduce the subject matter of the present patent application. It is not intended to provide an exclusive or exhaustive explanation of the various inventions disclosed in the following more detailed description.

The following discusses various components of the automated footwear platform including a motorized lacing engine, a mid-sole plate, and various other components of the platform. While much of this disclosure focuses on a motorized lacing engine, many of the mechanical aspects of the discussed designs are applicable to a human-powered lacing engine or other motorized lacing engines with additional or fewer capabilities. Accordingly, the term "automated" as used in "automated footwear platform" is not intended to only cover a system that operates without user input. Rather, the term "automated footwear platform" includes various electrically powered and human-power, automatically activated and human activated mechanisms for tightening a lacing or retention system of the footwear.

<FIG> is an exploded view illustration of components of a motorized lacing system for footwear, according to some example embodiments. The motorized lacing system <NUM> illustrated in <FIG> includes a lacing engine <NUM>, a lid <NUM>, an actuator <NUM>, a mid-sole plate <NUM>, a mid-sole <NUM>, and an outsole <NUM>. <FIG> illustrates the basic assembly sequence of components of an automated lacing footwear platform. The motorized lacing system <NUM> starts with the mid-sole plate <NUM> being secured within the mid-sole. Next, the actuator <NUM> is inserted into an opening in the lateral side of the mid-sole plate opposite to interface buttons that can be embedded in the outsole <NUM>. Next, the lacing engine <NUM> is dropped into the mid-sole plate <NUM>. In an example, the lacing system <NUM> is inserted under a continuous loop of lacing cable and the lacing cable is aligned with a spool in the lacing engine <NUM> (discussed below). Finally, the lid <NUM> is inserted into grooves in the mid-sole plate <NUM>, secured into a closed position, and latched into a recess in the mid-sole plate <NUM>. The lid <NUM> can capture the lacing engine <NUM> and can assist in maintaining alignment of a lacing cable during operation.

In an example, the footwear article or the motorized lacing system <NUM> includes or is configured to interface with one or more sensors that can monitor or determine a foot presence characteristic. Based on information from one or more foot presence sensors, the footwear including the motorized lacing system <NUM> can be configured to perform various functions. For example, a foot presence sensor can be configured to provide binary information about whether a foot is present or not present in the footwear. If a binary signal from the foot presence sensor indicates that a foot is present, then the motorized lacing system <NUM> can be activated, such as to automatically tighten or relax (i.e., loosen) a footwear lacing cable. In an example, the footwear article includes a processor circuit that can receive or interpret signals from a foot presence sensor. The processor circuit can optionally be embedded in or with the lacing engine <NUM>, such as in a sole of the footwear article.

Examples of the lacing engine <NUM> are described in detail in reference to <FIG>. Various additional details of the motorized lacing system <NUM> are discussed throughout the remainder of the description.

<FIG> are diagrams and drawings illustrating a motorized lacing engine, according to some example embodiments. <FIG> introduces various external features of an example lacing engine <NUM>, including a housing structure <NUM>, case screw <NUM>, lace channel <NUM> (also referred to as lace guide relief <NUM>), lace channel wall <NUM>, lace channel transition <NUM>, spool recess <NUM>, button openings <NUM>, buttons <NUM>, button membrane seal <NUM>, programming header <NUM>, spool <NUM>, and lace grove <NUM>. Additional details of the housing structure <NUM> are discussed below in reference to <FIG>.

In an example, the lacing engine <NUM> is held together by one or more screws, such as the case screw <NUM>. The case screw <NUM> is positioned near the primary drive mechanisms to enhance structural integrity of the lacing engine <NUM>. The case screw <NUM> also functions to assist the assembly process, such as holding the case together for ultra-sonic welding of exterior seams.

In this example, the lacing engine <NUM> includes a lace channel <NUM> to receive a lace or lace cable once assembled into the automated footwear platform. The lace channel <NUM> can include a lace channel wall <NUM>. The lace channel wall <NUM> can include chamfered edges to provide a smooth guiding surface for a lace cable to run in during operation. Part of the smooth guiding surface of the lace channel <NUM> can include a channel transition <NUM>, which is a widened portion of the lace channel <NUM> leading into the spool recess <NUM>. The spool recess <NUM> transitions from the channel transition <NUM> into generally circular sections that conform closely to the profile of the spool <NUM>. The spool recess <NUM> assists in retaining the spooled lace cable, as well as in retaining position of the spool <NUM>. However, other aspects of the design provide primary retention of the spool <NUM>. In this example, the spool <NUM> is shaped similarly to half of a yo-yo with a lace grove <NUM> running through a flat top surface and a spool shaft <NUM> (not shown in <FIG>) extending inferiorly from the opposite side. The spool <NUM> is described in further detail below in reference of additional figures.

The lateral side of the lacing engine <NUM> includes button openings <NUM> that enable buttons <NUM> for activation of the mechanism to extend through the housing structure <NUM>. The buttons <NUM> provide an external interface for activation of switches <NUM>, illustrated in additional figures discussed below. In some examples, the housing structure <NUM> includes button membrane seal <NUM> to provide protection from dirt and water. In this example, the button membrane seal <NUM> is up to a few mils (thousandth of an inch) thick clear plastic (or similar material) adhered from a superior surface of the housing structure <NUM> over a corner and down a lateral side. In another example, the button membrane seal <NUM> is a <NUM> mil thick vinyl adhesive backed membrane covering the buttons <NUM> and button openings <NUM>.

<FIG> is an illustration of housing structure <NUM> including top section <NUM> and bottom section <NUM>. In this example, the top section <NUM> includes features such as the case screw <NUM>, lace channel <NUM>, lace channel transition <NUM>, spool recess <NUM>, button openings <NUM>, and button seal recess <NUM>. The button seal recess <NUM> is a portion of the top section <NUM> relieved to provide an inset for the button membrane seal <NUM>. In this example, the button seal recess <NUM> is a couple mil (<NUM> mil equals <NUM>) recessed portion on the lateral side of the superior surface of the top section <NUM> transitioning over a portion of the lateral edge of the superior surface and down the length of a portion of the lateral side of the top section <NUM>.

In this example, the bottom section <NUM> includes features such as wireless charger access <NUM>, joint <NUM>, and grease isolation wall <NUM>. Also illustrated, but not specifically identified, is the case screw base for receiving case screw <NUM> as well as various features within the grease isolation wall <NUM> for holding portions of a drive mechanism. The grease isolation wall <NUM> is designed to retain grease or similar compounds surrounding the drive mechanism away from the electrical components of the lacing engine <NUM> including the gear motor and enclosed gear box. In this example, the worm gear <NUM> and worm drive <NUM> are contained within the grease isolation wall <NUM>, while other drive components such as gear box <NUM> and gear motor <NUM> are outside the grease isolation wall <NUM>. Positioning of the various components can be understood through a comparison of <FIG> with <FIG>, for example.

<FIG> is an illustration of various internal components of lacing engine <NUM>, according to example embodiments. In this example, the lacing engine <NUM> further includes spool magnet <NUM>, O-ring seal <NUM>, worm drive <NUM>, bushing <NUM>, worm drive key <NUM>, gear box <NUM>, gear motor <NUM>, motor encoder <NUM>, motor circuit board <NUM>, worm gear <NUM>, circuit board <NUM>, motor header <NUM>, battery connection <NUM>, and wired charging header <NUM>. The spool magnet <NUM> assists in tracking movement of the spool <NUM> though detection by a magnetometer (not shown in <FIG>). The o-ring seal <NUM> functions to seal out dirt and moisture that could migrate into the lacing engine <NUM> around the spool shaft <NUM>.

In this example, major drive components of the lacing engine <NUM> include worm drive <NUM>, worm gear <NUM>, gear motor <NUM> and gear box <NUM>. The worm gear <NUM> is designed to inhibit back driving of worm drive <NUM> and gear motor <NUM>, which means the major input forces coming in from the lacing cable via the spool <NUM> are resolved on the comparatively large worm gear and worm drive teeth. This arrangement protects the gear box <NUM> from needing to include gears of sufficient strength to withstand both the dynamic loading from active use of the footwear platform or tightening loading from tightening the lacing system. The worm drive <NUM> includes additional features to assist in protecting the more fragile portions of the drive system, such as the worm drive key <NUM>. In this example, the worm drive key <NUM> is a radial slot in the motor end of the worm drive <NUM> that interfaces with a pin through the drive shaft coming out of the gear box <NUM>. This arrangement prevents the worm drive <NUM> from imparting any axial forces on the gear box <NUM> or gear motor <NUM> by allowing the worm drive <NUM> to move freely in an axial direction (away from the gear box <NUM>) transferring those axial loads onto bushing <NUM> and the housing structure <NUM>.

<FIG> is an illustration depicting additional internal components of the lacing engine <NUM>. In this example, the lacing engine <NUM> includes drive components such as worm drive <NUM>, bushing <NUM>, gearbox <NUM>, gear motor <NUM>, motor encoder <NUM>, motor circuit board <NUM> and worm gear <NUM>. <FIG> adds illustration of battery <NUM> as well as a better view of some of the drive components discussed above.

<FIG> is another illustration depicting internal components of the lacing engine <NUM>. In <FIG> the worm gear <NUM> is removed to better illustrate the indexing wheel <NUM> (also referred to as the Geneva wheel <NUM>). The indexing wheel <NUM>, as described in further detail below, provides a mechanism to home the drive mechanism in case of electrical or mechanical failure and loss of position. In this example, the lacing engine <NUM> also includes a wireless charging interconnect <NUM> and a wireless charging coil <NUM>, which are located inferior to the battery <NUM> (which is not shown in this figure). In this example, the wireless charging coil <NUM> is mounted on an external inferior surface of the bottom section <NUM> of the lacing engine <NUM>.

<FIG> is a cross-section illustration of the lacing engine <NUM>, according to example embodiments. <FIG> assists in illustrating the structure of the spool <NUM> as well as how the lace grove <NUM> and lace channel <NUM> interface with lace cable <NUM>. As shown in this example, lace <NUM> runs continuously through the lace channel <NUM> and into the lace grove <NUM> of the spool <NUM>. The cross-section illustration also depicts lace recess <NUM> and spool mid-section, which are where the lace <NUM> will build up as it is taken up by rotation of the spool <NUM>. The spool mid-section <NUM> is a circular reduced diameter section disposed inferiorly to the superior surface of the spool <NUM>. The lace recess <NUM> is formed by a superior portion of the spool <NUM> that extends radially to substantially fill the spool recess <NUM>, the sides and floor of the spool recess <NUM>, and the spool mid-section <NUM>. In some examples, the superior portion of the spool <NUM> can extend beyond the spool recess <NUM>. In other examples, the spool <NUM> fits entirely within the spool recess <NUM>, with the superior radial portion extending to the sidewalls of the spool recess <NUM>, but allowing the spool <NUM> to freely rotation with the spool recess <NUM>. The lace <NUM> is captured by the lace groove <NUM> as it runs across the lacing engine <NUM>, so that when the spool <NUM> is turned, the lace <NUM> is rotated onto a body of the spool <NUM> within the lace recess <NUM>.

As illustrated by the cross-section of lacing engine <NUM>, the spool <NUM> includes a spool shaft <NUM> that couples with worm gear <NUM> after running through an O-ring <NUM>. In this example, the spool shaft <NUM> is coupled to the worm gear via keyed connection pin <NUM>. In some examples, the keyed connection pin <NUM> only extends from the spool shaft <NUM> in one axial direction, and is contacted by a key on the worm gear in such a way as to allow for an almost complete revolution of the worm gear <NUM> before the keyed connection pin <NUM> is contacted when the direction of worm gear <NUM> is reversed. A clutch system could also be implemented to couple the spool <NUM> to the worm gear <NUM>. In such an example, the clutch mechanism could be deactivated to allow the spool <NUM> to run free upon de-lacing (loosening). In the example of the keyed connection pin <NUM> only extending is one axial direction from the spool shaft <NUM>, the spool is allowed to move freely upon initial activation of a de-lacing process, while the worm gear <NUM> is driven backward. Allowing the spool <NUM> to move freely during the initial portion of a de-lacing process assists in preventing tangles in the lace <NUM> as it provides time for the user to begin loosening the footwear, which in turn will tension the lace <NUM> in the loosening direction prior to being driven by the worm gear <NUM>.

<FIG> is another cross-section illustration of the lacing engine <NUM>, according to example embodiments. <FIG> illustrates a more medial cross-section of the lacing engine <NUM>, as compared to <FIG>, which illustrates additional components such as circuit board <NUM>, wireless charging interconnect <NUM>, and wireless charging coil <NUM>. <FIG> is also used to depict additional detail surround the spool <NUM> and lace <NUM> interface.

<FIG> is a top view of the lacing engine <NUM>, according to example embodiments. <FIG> emphasizes the grease isolation wall <NUM> and illustrates how the grease isolation wall <NUM> surrounds certain portions of the drive mechanism, including spool <NUM>, worm gear <NUM>, worm drive <NUM>, and gear box <NUM>. In certain examples, the grease isolation wall <NUM> separates worm drive <NUM> from gear box <NUM>. <FIG> also provides a top view of the interface between spool <NUM> and lace cable <NUM>, with the lace cable <NUM> running in a medial-lateral direction through lace groove <NUM> in spool <NUM>.

<FIG> is a top view illustration of the worm gear <NUM> and index wheel <NUM> portions of lacing engine <NUM>, according to example embodiments. The index wheel <NUM> is a variation on the well-known Geneva wheel used in watchmaking and film projectors. A typical Geneva wheel or drive mechanism provides a method of translating continuous rotational movement into intermittent motion, such as is needed in a film projector or to make the second hand of a watch move intermittently. Watchmakers used a different type of Geneva wheel to prevent over-winding of a mechanical watch spring, by using a Geneva wheel with a missing slot (e.g., one of the Geneva slots <NUM> would be missing). The missing slot would prevent further indexing of the Geneva wheel, which was responsible for winding the spring and prevents over-winding. In the illustrated example, the lacing engine <NUM> includes a variation on the Geneva wheel, indexing wheel <NUM>, which includes a small stop tooth <NUM> that acts as a stopping mechanism in a homing operation. As illustrated in <FIG>, the standard Geneva teeth <NUM> simply index for each rotation of the worm gear <NUM> when the index tooth <NUM> engages the Geneva slot <NUM> next to one of the Geneva teeth <NUM>. However, when the index tooth <NUM> engages the Geneva slot <NUM> next to the stop tooth <NUM> a larger force is generated, which can be used to stall the drive mechanism in a homing operation. Alternatively, the larger force and different force profile generated when the index tooth <NUM> engages the stop tooth <NUM> can be detected by a processor circuit within the lacing engine to identify a home position. The side profile of the stop tooth <NUM> is steeper and generally straight (as compared to the Geneva teeth <NUM> side profile). The stop tooth <NUM> can be used to create a known location of the mechanism for homing in case of loss of other positioning information, such as the motor encoder <NUM>.

In this example, the homing apparatus (indexing wheel <NUM>) is designed to allow for four complete revolutions between home positions (other designs can be implemented to achieve different numbers of revolutions). The homing apparatus has two home positions, one that represents a completely loose state (all lace unwound from the spool) and a second one that represents a completely tight state (as much lace is the system can wind onto the spool). When the homing apparatus hits either home position the interaction between the index tooth <NUM> and the stop tooth <NUM> generates a large enough force to stall the drive mechanism. The system can measure the force through a measurement of motor current. Measuring motor current over time can result in generation of a force profile, which can be used to identify the home positions. The force profile associated with the index tooth <NUM> engaging the stop tooth <NUM> is sufficiently different than the force profile generated by the index tooth <NUM> engaging one of the Geneva teeth <NUM>, that the processor can identify the difference. In an example, the force profile generated by hitting the stop tooth has a larger magnitude and a fast rate of change (e.g., higher slope) over time. The force profile generated by the engagement of the stop tooth is also designed to be distinguishable from force profiles generated from pulls on the lace cable, which can be transmitted through the spool into the drive mechanism. Force profiles generated by forces transmitted through the lace cable will generally be lower in magnitude and the rate of change will be slower (e.g., a lower slope) over time.

<FIG> are illustrations of the worm gear <NUM> and index wheel <NUM> moving through an index operation, according to example embodiments. As discussed above, these figures illustrate what happens during a single full revolution of the worm gear <NUM> starting with <FIG> though <FIG>. In <FIG>, the index tooth <NUM> of the worm gear <NUM> is engaged in the Geneva slot <NUM> between a first Geneva tooth 155a of the Geneva teeth <NUM> and the stop tooth <NUM>. <FIG> illustrates the index wheel <NUM> in a first index position, which is maintained as the index tooth <NUM> starts its revolution with the worm gear <NUM>. In <FIG>, the index tooth <NUM> begins to engage the Geneva slot <NUM> on the opposite side of the first Geneva tooth 155a. Finally, in <FIG> the index tooth <NUM> is fully engaged within a Geneva lot <NUM> between the first Geneva tooth 155a and a second Geneva tooth 155b. The process shown in <FIG> continues with each revolution of the worm gear <NUM> until the index tooth <NUM> engages the stop tooth <NUM>. As discussed above, when the index tooth <NUM> engages the stop tooth <NUM>, the increased forces can stall the drive mechanism.

<FIG> is an exploded view of lacing engine <NUM>, according to example embodiments. The exploded view of the lacing engine <NUM> provides an illustration of how all the various components fit together. <FIG> shows the lacing engine <NUM> upside down, with the bottom section <NUM> at the top of the page and the top section <NUM> near the bottom. In this example, the wireless charging coil <NUM> is shown as being adhered to the outside (bottom) of the bottom section <NUM>. The exploded view also provide a good illustration of how the worm drive <NUM> is assembled with the bushing <NUM>, drive shaft <NUM>, gear box <NUM> and gear motor <NUM>. The illustration does not include a drive shaft pin that is received within the worm drive key <NUM> on a first end of the worm drive <NUM>. As discussed above, the worm drive <NUM> slides over the drive shaft <NUM> to engage a drive shaft pin in the worm drive key <NUM>, which is essentially a slot running transverse to the drive shaft <NUM> in a first end of the worm drive <NUM>.

<FIG> is a block diagram illustrating components of a motorized lacing system <NUM> for footwear, according to some example embodiments. The system <NUM> illustrates basic components of a motorized lacing system such as including interface buttons <NUM>, optional foot presence sensor(s) <NUM>, a printed circuit board assembly (PCA) with a processor circuit <NUM>, a battery <NUM>, a charging coil <NUM>, an encoder <NUM>, a motor <NUM>, a transmission <NUM>, and a spool <NUM>. In this example, the interface buttons <NUM> and foot presence sensor(s) <NUM> can communicate with the circuit board (PCA) <NUM>, which also communicates with the battery <NUM> and charging coil <NUM>. The encoder <NUM> and motor <NUM> are also connected to the circuit board <NUM> and each other. The transmission <NUM> couples the motor <NUM> to the spool <NUM> to form the drive mechanism <NUM>. In this example, the motor <NUM>, transmission <NUM>, and spool <NUM> make up the drive mechanism <NUM>, which in some examples also includes the encoder <NUM>.

In an example, the processor circuit <NUM> controls one or more aspects of the drive mechanism <NUM>. For example, the processor circuit <NUM> can be configured to receive information from the buttons <NUM> and/or from the foot presence sensor <NUM> and/or from the battery <NUM> and/or from the drive mechanism <NUM> and/or from the encoder <NUM>, and can be further configured to issue commands to the drive mechanism <NUM>, such as to tighten or loosen the footwear, or to obtain or record sensor information, among other functions. As discussed further below, in some examples the processor circuit <NUM> can measure voltage and current from the battery <NUM>. The processor circuit <NUM> can also monitor signals from the encoder <NUM>. Information from the battery <NUM> and encoder <NUM> can be used by the processor circuit <NUM> to control the drive mechanism <NUM>, in particular the motor <NUM>. In some examples, the processor circuit <NUM> can also measure current draw from the motor <NUM>, which can be used as a measure of torque being developed by the motor <NUM>. As discussed further below, voltage can be measured by processor circuit <NUM>, and voltage can be used as a measure of motor speed (or they are directly related).

<FIG> are diagrams and flowcharts illustrating aspects of a motor control scheme for controlling a motorized lacing engine, according to some example embodiments. The motor control schemes discussed herein can control the operation of drive mechanism <NUM> and more specifically motor <NUM> (or motor <NUM> as illustrated in <FIG>). The motor control schemes include concepts such as variable sized control segments (<FIG>), motion profiles (<FIG>), and modification of motor control parameters based on battery voltage.

<FIG> includes diagrams illustrating the variable size control segments concept, according to an example embodiment. In this example, the variable segment size motor control scheme involves dividing up the total travel, in terms of lace take-up, into segments, with the segments varying in size based on position on a continuum of lace travel (e.g., between home/loose position on one end and max tightness on the other). As the motor is controlling a radial spool and will be controlled, primarily, via a radial encoder on the motor shaft, the segments can be sized in terms of degrees of spool travel (which can also be viewed in terms of encoder counts). On the loose side of the continuum, the segments can be larger, such as <NUM> degrees of spool travel, as the amount of lace movement is less critical. However, as the laces are tightened each increment of lace travel becomes more and more critical to obtain the desired amount of lace tightness. Other parameters, such as motor current, can be used as secondary measures of lace tightness or continuum position. <FIG> includes two separate illustrations of different segment sizes based on position along a tightness continuum.

In an example, the variable size control segments involve dividing up the total rotary travel of the drive mechanism into variable sized segments based on position within the continuum of travel. As discussed above, in certain examples, the drive mechanism <NUM> can be configured to have a limited total operational travel. The total operation travel of the drive mechanism can be viewed in terms of rotations or in terms of a linear distance. When viewed in terms of a linear distance, the total operational travel can be viewed in terms of the amount of lace (or tensioning member) take-up the drive mechanism is capable of. The continuum of total operational travel of the drive mechanism can be viewed in terms of lace take-up going between a home (or fully loose) position to max tightness (e.g., <NUM> full revolutions of the spool <NUM> as controlled by the mechanical stop mechanism discussed above). Movements of the drive mechanism <NUM> on the loose side of the continuum can be much more dramatic (e.g., larger), while on the maximum tightness side the commanded movements need to have a much finer level of control, such as is illustrated by control segments <NUM>. Accordingly, in an example, the movement continuum is divided into segments or groups with each unit within a segment or group representing a certain move size (e.g., degrees of rotation, encoder counts, or linear distance). On the loose side of the continuum, the unit size can be large or command a bigger rotational movement of the drive mechanism <NUM>. On the tight side of the continuum, the units can be much smaller to command a small rotational movement of the drive mechanism <NUM>.

In an example, the variable control segments <NUM> can include a continuum of travel <NUM>, which can be broken into six control segments <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>. The continuum of travel <NUM> can go from detangling segments <NUM> to max tightness segments <NUM>, with homing segment <NUM>, comfort segments <NUM>, performance segments <NUM>, and high performance segments <NUM> in between. As illustrated by the different lateral distances of the blocks illustrating the different control segments within the variable control segments <NUM>, each different segment unit can command the drive mechanism <NUM> to move a different amount. The segment units can be defined in terms of degrees of rotation of the spool, or in terms of linear travel distance of a lace.

The motion profile concept involves grouping one or move movements of the drive mechanism into a profile to command a certain desired outcome. Each motion profile will include parameters to control drive mechanism <NUM> movement. In an example, the parameters are viewed in terms of controlling spool <NUM> movement. The motion profiles can be generated from a table of movements. The motion profiles can be modified by additional global parameters, such as gear reduction multipliers and/or scaling factors associated with battery voltage. For example, the motion control techniques discussed below in reference to <FIG> and <FIG>, can modify a scaling factor that will subsequently be used to modify the motion profiles.

<FIG> illustrates using a tightness continuum position to build a table of motion profiles based on current tightness continuum position and desired end position. The motion profiles can then be translated into specific inputs from user input buttons. In this example, the motion profiles include parameters of spool motion, such as acceleration (Accel (deg/s/s)), velocity (Vel (deg/s)), deceleration (Dec (deg/s/s)), and angle of movement (Angle (deg)). In some examples, the movement parameters can be alternatively expressed in terms of lace movement acceleration, velocity, deceleration and linear distance.

<FIG> depicts example motion profiles plotted on a velocity over time graph. Graph <NUM> illustrates velocity of time profiles for different motion profiles, such as a home-to-comfort profile and a relax profile. The graph <NUM> illustrates a detangle movement profile, where the system is tightened and loosened in rapid succession to work on eliminating a tangle within the drive mechanism <NUM> (e.g., where the lace gets tangled in the spool <NUM>.

<FIG> is a graphic illustrating example user inputs to activate various motion profiles along the tightness continuum. For example, a short button activation on the plus actuator can be programmed to move to progressively tighter position along the continuum, such as from Home/Loose to Comfort. Conversely, a short button activation on the negative actuator can be programmed to move to progressively looser position, such as from Performance to Comfort. A double press of individual buttons can activate different profiles. For example, a double press on the plus actuator can be programmed to more rapidly move to the next progressively tighter position on the continuum, such as from Performance to Max Tightness. While a double press on the negative actuator can be programmed to transition all the way back to Home/Loose position, regardless of starting position. Holding an actuator button can be programmed to tighten (plus actuator) or loosen (negative actuator) until released or a stop is reached (e.g., Max Tightness or Home/Loose).

<FIG> and <FIG> include flowcharts illustrating example drive mechanism control schemes based at least in part on different operating zones based on battery voltage levels. In devices utilizing motors powered by batteries, the available battery voltage can have a direct effect on the speed (velocity) the motor is able to operate at, with the higher the available voltage the higher the speed. Batteries generally have a range of operating voltages that they deliver from fully charged to a low battery level (systems are usually designed not to completely deplete/discharge a battery). During the discharge cycle, the voltage supplied by a battery will gradually decrease until a battery management system (BMS) shuts down the battery to avoid damage from discharge. For example, in a particular design of the lacing engine discussed herein, a battery with an operating voltage range of <NUM>. 3v to <NUM>. 6v can be used. Over this operating range the motor will naturally exhibit a potentially wide variation in output speed, without some form of motor control. In certain devices a variable in motor output speed can result in a negative consumer impression and/or an undesirable variation in perceived or actual performance. For example, a lacing engine may exhibit an undesirable variation in the maximum amount of lace tightness or an undesirable variation in the time it takes to attain a desired tightness level. Accordingly, to resolve these potentially undesirable performance variations, a motor control scheme was devised to smooth out the motor output speed over at least a portion of the voltage operating range of the motor. In this example, two operating zones were choosen so that over a portion of the operating range the motor can be operated at a level of performance above what is possible at the low end of the operating voltage range, while still eliminating some of the undesirable variations in performance. Use of this scheme can also provide the benefit of delivering a more consistent user experience, such as speed of operation and audible motor sounds during operation.

In this example, a voltage threshold is selected as the lower end of a primary operating voltage range. In some examples, a desired operating speed is selected instead of or as a means of determining a threshold voltage. In these examples, the motor being used has a more or less direct relationship between input voltage and output speed (velocity), accordingly choosing one ends up determining the other. At the selected or determined voltage threshold, the motor can be operated at <NUM>% duty cycle to attain a target output speed. At voltages above the threshold voltage, the motor can be operated at less than <NUM>% duty cycle to enable the motor to maintain the target output speed. Accordingly, at all operating voltage deliverable by the battery above the threshold voltage, the motor can be operated at a constant output speed. The control scheme provides a more consistent user experience in terms of performance, including lace tightening speed, tension, and audible feedback to the user. One additional benefit, results for an operating parameter, such as audible feedback, changing when the battery voltage drops below the threshold voltage. Such a change in a noticeable operating parameter can be an indication to a user that the battery needs to be charged.

In this example, once the battery voltage drops below the threshold voltage the system performance drops to a level consistent with the lowest operating voltage (sometimes referred to as the critically low battery level). The drop in output performance of the drive system can be an indicator to the user that the battery needs to be charged soon. The drop in performance can be designed in such a way to allow for a period of continued operation at the lower performance level.

In an example lacing system, a battery with an operating range of <NUM>. 3v to <NUM>. 6v can be used. In this system, a threshold voltage of <NUM>. 8v can be selected. At battery voltages above <NUM>. 8v, the system operates at a target output speed equal to the output speed at <NUM>% duty cycle at <NUM>. Accordingly, when the battery is fully charged (<NUM>. 3v) the processor circuit <NUM> can modulate the power delivered to the motor to attain the target output speed. Accordingly, at <NUM>. 3v the motor will be operated at something less than <NUM>% duty cycle. Once the voltage deliverable by the battery drops below <NUM>. 8v, the system drops performance to so that the target output speed is equal to the output speed at <NUM>% duty cycle at <NUM>. 6v (critically low battery level in this example system).

<FIG> is a flowchart illustrating a motor control technique <NUM>, according to an example embodiment. In this example, the system <NUM> can implement the motor or drive system control technique <NUM> including operations such as segmenting an operating range (<NUM>), defining a plurality of moves (<NUM>), creating a plurality of motion profiles (<NUM>), and commanding movements (<NUM>).

Motor control technique <NUM> can begin at operation <NUM> with the processor circuit <NUM> segmenting an operating range, such as continuum of travel <NUM>, into different control segments. In some examples, at <NUM> the processor circuit <NUM> accesses a set of control segments for a particular operating range, as the set of control segments can be predetermined for a particular system. As illustrated in <FIG>, the control segments can include segments ranging from detangling segments <NUM> to max tightness segments <NUM>. Each control segment can represent a different amount of travel, expressed in degrees of rotation or linear distance. Segmenting the continuum of travel into different sized segment can simplify motion profiles using the control segments by automatically varying the movement sizes based on where along the continuum of travel the system is operating. For example, a single button push when the footwear platform is in a home (loose) state, can result in a much greater amount of lace travel being commanded versus when the footwear platform is near a maximum tightness state. In certain examples, the definition of control segments is performed outside the system <NUM>, with operating instructions for system <NUM> utilizing the preprogrammed control segments. In these examples, the processor circuit <NUM> can access preprogrammed control segment from a data structure stored in memory within system <NUM>.

At <NUM>, the motor control technique <NUM> can continue with the processor circuit <NUM> defining (or accessing) a plurality of motor moves. The motor moves can be defined in terms of control segments, such as move two home segments <NUM> and three comfort segments <NUM>. The motor moves can also include performance parameters, such as acceleration, velocity, and deceleration. In some examples, the motor moves can include a distance parameter defined in terms of control segments, degrees of rotation, or linear travel distance. Operation <NUM> is another operation which can be preprogrammed into the instructions loaded into system <NUM>, in this scenario processor circuit <NUM> can access preprogrammed motor moves from a table or similar data structure stored in memory on system <NUM>.

At <NUM>, the motor control technique <NUM> can continue with processor circuit creating (or accessing) a plurality of motion profiles. The motion profiles can include one or more motor moves. The motor moves within a motion profile can be defined to reach different states for the footwear platform, such as a loose (home) state or a maximum tightness state. Operation <NUM> is another operation that can be preprogrammed into instructions loaded into system <NUM>, when preprogrammed the processor circuit <NUM> accesses motion profiles when commanding movements.

At <NUM>, the motor control technique <NUM> continues with processor circuit <NUM> using motion profiles to command movements of drive mechanism <NUM>. Commanding movements can include selecting motion profiles based on a current location along a travel continuum. For example, the processor circuit <NUM> only selects a return home motion profile, when the system is in a location away from the home position.

<FIG> is a flowchart illustrating a motor control technique <NUM>, according to example embodiments. In some examples, the motor control technique <NUM> further defines how the processor circuit <NUM> commands movement according to operation <NUM> discussed above. In other examples, the motor control technique <NUM> can be implemented independently of operation <NUM> or motor control technique <NUM>. In the illustrated example, the motor control technique <NUM> can include operations such as determining a first target velocity (<NUM>), determining a second target velocity (<NUM>), measuring a battery voltage (<NUM>), determining if the battery voltage transgresses a threshold (<NUM>), and setting a operating parameter accordingly (<NUM>, <NUM>).

At <NUM>, the motor control technique <NUM> can begin with the processor circuit <NUM> determining (or accessing) a first target motor output velocity. In certain examples, the first target motor output velocity is determined based on determining an output velocity of the motor at a threshold battery voltage with the system operating at <NUM>% duty cycle. In some examples, the first target velocity is preprogrammed into the system <NUM>, and the processor circuit <NUM> merely accesses the first target velocity at operation <NUM>.

At <NUM>, the motor control technique <NUM> can continue with the processor circuit <NUM> determining (or accessing) a second target motor output velocity. In certain examples, the second target motor output velocity is determined based on determining an output velocity at a critically low battery level (e.g., a lowest allowable operating voltage) with the system operating at <NUM>% duty cycle. In some example, the second target velocity is preprogrammed into the system <NUM>, and the processor circuit <NUM> merely accesses the second target velocity at operation <NUM>.

In certain examples, the operations <NUM> and <NUM> are performed outside the real-time operation of system <NUM>. In these examples, the first and second target motor output velocities can be determined or selected. In an example, a threshold battery voltage can be selected and used to determine the first and second target motor output velocities. In another example, a first target motor output velocity can be selected and used to determine a threshold voltage level. In this example, the threshold voltage level is the level at which the system can attain the selected first target motor output velocity while running at <NUM>% duty cycle.

At <NUM>, the motor control technique <NUM> can continue with the processor circuit <NUM> receiving a signal indicative of the current battery output voltage that is being delivered to the drive mechanism <NUM>. In certain examples, the processor circuit <NUM> can include a volt meter, in other examples the battery, BMS, or another component can provide the necessary signal indicative of voltage level to the processor circuit <NUM>.

At <NUM>, the motor control technique <NUM> continues with the processor circuit <NUM> using the voltage level indication to determine whether the voltage being delivered to the motor transgresses a threshold voltage. As discussed above, in some examples, the system <NUM> can be operated with a certain voltage range with certain operating parameters and in a second voltage range with a second set of operating parameters.

If the voltage measured being delivered to the motor transgresses the threshold voltage, then the motor control technique <NUM> continues at <NUM> with the processor circuit <NUM> operating the drive system <NUM> using a first set of operating characteristics (with at least one operating parameter set to a first value). In an example, the controlled operating parameter is output velocity for the motor, and the motor is controlled across a range of input voltages at a single output velocity at operation <NUM>.

If the voltage measured being delivered to the motor does not transgress the threshold voltage, then the motor control technique <NUM> continues at <NUM> with the processor circuit <NUM> operating the drive system <NUM> using a second set of operation characteristics. The operating characteristics includes at least one operating parameter, which in this example is motor output velocity. In this example, the motor output velocity is operated at a second target velocity when the battery voltage falls below a predetermined threshold voltage. The operating characteristic being controlled could also be current or duty cycle, among others.

The following examples provide additional details on the motor control techniques discussed above.

Claim 1:
A motorized lacing system (<NUM>) comprising:
a mid-sole (<NUM>) and an out-sole (<NUM>);
a mid-sole plate (<NUM>) disposed within the mid-sole;
a lacing engine (<NUM>) received in the mid-sole plate and including:
a lace spool (<NUM>) adapted for receiving a portion of a lace (<NUM>) for securing a footwear platform to a user's foot to take up or release lace from the lace spool; and
a drive mechanism comprising a worm drive (<NUM>), a worm gear (<NUM>) and a gear motor (<NUM>), wherein the worm drive is operatively coupled to the gear motor, and wherein the worm gear is coupled to the lace spool, such that the motor is configured to turn the worm drive to rotate the worm gear and the lace spool;
a battery (<NUM>) to power the gear motor; and
an indexing wheel (<NUM>), coupled to the worm gear, configured to home the drive mechanism in case of electrical or mechanical failure and loss of position; and
a processor circuit (<NUM>) configured to control the lacing engine to rotate the lace spool to tighten or loosen the footwear platform.