Motor control for automated footwear platforms

Abstract

Systems, apparatus, and methods relating to automated footwear platforms, including motor control technology. The motor control technology may include operations such as segmenting a predetermined travel distance, defining multiple actions, creating multiple motion patterns, and commanding movement. These multiple actions may utilize segmented travel distances of a drive mechanism associated with the footwear platform. Each of the multiple motion patterns may include one or more of the multiple actions. Commanding the movement of the drive mechanism may be based on selecting one or more motion patterns from the multiple motion patterns.

Description

[0001] This application is a divisional application of the application filed on March 15, 2017, with application number 201780027246.X and invention title "Motor control for automated footwear platform".

[0002] Priority requirements

[0003] This application claims the benefit of priority to U.S. Provisional Application No. 62 / 308,735, filed March 15, 2016, which is incorporated herein by reference in its entirety.

[0004] The following specifications describe various aspects of a motorized lacing system, motorized and non-motorized lacing engines, footwear components related to the lacing engines, an automated lacing footwear platform, and related assembly processes. More specifically, the following specifications describe a motor control method used within a motorized lacing engine for use in an automated footwear platform. background

[0005] Devices for automatically tightening footwear articles have been previously proposed. In U.S. Patent No. 6,691,433, entitled "Automatic Tightening Shoe," Liu provides a first fastener and a second fastener mounted on the upper portion of a shoe, the second fastener being connected to a closure member and capable of removably engaging with the first fastener to hold the closure member in 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 wires, and a motor unit. Each wire has a first end connected to the spool and a second end corresponding to a wire 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 wires onto the spool for pulling the second fastener toward the first fastener. Liu also teaches a guide tube unit through which the pull wires can extend. Brief description of the attached diagram

[0006] In accompanying drawings that are not drawn to scale, similar numbers can describe similar parts in different views. Similar numbers with different letter suffixes can represent different instances of similar parts. The accompanying drawings illustrate, in a general manner, by way of example and not limitation, several embodiments discussed in this document.

[0007] Figure 1 This is an exploded view illustrating components of a motorized tethering system according to some exemplary embodiments.

[0008] Figures 2A to 2N The illustrations and diagrams show a motorized tethered engine according to some exemplary embodiments.

[0009] Figure 3 This is a block diagram illustrating components of a motorized tethering system according to some exemplary embodiments.

[0010] Figures 4 to 7 This is a diagram illustrating a motor control scheme for a motorized tethered engine according to some exemplary embodiments.

[0011] Figures 8 to 9 This is a flowchart illustrating a motor control technology for an automated footwear platform according to some exemplary embodiments.

[0012] The titles provided in this article are for convenience only and do not necessarily affect the scope or meaning of the terms used. Detailed description

[0013] In the 1989 film *Back to the Future Part II*, the fictional powerful straps worn by Marty McPhee... The concept of self-tensioning shoelaces was first widely popularized in athletic shoes. Despite At least one high-performance lacing sneaker resembling the prop from Back to the Future Part II has been released, but the internal mechanical systems and surrounding footwear platforms used in these early models are not necessarily suitable for mass production or everyday use. Furthermore, previous designs for motorized lacing systems have several drawbacks, such as high manufacturing costs, complexity, difficult assembly, lack of maintainability, and weak or fragile mechanics—to name just a few. The inventors have developed a modular footwear platform to accommodate both motorized and non-motorized lacing engines, which, among other things, addresses some or all of the aforementioned problems. The components discussed below offer a variety of benefits, including, but not limited to: maintainable components, interchangeable automatic lacing engines, robust mechanical design, reliable operation, streamlined assembly processes, and retail-grade customization. Many other benefits of the components described below will be apparent to those skilled in the art.

[0014] The motorized lacing engine discussed below was developed to provide a robust, durable, and interchangeable component for automated lacing footwear platforms from the ground up. The lacing engine incorporates unique design elements that enable retail-grade final assembly within modular footwear platforms. The lacing engine design allows for the utilization of largely known assembly techniques in the footwear assembly process, while unique adaptations to standard assembly processes still leverage current assembly resources.

[0015] In the example, the modular automated lacing footwear platform includes a sole interlayer plate fixed to the sole interlayer for housing the lacing engine. The sole interlayer plate is designed to allow the lacing engine to be installed in the footwear platform at the latest at the time of purchase. Other aspects of the sole interlayer plate and the modular automated footwear platform allow for the interchangeable use of different types of lacing engines. For example, the motorized lacing engine discussed below can be replaced with a human-driven lacing engine. Alternatively, a fully automated motorized lacing engine with foot presence sensing or other optional features can be housed within a standard sole interlayer plate.

[0016] The automated footwear platforms discussed in this article may include motorized lacing engines to provide automatic (or user-activated) tightening of shoelaces within the footwear platform. Motorized lacing engines utilize custom motor control processes to provide certain lacing tightening functions for the footwear platform.

[0017] This initial overview is intended to introduce the subject matter of this patent application. It is not intended to provide an exclusive or exhaustive interpretation of the various inventions disclosed in the more detailed description below.

[0018] Automated footwear platform

[0019] The following discusses several components of an automated footwear platform, including a motorized lacing engine, a midsole plate, and several other components of the platform. While much of this disclosure focuses on motorized lacing engines, many mechanical aspects of the designs discussed can be applied to human-driven lacing engines or other motorized lacing engines with additional or fewer capabilities. Therefore, the term "automated" as used in "automated footwear platform" is not intended to cover only systems that operate without user input. Rather, the term "automated footwear platform" encompasses a variety of electrically and human-driven, automatically and human-activated mechanisms for tightening or retaining the lacing system of footwear.

[0020] Figure 1 This is an exploded view illustrating components of a motorized lacing system for footwear according to some exemplary embodiments. Figure 1 The motorized lacing system 1 shown in the figure includes a lacing engine 10, a cover 20, an actuator 30, a sole interlayer plate 40, a sole interlayer 50, and an outsole 60. Figure 1The diagram illustrates the basic assembly sequence of the components of an automated lacing footwear platform. The motorized lacing system 1 begins by securing the sole interlayer plate 40 within the sole interlayer. Next, the actuator 30 is inserted into an opening in the outer portion of the sole interlayer plate in the opposite direction to the interface button that can be embedded in the outsole 60. Next, the lacing engine 10 is lowered into the sole interlayer plate 40. In this example, the lacing system 1 is inserted under a continuous loop of lacing cables, and the lacing cables are aligned with the spools in the lacing engine 10 (discussed below). Finally, a cover 20 is inserted into a recess in the sole interlayer plate 40, secured to a closed position, and locked in a recess within the sole interlayer plate 40. The cover 20 can capture the lacing engine 10 and can help maintain the alignment of the lacing cables during operation.

[0021] In the example, the footwear article or motorized lacing system 1 includes one or more sensors capable of monitoring or determining foot presence characteristics, or is configured to interact with such sensors. Based on information from the one or more foot presence sensors, the footwear including the motorized lacing system 1 can be configured to perform various functions. For example, the foot presence sensors can be configured to provide binary information about the presence of a foot in the footwear. If the binary signal from the foot presence sensors indicates the presence of a foot, the motorized lacing system 1 can be activated, such as automatically tightening or loosening (i.e., releasing) the footwear lacing cables. In the example, the footwear article includes processor circuitry capable of receiving or decoding signals from the foot presence sensors. The processor circuitry may optionally be embedded in or incorporated into the lacing engine 10, such as in the sole of the footwear article.

[0022] Reference Figures 2A to 2N An example of the tethered engine 10 is described in detail. Several additional details of the motorized tethered system 1 are discussed throughout the rest of the specification.

[0023] Figures 2A to 2N The illustrations and diagrams show a motorized tethered engine according to some exemplary embodiments. Figure 2A Several external features of the exemplary lacing engine 10 are described, including a housing structure 100, a housing screw 108, a lace channel 110 (also referred to as a lace guide relief 110), a lace channel wall 112, a lace channel transition 114, a spool recess 115, a button opening 120, a button 121, a button diaphragm seal 124, a programming header 128, a spool 130, and a lace groove 132. Further details of the housing structure 100 will be referenced below. Figure 2B Let's have a discussion.

[0024] In the example, the tethered motor 10 is held together by one or more screws (such as housing screws 108). The housing screws 108 are positioned near the main drive mechanism to enhance the structural integrity of the tethered motor 10. The housing screws 108 also assist in assembly processes, such as holding the housing together for ultrasonic welding of the external joints.

[0025] In this example, the lacing engine 10 includes a shoelace channel 110 that receives shoelaces or shoelace cables once the lacing engine 10 is assembled into an automated footwear platform. The shoelace channel 110 may include a shoelace channel wall 112. The shoelace channel wall 112 may include chamfered edges to provide a smooth guiding surface for the shoelace cables during operation. A portion of the smooth guiding surface of the shoelace channel 110 may include a channel transition 114, which is a widened portion of the shoelace channel 110 leading to a spool recess 115. The spool recess 115 transitions from the channel transition 114 to a generally circular portion that closely conforms to the profile of the spool 130. The spool recess 115 helps retain wound shoelace cables and helps maintain the position of the spool 130. However, other aspects of the design provide primary retention of the spool 130. In this example, the spool 130 is shaped like a half of a yo-yo, having a shoelace groove 132 extending through a flat top surface and a spool shaft 133 extending downward from the opposite side. Figure 2A (Not shown in the figure). The spool 130 will be described in more detail below with reference to the additional figures.

[0026] The outer portion of the tethered motor 10 includes a button opening 120 for a button 121 that extends through the housing structure 100 to activate the mechanism. As illustrated in additional figures discussed below, the button 121 provides an external interface for activating the switch 122. In some examples, the housing structure 100 includes a button diaphragm seal 124 to provide protection against dirt and water. In this example, the button diaphragm seal 124 is a transparent plastic (or similar material) several mils (thousandths of an inch) thick, bonded from the upper surface of the housing structure 100 across a corner and downwards along the outer portion. In another example, the button diaphragm seal 124 is a 2-mil thick vinyl adhesive backing film covering the button 121 and the button opening 120.

[0027] Figure 2BThis is an illustration of a housing structure 100 including a top portion 102 and a bottom portion 104. In this example, the top portion 102 includes features such as a housing screw 108, a lace channel 110, a lace channel transition 114, a spool recess 115, a button opening 120, and a button sealing recess 126. The button sealing recess 126 is a portion of the top portion 102 that is released to provide for insertion of a button diaphragm seal 124. In this example, the button sealing recess 126 is a few mils of recess located on the outer side of the upper surface of the top portion 104, transitioning over a portion of the outer edge of the upper surface and extending the length of a portion of the outer side of the top portion 104.

[0028] In this example, the bottom portion 104 includes features such as a wireless charger inlet 105, a joint 106, and a grease barrier 109. Also illustrated (but not specifically identified) are a housing screw base for receiving the housing screw 108 and various features within the grease barrier 109 for holding the drive mechanism. The grease barrier 109 is designed to keep grease or similar compounds around the drive mechanism away from the electrical components of the tethered engine 10, including the geared motor and enclosed gearbox. In this example, the worm gear 150 and worm drive 140 are contained within the grease barrier 109, while other drive components (such as the gearbox 144 and geared motor 145) are outside the grease barrier 109. For example, by comparison... Figure 2B and Figure 2C The positioning of multiple components can be understood.

[0029] Figure 2C This is an illustration of multiple internal components of a tether motor 10 according to an exemplary embodiment. In this example, the tether motor 10 also includes a spool magnet 136, an O-ring seal 138, a worm gear drive 140, a bushing 141, a worm gear drive key 142, a gearbox 144, a gear motor 145, a motor encoder 146, a motor circuit board 147, a worm gear 150, a circuit board 160, a motor head 161, a battery connector 162, and a wired charging head 163. The spool magnet 136 facilitates the movement of a magnetometer (…). Figure 2C The detection (not shown) is used to track the movement of the spool 130. The O-ring seal 138 acts to seal out dirt and moisture that may migrate into the tethered engine 10 around the spool shaft 133.

[0030] In this example, the main drive components of the lacing engine 10 include a worm drive 140, a worm gear 150, a gear motor 145, and a gearbox 144. The worm gear 150 is designed to prevent reverse drive between the worm drive 140 and the gear motor 145, meaning that the main input force from the lacing cable via the spool 130 is addressed on the relatively large worm gear and worm drive teeth. This arrangement protects the gearbox 144 from the need for gears of sufficient strength to withstand the dynamic loads from active use of the footwear platform or the tightening loads from the lacing system. The worm drive 140 includes additional features to help protect more vulnerable parts of the drive system, such as a worm drive key 142. In this example, the worm drive key 142 is a radial groove in the motor end of the worm drive 140 that engages with a pin via a drive shaft extending from the gearbox 144. This arrangement prevents the worm drive 140 from exerting any axial force on the gearbox 144 or gear motor 145 by allowing the worm drive 140 to move freely in the axial direction (away from the gearbox 144) to transfer those axial loads to the bushing 141 and housing structure 100.

[0031] Figure 2D This is an illustration depicting additional internal components of the belt engine 10. In this example, the belt engine 10 includes drive components such as a worm drive 140, a bushing 141, a gearbox 144, a gear motor 145, a motor encoder 146, a motor circuit board 147, and a worm gear 150. Figure 2D An illustration of battery 170 has been added, along with better views of some of the drive components discussed above.

[0032] Figure 2E This is another illustration depicting the internal components of the belted engine 10. Figure 2E In this illustration, the worm gear 150 is removed to better illustrate the indexing wheel 151 (also known as the Geneva wheel 151). As described in further detail below, the indexing wheel 151 provides a mechanism for returning the drive mechanism to its home position in the event of electrical or mechanical failure and loss of position. In this example, the tethered motor 10 also includes a wireless charging interconnect 165 and a wireless charging coil 166, located below the battery 170 (not shown in this figure). In this example, the wireless charging coil 166 is mounted on the lower surface of the outer side of the bottom portion 104 of the tethered motor 10.

[0033] Figure 2F This is a cross-sectional view of the tethered engine 10 according to an exemplary embodiment. Figure 2FThe illustration helps to show the structure of the spool 130 and how the lace groove 132 and lace channel 110 mate with the lace cable 131. As shown in this example, the lace 131 extends continuously through the lace channel 110 and enters the lace groove 132 of the spool 130. This cross-sectional illustration also depicts the lace recess 135 and the middle portion of the spool, where the lace 131 gathers as the lace is wound up due to the rotation of the spool 130. The middle portion 137 of the spool is a circular, decreasing-diameter portion disposed below the upper surface of the spool 130. The lace recess 135 is formed by the upper portion of the spool 130, which extends radially to substantially fill the spool recess 115, the sides and bottom of the spool recess 115, and the middle portion 137 of the spool. In some examples, the upper portion of the spool 130 may extend beyond the spool recess 115. In other examples, the spool 130 fits completely within the spool recess 115, with its upper radial portion extending to the sidewall of the spool recess 115, but allowing the spool 130 to rotate freely with the spool recess 115. The shoelace 131 is captured by the shoelace groove 132 as it extends through the lacing engine 10, such that as the spool 130 rotates, the shoelace 131 rotates onto the body of the spool 130 within the shoelace recess 135.

[0034] As illustrated in cross-section through the lacing engine 10, the spool 130 includes a spool shaft 133, which engages with the worm gear 150 after extending through the O-ring 138. In this example, the spool shaft 133 is engaged to the worm gear via a keyed connecting pin 134. In some examples, the keyed connecting pin 134 extends from the spool shaft 133 only in one axial direction and engages via a key on the worm gear, allowing the worm gear 150 to undergo a near-complete revolution before the keyed connecting pin 134 engages when the worm gear 150 is reversed. A clutch system can also be implemented to engage the spool 130 with the worm gear 150. In such an example, the clutch mechanism can be deactivated to allow the spool 130 to move freely when the laces are untied (loosened). In the example where the keyed connecting pin 134 extends from the spool shaft 133 only in one axial direction, the spool is allowed to move freely during the initial activation of the untying process, while the worm gear 150 is driven backward. Allowing the spool 130 to move freely during the initial part of the untying process helps prevent tangling in the shoelaces 131, as it gives the user time to begin loosening the shoes, which in turn will tension the shoelaces 131 in the loosening direction before being driven by the worm gear 150.

[0035] Figure 2G This is another cross-sectional view of the tethered engine 10 according to an exemplary embodiment. Figure 2F compared to, Figure 2G The illustration shows a cross-section of the inner side of the tethered engine 10. Figure 2G Additional components such as circuit board 160, wireless charging interconnect 165, and wireless charging coil 166 are illustrated. Figure 2G It is also used to depict additional details around the interface of the spool 130 and the shoelace 131.

[0036] Figure 2H This is a top view of the tether engine 10 according to an exemplary embodiment. Figure 2H The grease isolation wall 109 is highlighted and illustrated, showing how it surrounds certain parts of the drive mechanism, including the spool 130, worm gear 150, worm drive 140, and gearbox 145. In some examples, the grease isolation wall 109 separates the worm drive 140 from the gearbox 145. Figure 2H A top view of the interface between the spool 130 and the shoelace cable 131 is also provided, wherein the shoelace cable 131 extends in an inside-out direction through the shoelace groove 132 in the spool 130.

[0037] Figure 2I This is a top view illustration of the worm gear 150 and marker wheel 151 portions of the belt-fastening engine 10 according to an exemplary embodiment. The marker wheel 151 is a variation of the Geneva wheel, a well-known type used in watchmaking and film projectors. A typical Geneva wheel or drive mechanism provides a method for converting continuous rotational motion into intermittent motion, as required in film projectors or for making the second hand of a watch move intermittently. By using Geneva wheels with missing slots (e.g., one of the Geneva slots 157 is missing), watchmakers use different types of Geneva wheels to prevent over-winding of the mechanical watch spring. The missing slot prevents further marking of the Geneva wheel, which is responsible for winding the spring and preventing over-winding. In the illustrated example, the belt-fastening engine 10 includes a variation of the Geneva wheel, marker wheel 151, which includes a small stop tooth 156 that acts as a stop mechanism in homing operation. Figures 2J to 2M As illustrated, when the marking tooth 152 engages with the groove 157 of a groover tooth 155 adjacent to one of the groover teeth 155, the standard groover tooth 155 simply marks each rotation of the worm gear 150. However, when the marking tooth 152 engages with the groove 157 of the groover tooth 156 adjacent to the stop tooth 156, a greater force is generated, which can be used to stop the drive mechanism during a return-to-home operation. The side profile of the stop tooth 156 is steep and generally straight (compared to the side profile of the groover tooth 155). The stop tooth 156 can be used to generate a known position for a mechanism (such as the motor encoder 146) to be used for return-to-home in the event of loss of other positioning information.

[0038] In this example, the return-to-position device (marker wheel 151) is designed to allow four complete rotations between home positions. The return-to-position device has two home positions: one representing a fully loose state (all shoelaces untied from the spool), and the second representing a fully tightened state (the system winds as many shoelaces as possible onto the spool). When the return-to-position device encounters either home position, the interaction between the marker tooth 152 and the stop tooth 156 generates a force large enough to stop the drive mechanism. The system can measure the force via motor current. The force profile associated with the engagement of the marker tooth 152 and the stop tooth 156 is significantly different from the force profile generated by the engagement of the marker tooth 152 and one of the slotted teeth 155, and the processor can identify this difference. In this example, the force profile generated by encountering the stop tooth has a larger amplitude and a faster rate of change (e.g., a higher slope). The force profile generated by engaging the stop tooth is also designed to differ from the force profile generated by pulling on the shoelace cable, which can be transmitted to the drive mechanism via the spool. The force generated by the force transmitted through the shoelace cables will be generally smaller in amplitude and slower in rate of change (e.g., lower slope).

[0039] Figures 2J to 2M This is an illustration of a worm gear 150 and a marker wheel 151 that move via a marking operation according to an exemplary embodiment. As described above, from Figure 2J Start to Figure 2M These accompanying figures illustrate what happens during a single complete rotation of the worm gear 150 around its axis. Figure 2J In the worm gear 150, the marking tooth 153 is engaged in the groove 157 between the first groove tooth 155a and the stop tooth 156 in the groove tooth 155. Figure 2K The illustration shows the marking wheel 151 in the first marking position, which is held in place as the marking tooth 153 begins its rotation about its axis along with the worm gear 150. Figure 2L In the middle, the marking tooth 153 begins to engage with the groove 157 on the opposite side of the first groove tooth 155a. Finally, in Figure 2M In the middle, the marking tooth 153 is fully engaged in the groove 157 of the groove wheel between the first groove wheel tooth 155a and the second groove wheel tooth 155b. Figures 2J to 2M The process shown continues with each rotation of the worm gear 150 around its axis until the marking tooth 153 engages the stop tooth 156. As described above, when the marking tooth 153 engages the stop tooth 156, the increased force causes the drive mechanism to stop.

[0040] Figure 2N This is an exploded view of the lacing engine 10 according to an exemplary embodiment. The exploded view of the lacing engine 10 provides an illustration of how all the different components fit together. Figure 2NAn inverted tethered motor 10 is shown, with the bottom portion 104 at the top of the page and the top portion 102 near the bottom. In this example, the wireless charging coil 166 is shown as being bonded to the outside (bottom) of the bottom portion 104. The exploded view also provides a good illustration of how the worm drive 140 is assembled with the bushing 141, drive shaft 143, gearbox 144, and gear motor 145. This illustration does not include the drive shaft pin housed within the worm drive key 142 at the first end of the worm drive 140. As described above, the worm drive 140 slides on the drive shaft 143 to engage the drive shaft pin in the worm drive key 142, which is essentially a slot extending transversely to the drive shaft 143 in the first end of the worm drive 140.

[0041] Figure 3 This is a block diagram illustrating components of a motorized lacing system 1000 for footwear according to some exemplary embodiments. System 1000 illustrates basic components of the motorized lacing system, including an interface button 1001, an optional foot presence sensor 1010, a printed circuit board assembly (PCA) 1020 with processor circuitry, a battery 1021, a charging coil 1022, an encoder 1025, a motor 1041, a gearbox 1042, and a spool 1043. In this example, the interface button 1001 and the foot presence sensor 1010 can communicate with the circuit board (PCA) 1020, which also communicates with the battery 1021 and the charging coil 1022. The encoder 1025 and the motor 1041 are also connected to the circuit board 1020 and to each other. The gearbox 1042 connects the motor 1041 to the spool 1043 to form a drive mechanism 1040. In this example, motor 1041, gearbox 1042 and spool 1043 constitute drive mechanism 1040. In some examples, drive mechanism 1040 also includes encoder 1025.

[0042] In the example, processor circuitry 1020 controls one or more aspects of drive mechanism 1040. For example, processor circuitry 1020 may be configured to receive information from button 1001 and / or foot presence sensor 1010 and / or from battery 1021 and / or from drive mechanism 1040 and / or from encoder 1025, and may also be configured to issue commands to drive mechanism 1040, such as to tighten or loosen footwear, or to acquire or record sensor information, and other functions. As discussed further below, in some examples, processor circuitry 1020 may measure voltage and current from battery 1021. Processor circuitry 1020 may also monitor signals from encoder 1025. Processor circuitry 1020 may use information from battery 1021 and encoder 1025 to control drive mechanism 1040, particularly motor 1041. In some examples, processor circuitry 1020 may also measure current draw from motor 1041, which may be used as a measurement of the torque being generated by motor 1041. As discussed further below, the voltage can be measured by the processor circuit 1020, and the voltage can be used as a measurement of the motor speed (or they are directly related).

[0043] Motor control scheme

[0044] Figures 4 to 9 This document illustrates various aspects of a motor control scheme for controlling a motorized tethered engine according to some exemplary embodiments. The motor control scheme discussed herein can control the operation of drive mechanism 1040, and more specifically, can control motor 1041 (or as...). Figures 1 to 2N The operation of the motor 145 shown in the figure. Motor control schemes include, for example, variable-size control segments (…). Figure 4 ), motion profiles () Figures 5 to 7 The concept of modifying motor control parameters based on battery voltage.

[0045] Figure 4This includes a diagram illustrating the concept of a variable-segment control segment according to an exemplary embodiment. In this example, with regard to shoelace take-up, the variable-segment size motor control scheme involves dividing the total travel into multiple segments, the size of which varies based on the position on a continuous shoelace travel (e.g., between the home / loose position at one end and the maximum tightening at the other end). Since the motor is controlling the radial spool and will be controlled primarily by a radial encoder on the motor shaft, the segment size can be determined based on the degree of spool travel (or can be viewed from the encoder count). On the loose side of the continuum, because the amount of shoelace movement is less important, the segments can be larger, such as 10 degrees of thread travel. However, as the shoelace is tightened, each increase in shoelace travel becomes increasingly important for achieving the desired shoelace tightening. Other parameters, such as motor current, can be used as auxiliary measurements of shoelace tightening or continuous position. Figure 4 Includes two separate illustrations based on different segment sizes along the position of the tightened continuum.

[0046] In the example, the variable-size control segment includes dividing the total rotational stroke of the drive mechanism into variable-size segments based on its position within the stroke continuum. As described above, in some examples, the drive mechanism 1040 may be configured to have a finite total operating stroke. The total operating stroke of the drive mechanism can be viewed in terms of rotation or in terms of linear distance. When viewed in terms of linear distance, the total operating stroke can be viewed in terms of the amount of lace (or tensioning member) that the drive mechanism is able to take up. The continuum of the total operating stroke of the drive mechanism can be viewed in terms of the progress of lace take-up from the home (or fully loose) position to the maximum tension (e.g., four complete rotations of the spool 1043 controlled by the aforementioned mechanical stop mechanism). The movement of the drive mechanism 1040 on the loose side of the continuum can be more abrupt (e.g., greater), while on the maximum tension side, the commanded movement requires a finer level of control, as illustrated by control segment 401. Therefore, in this example, the moving continuum is divided into multiple segments or groups, where each unit within a segment or group represents a specific dimension of movement (e.g., rotation, encoder count, or linear distance). On the loose side of the continuum, the unit size can be large or command the drive mechanism 1040 to perform larger rotational movements. On the tight side of the continuum, the units can be smaller to command the drive mechanism 1040 to perform smaller rotational movements.

[0047] In the example, the variable control segment 402 may include a travel continuum 410, which can be divided into six control segments 415, 420, 425, 430, 435, and 440. The travel continuum 410 extends from detangling segments 415 to the maximum tightening segment 440, with return-to-situ segments 420, comfort segments 425, performance segments 430, and high-performance segments 435 in between. As shown in the figure illustrating the different lateral distances of the blocks of different control segments within the variable control segment 402, each different segment unit can command the drive mechanism 1040 to move by a different amount. The segment units can be defined based on the rotational degree of the spool or the straight-line travel distance of the shoelace.

[0048] The motion pattern design involves assembling one or more movements of the drive mechanism into a pattern that commands a desired result. Each motion pattern will include parameters controlling the movement of the drive mechanism 1010. In the example, the parameters are viewed in relation to the movement of the control spool 1009. Motion patterns can be generated from a table of movements. Motion patterns can be modified using other global parameters, such as gear reduction multipliers and / or scaling factors associated with battery voltage. For example, see the following reference... Figure 8 and Figure 9 The motion control techniques discussed can modify the scaling factor, which will then be used to modify the motion pattern.

[0049] Figure 5 The diagram illustrates a table that constructs a motion pattern using the position of the tightening continuum based on the current position and the desired end position. The motion pattern can then be translated into specific input from a user input button. In this example, the motion pattern includes parameters of the spool's motion, such as acceleration (acceleration (degrees / seconds)), velocity (velocity (degrees / seconds)), deceleration (deceleration (degrees / seconds)), and angle of movement (angle (degrees)). In some examples, the movement parameters can alternatively be represented based on the shoelace's acceleration, velocity, deceleration, and straight-line distance.

[0050] Figure 6 Exemplary motion patterns are depicted on a velocity-time graph. Graph 601 illustrates the velocity-time patterns of different motion patterns, such as the in-situ to comfortable and relaxed patterns. Graph 602 illustrates an entanglement movement pattern in which the system rapidly and continuously tightens and relaxes in an effort to eliminate entanglement within the drive mechanism 1040 (e.g., entanglement of shoelaces in the spool 1043).

[0051] Figure 7This diagram illustrates exemplary user input to activate multiple motion patterns along a tightening continuum. For example, a short button activation on a plus actuator can be programmed to move along the continuum to a progressively tighter position, such as from home / release to comfort. Conversely, a short button activation on a negative actuator can be programmed to move to a progressively looser position, such as from performance to comfort. Double-pressing the individual buttons can activate different patterns. For example, a double-press on a plus actuator can be programmed to move more quickly to the next progressively tighter position on the continuum, such as from performance to maximum tightness. A double-press on a negative actuator can be programmed to transition back to the home / release position, regardless of the starting position. Holding actuator buttons can be programmed to tighten (plus actuator) or release (negative actuator) until released or a stop position is reached (e.g., maximum tightness or home / release).

[0052] Figure 8 and Figure 9This includes flowcharts illustrating exemplary drive mechanism control schemes based at least in part on different operating zones based on battery voltage levels. In devices utilizing battery-powered motors, the available battery voltage directly affects the rotational speed (speed) at which the motor can operate, with higher available voltage resulting in higher speeds. Batteries generally have an operating voltage range from fully charged to low battery levels (systems are typically designed to not completely deplete / discharge the battery). During a discharge cycle, the voltage supplied by the battery gradually decreases until the battery management system (BMS) shuts off the battery to prevent damage from discharge. For example, in the specific design of the lace-up motor discussed herein, a battery with an operating voltage range of 4.3V to 3.6V can be used. In the absence of some form of motor control, the motor will naturally exhibit a wide possible variation in output speed within this operating range. In some devices, variations in motor output speed can lead to negative consumer impressions and / or undesirable variations in perceived or actual performance. For example, a lace-up motor might exhibit undesirable variations in maximum lace tightening or in the time taken to reach a desired tightening level. Therefore, to address these potential undesirable performance variations, a motor control scheme is designed to smooth the motor output speed over at least a portion of the motor's voltage operating range. In this example, two operating zones are selected such that, for a portion of the operating range, the motor can operate at a performance level higher than the possible performance levels at the lower end of the operating voltage range, while still eliminating some undesirable performance variations. Using this scheme also provides the benefits of a more consistent user experience, such as operating speed and the motor sound heard during operation.

[0053] In this example, a voltage threshold is chosen as the lower end of the primary operating voltage range. In some examples, the desired operating speed is chosen instead of or as a means of determining the threshold voltage. In these examples, the motor used has some direct relationship between input voltage and output speed (velocity), so choosing one determines the other. At the selected or determined voltage threshold, the motor can operate at 100% duty cycle to achieve the target output speed. At voltages above the threshold voltage, the motor can operate at less than 100% duty cycle to maintain the target output speed. Therefore, at the full operating voltage available from the battery above the threshold voltage, the motor can operate at a constant output speed. This control scheme provides a more consistent user experience in terms of performance, including lace tightening speed, tension, and audible feedback to the user. An additional benefit is that operating parameters (such as audible feedback) change when the battery voltage drops below the threshold voltage. This significant change in operating parameters can indicate to the user that the battery needs to be charged.

[0054] In this example, once the battery voltage drops below the threshold voltage, system performance degrades to a level consistent with the minimum operating voltage (sometimes referred to as the critical low battery level). This degradation in the drive system's output performance can serve as an indication to the user that the battery needs to be charged as soon as possible. This performance degradation can be designed in a way that allows for continued operation at lower performance levels for a period of time.

[0055] In the exemplary tethered system, a battery with an operating range of 4.3V to 3.6V can be used. A threshold voltage of 3.8V can be selected in this system. At battery voltages above 3.8V, the system operates at a target output speed equal to the output speed at 100% duty cycle at 3.8V. Therefore, when the battery is fully charged (4.3V), the processor circuitry 1020 can regulate the power supplied to the motor to achieve the target output speed. Thus, at 4.3V, the motor will operate at a duty cycle less than 100%. Once the voltage available from the battery drops below 3.8V, the system will degrade its performance so that the target output speed is equal to the output speed at 100% duty cycle at 3.6V (the critically low battery level in this exemplary system).

[0056] Figure 8 This is a flowchart illustrating a motor control technology 800 according to an exemplary embodiment. In this example, system 1000 may implement motor or drive system control technology 800, including operations such as segmenting the operating range (810), defining multiple actions (820), creating multiple motion patterns (830), and commanding movement (840).

[0057] Motor control technology 800 may begin at operation 810, where processor circuitry 1020 segments the operating range (such as the stroke continuum 410) into different control segments. In some examples, at 810, processor circuitry 1020 accesses a set of control segments for a specific operating range, because this set of control segments can be predetermined for a specific system. Figure 4As shown, control segments can include segments ranging from untangling segment 415 to maximum tightening segment 440. Each control segment can represent a different amount of travel, expressed in rotational degrees or linear distance. Segmenting continuous travel segments into segments of different sizes by using control segments that automatically change the size of movement based on the position of the system operating along the travel continuum can simplify motion patterns. For example, when the footwear platform is in the home (loose) state, pressing a single button can result in a much larger commanded amount of lace travel than when the footwear platform is near the maximum tightening state. In some examples, the definition of control segments is executed outside of system 1000, where the operating instructions of system 1000 use pre-programmed control segments. In these examples, processor circuitry 1020 can access the pre-programmed control segments from data structures stored in memory within system 1000.

[0058] At 820, motor control technology 800 can continue, where processor circuitry 1020 defines (or accesses) multiple motor actions. Motor actions can be defined according to control segments, such as moving two in-situ segments 420 and three comfort segments 425. Motor actions can also include performance parameters such as acceleration, speed, and deceleration. In some examples, motor actions may include distance parameters defined based on control segments, rotational speed, or linear travel distance. Operation 820 is another operation that can be pre-programmed into instructions loaded into system 1000, in which case processor circuitry 1020 can access the pre-programmed motor actions from tables or similar data structures stored in memory on system 1000.

[0059] At 830, motor control technology 800 can continue, where the processor circuitry creates (or accesses) multiple motion patterns. A motion pattern can include one or more motor actions. Motor actions within a motion pattern can be defined as reaching different states of the footwear platform, such as a loose (in-place) state or a maximum tightening state. Operation 830 is another operation that can be pre-programmed into instructions loaded into system 1000; when pre-programmed, the processor circuitry 1020 accesses the motion pattern when the command moves.

[0060] At 840, motor control technology 800 continues, wherein processor circuitry 1020 uses motion patterns to command movement of drive mechanism 1040. Commanding movement may include selecting a motion pattern based on the current position along the stroke continuum. For example, when the system is in a position away from its home position, processor circuitry 1020 only selects a motion pattern that returns to the home position.

[0061] Figure 9This diagram illustrates a flowchart of a motor control technique 900 according to an exemplary embodiment. In some examples, the motor control technique 900 further defines how the processor circuitry 1020 commands movement according to the operation 840 discussed above. In other examples, the motor control technique 900 may be implemented independently of operation 840 or the motor control technique 800. In the illustrated example, the motor control technique 900 may include operations such as: determining a first target speed (910), determining a second target speed (920), measuring battery voltage (930), determining whether the battery voltage exceeds a threshold (940), and setting operating parameters (950, 960) accordingly.

[0062] At 910, motor control technology 900 may begin by determining (or accessing) a first target motor output speed via processor circuitry 1020. In some examples, the first target motor output speed is determined based on the motor's output speed at a threshold battery voltage while the system operates at 100% duty cycle. In some examples, the first target speed is pre-programmed into system 1000, and at operation 910, processor circuitry 1020 only accesses the first target speed.

[0063] At 920, motor control technology 900 can continue, where processor circuitry 1020 determines (or accesses) a second target motor output speed. In some examples, the second target motor output speed is determined based on an output speed determined at a critically low battery level (e.g., minimum permissible operating voltage) while the system operates at 100% duty cycle. In some examples, the second target speed is pre-programmed into system 1000, and at operation 920, processor circuitry 1020 only accesses the second target speed.

[0064] In some examples, operations 910 and 920 are performed outside of the real-time operation of system 1000. In these examples, a first target motor output speed and a second target motor output speed can be determined or selected. In one example, a threshold battery voltage can be selected and used to determine the first and second target motor output speeds. In another example, the first target motor output speed can be selected and used to determine the threshold voltage level. In this example, the threshold voltage level is the level at which the system can achieve the selected first target motor output speed when operating at 100% duty cycle.

[0065] At 930, motor control technology 900 can continue, wherein processor circuit 1020 receives a signal indicating the current battery output voltage transmitted to drive mechanism 1040. In some examples, processor circuit 1020 may include a voltmeter; in other examples, a battery, BMS, or other components may provide the necessary signals to processor circuit 1020 indicating the voltage level.

[0066] At 940, motor control technology 900 continues, wherein processor circuitry 1020 uses a voltage level indication to determine whether the voltage supplied to the motor exceeds a threshold voltage. As described above, in some examples, system 1000 can operate within a specific voltage range with specific operating parameters, and within a second voltage range with a second set of operating parameters.

[0067] If the measured voltage delivered to the motor exceeds the threshold voltage, motor control technology 900 continues at 950, where processor circuitry 1020 operates drive system 1040 using a first set of operating characteristics (at least one operating parameter is set to a first value). In this example, at operation 950, the controlled operating parameter is the motor's output speed, and the motor is controlled at a single output speed within the input voltage range.

[0068] If the measured voltage delivered to the motor does not exceed the threshold voltage, the motor control technology 900 continues at 960, where the processor circuit 1020 operates the drive system 1040 using a second set of operating characteristics. The operating characteristics include at least one operating parameter, which in this example is the motor output speed. In this example, the motor output speed operates at a second target speed when the battery voltage drops below a predetermined threshold voltage. The controlled operating characteristic could also be current or duty cycle, etc.

[0069] The following example provides further details about the motor control techniques discussed above.

[0070] Example

[0071] The inventors have recognized, among other things, the need for improved motor control for motorized lacing engines used in automated and semi-automated shoelace tightening. This document describes examples of motor control for controlling motorized lacing engines within a footwear platform. The following examples provide non-limiting examples of the methods discussed herein for controlling motors within lacing engines in footwear components.

[0072] Example 1 describes a method for controlling a motor within a drive mechanism in an automated footwear platform. In this example, the method may include segmenting a predetermined travel distance, defining multiple actions, creating multiple motion patterns, and commanding movement of the drive mechanism. The predetermined travel distance is associated with the drive mechanism and may be segmented into multiple segments. Multiple actions are defined for the drive mechanism to perform functions associated with tightening or loosening laces on the footwear platform. Multiple motion patterns are created such that each of the multiple motion patterns includes one or more actions from the multiple actions. Commanding movement includes operating the drive mechanism based on selecting one or more motion patterns from the multiple motion patterns.

[0073] In Example 2, the subject matter described in Example 1 may optionally include: each of the plurality of actions has an acceleration parameter, a velocity parameter, a deceleration parameter, and a distance parameter.

[0074] In Example 3, the subject matter described in Example 2 may optionally include: the distance parameter being provided as segments of a plurality of segments.

[0075] In Example 4, the subject described in Example 2 may optionally include: the distance parameter being provided in degrees of rotation.

[0076] In Example 5, the subject matter described in Example 4 may optionally include: applying rotation degrees to multiple segments to determine the selection of the segment associated with each movement among the multiple segments.

[0077] In Example 6, the subject matter according to any one of Examples 1 to 5 may optionally include: the command movement further includes the following operations: determining a first target speed for operating the motor within the drive mechanism when the voltage supplied to the motor is higher than a threshold voltage; determining a second target speed for operating the motor when the voltage supplied to the motor is lower than a threshold voltage; measuring a first voltage supplied by the battery; and setting a speed parameter equal to the first target speed when the first voltage is determined to be at or above the threshold voltage, or setting a speed parameter equal to the second target speed when the first voltage is determined to be lower than the threshold voltage.

[0078] In Example 7, the subject matter according to any one of Examples 1 to 5 may optionally include: the command movement further includes the following operations: using processor circuitry coupled to a motor within the drive mechanism to measure the battery voltage supplied to the motor to determine an input battery voltage; using the processor circuitry to compare the input battery voltage with a threshold voltage to determine whether the input battery voltage is higher or lower than the threshold voltage (e.g., exceeds the threshold voltage); when it is determined that the input battery voltage is higher than the threshold voltage, applying a first scaling factor to one or more selected motion modes, or when it is determined that the input battery voltage is lower than the threshold voltage, applying a second scaling factor to one or more selected motion modes.

[0079] In Example 8, the subject matter according to any one of Examples 1 to 7 may optionally include: the command movement further includes receiving user input and selecting one or more motion modes based on the user input.

[0080] In Example 9, the subject matter described in Example 8 may optionally include: selecting a motion pattern by identifying the current position along a predetermined travel distance.

[0081] In Example 10, the subject matter according to Example 9 may optionally include: identifying the current location by identifying a segment among a plurality of segments that is associated with the current location.

[0082] In Example 11, the subject matter according to any one of Examples 9 and 10 may optionally include: identifying the current position by analyzing data received from an encoder coupled to a drive mechanism, the encoder being configured to provide an output that can be correlated with a distance or position along a predetermined travel distance.

[0083] In Example 12, the subject matter according to any one of Examples 9 to 11 may optionally include: one or more motion modes having multiple motion modes representing movement between states.

[0084] In Example 13, the subject matter according to any one of Examples 9 to 12 may optionally include states including in-situ / loose state, comfort state, performance state, and maximum tightness state.

[0085] In Example 14, the subject matter according to Example 13 may optionally include: receiving user input by receiving a short button press, wherein selecting a motion pattern selects a pattern for moving to an adjacent state.

[0086] In Example 15, the subject matter described in Example 13 may optionally include receiving user input by receiving a short button press on an actuator, which results in the selection of a form for moving to the next progressively tighter state.

[0087] In Example 16, the subject matter described in Example 13 may optionally include receiving user input by receiving a double-time button press on the deceleration actuator, which results in the selection of a mode for moving to the home / release state.

[0088] In Example 17, the subject matter described in Example 13 may optionally include receiving user input by receiving a hold button press, which results in the selection of a mode for movement until the hold button press input is released.

[0089] Example 18 describes a subject matter including a method for controlling a motor. In this example, the motor control method may include the following operations: Receiving a signal representing an input battery voltage supplied to the motor using processor circuitry coupled to a drive system including the motor; comparing the input battery voltage with a threshold voltage using the processor circuitry to determine whether the input battery voltage exceeds the threshold voltage; when it is determined that the input battery voltage exceeds the threshold voltage, controlling the motor within the drive system using the processor circuitry to produce a first operating characteristic corresponding to operation of the motor at a first operating voltage; and when it is determined that the input battery voltage does not exceed the threshold voltage, controlling the motor using the processor circuitry to produce a second operating characteristic corresponding to operation of the motor at a second operating voltage.

[0090] In Example 19, the subject matter described in Example 18 may optionally include: a first operating characteristic and a second operating characteristic selected from a set of operating characteristics, including speed and torque. In some systems, speed is related to input voltage and torque is related to input current.

[0091] In Example 20, the subject matter according to any one of Examples 18 to 19 may optionally include: the drive system bearing a constant load.

[0092] In Example 21, the subject matter according to any one of Examples 18 to 20 may optionally include: a first operating voltage corresponding to a voltage higher than a threshold voltage.

[0093] In Example 22, the subject matter according to any one of Examples 18 to 20 may optionally include: a first operating voltage equal to a threshold voltage.

[0094] In Example 23, the subject matter according to any one of Examples 18 to 22 may optionally include: the second operating voltage corresponds to a voltage below a threshold voltage.

[0095] In Example 24, the subject matter described in Example 23 may optionally include: a second operating voltage corresponding to a minimum effective operating voltage associated with a motor, drive system, or tethered engine.

[0096] In Example 25, the subject matter according to any one of Examples 18 to 24 may optionally include: if the input battery voltage is higher than a first operating voltage, operating the motor may include adjusting the voltage supplied to the motor to cause the motor to operate with a first operating characteristic corresponding to operation of the motor at 100% duty cycle under constant load at the first operating voltage.

[0097] In Example 26, the subject matter described in Example 25 may optionally include: regulating the voltage supplied to the motor by pulse modulation of the voltage with a duty cycle of less than 100%.

[0098] In Example 27, the subject matter according to Example 18 may optionally include: a first operating characteristic of the motor being a first audible pitch generated by the motor, wherein a second operating characteristic is a second audible pitch, and wherein the first audible pitch is different from the second audible pitch.

[0099] In Example 28, the subject matter described in Example 27 may optionally include: the audible pitch generated by the motor is primarily based on the operating speed, and the motor operates at a first operating speed when the battery voltage is above a threshold voltage, and at a second operating speed when the battery voltage is below the threshold voltage.

[0100] In Example 29, the subject matter according to any one of Examples 18 to 28 may optionally include: a first operating voltage of 3.8 volts and a second operating voltage of 3.6 volts.

[0101] In Example 30, the subject matter according to any one of Examples 18 to 28 may optionally include: a first operating voltage at approximately 30% of the maximum voltage operating range.

[0102] In Example 31, the subject matter according to Example 30 may optionally include: a maximum voltage operating range extending from 4.3V to 3.6V, and approximately 3.8V at 30% of the maximum voltage operating range.

[0103] In Example 32, the subject matter according to any one of Examples 18 to 31 may optionally include: the second operating voltage being at approximately 0% of the maximum voltage operating range.

[0104] In Example 33, the subject matter described in Example 32 may optionally include: a maximum voltage operating range extending from 4.3V to 3.6V, and 3.6V at 0% of the maximum voltage operating range.

[0105] In Example 34, the subject matter according to any one of Examples 18 to 33 may optionally include: calculating a threshold voltage by determining the voltage at a selected speed that the motor can generate when operating at 100% duty cycle under constant operating load.

[0106] In Example 35, the subject matter described in Example 34 may optionally include: selecting a speed less than the maximum speed that the motor can produce when receiving the maximum battery voltage and operating at 100% duty cycle.

[0107] In Example 36, the subject matter described in Example 35 may optionally include: the selected speed is a predetermined percentage of the maximum speed.

[0108] In Example 37, the subject matter according to any one of Examples 34 to 36 may optionally include: an operating characteristic of the motor speed, wherein the motor duty cycle is controlled to produce a first constant speed when the input battery voltage is at or above a threshold voltage, and the motor duty cycle is controlled to produce a second constant speed when the input battery voltage is below the threshold voltage.

[0109] Example 38 describes a subject matter including a method for controlling a motor, wherein the method can be used to control a motor within a lacing engine of an automated footwear platform as described above. In this example, the method may include the following operations, wherein these operations can be performed by processor circuitry within the lacing engine: determining when the voltage supplied to the motor is higher than a threshold voltage, or accessing a first target speed for operating the motor; determining when the voltage supplied to the motor is lower than a threshold voltage, or accessing a second target speed for operating the motor; measuring a first voltage supplied by a battery, or receiving a signal indicating the first voltage supplied by the battery; operating the motor at the first target speed based on determining that the first voltage is at or above the threshold voltage, or operating the motor at the second target speed based on determining that the first voltage is lower than the threshold voltage.

[0110] Example 39 describes a system, such as the tethered motor system described herein. In this example, the system may include a battery, a motor, and processor circuitry. The battery may include an operating voltage range. The motor may include a drive system. The processor circuitry may include a processor and a memory device, and the memory device may include instructions that, when executed by the processor circuitry, cause the system to perform operations such as: measuring or receiving a voltage supplied by the battery to the motor to obtain an input battery voltage; comparing the input battery voltage to a threshold voltage to determine whether the input battery voltage exceeds the threshold voltage; when it is determined that the input battery voltage exceeds the threshold voltage, controlling the motor within the drive system to produce a first output speed corresponding to the motor's operation at a first operating voltage; and finally, when it is determined that the input battery voltage does not exceed the threshold voltage, controlling the motor to produce a second output speed corresponding to the motor's operation at a second operating voltage.

[0111] Example 40 describes a memory device or non-transitory computer-readable medium including instructions that, when executed by a motor controller, cause the motor controller to perform the following operations: Measuring or receiving a voltage supplied to the motor by a battery to obtain an input battery voltage. Comparing the input battery voltage to a threshold voltage to determine whether the input battery voltage exceeds the threshold voltage. When it is determined that the input battery voltage exceeds the threshold voltage, controlling the motor within the drive system to produce a first output speed corresponding to operation of the motor at a first operating voltage. Finally, when it is determined that the input battery voltage does not exceed the threshold voltage, controlling the motor to produce a second output speed corresponding to operation of the motor at a second operating voltage. The memory device may also include instructions that cause the motor controller to perform the operations described in any of Examples 1 to 37.

[0112] Additional notes

[0113] Throughout this specification, multiple instances can implement components, operations, or structures described as single instances. While the various operations of one or more methods are illustrated and described as separate operations, one or more of these separate operations can be performed simultaneously, and they do not need to be performed in the order shown. Structures and functions presented as separate components in the example constructions can be implemented as composite structures or components. Similarly, structures and functions presented as single components can be implemented as separate components. These and other variations, modifications, additions, and improvements fall within the scope of the subject matter herein.

[0114] Although an overview of the subject matter of the invention has been described with reference to specific exemplary embodiments, various modifications and changes may be made to these embodiments without departing from the broader scope of embodiments of this disclosure. These embodiments of the subject matter of the invention may be referred to herein individually or uniformly as the term "invention," which is merely for convenience and is not intended to voluntarily limit the scope of this application to any single disclosure or inventive concept (if more than one is disclosed in fact).

[0115] The embodiments illustrated herein have been described in sufficient detail to enable those skilled in the art to practice the disclosed teachings. Other embodiments may be used and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. Therefore, this disclosure should not be construed as limiting, and the scope of the various embodiments includes the full scope of the authorized equivalents of the disclosed subject matter.

[0116] As used herein, the term "or" can be interpreted as inclusive or exclusive. Furthermore, multiple instances may be provided for a resource, operation, or structure described herein as a single instance. Moreover, the boundaries between various resources, operations, modules, engines, and data stores are somewhat arbitrary, and a particular operation is illustrated within the context of a particular illustrative construct. Other allocations of functionality are foreseeable and may fall within the scope of various embodiments of this disclosure. Generally, structures and functions presented as separate resources in exemplary constructs may be implemented as combined structures or resources. Similarly, structures and functions presented as single resources may be implemented as separate resources. These and other variations, modifications, additions, and improvements fall within the scope of embodiments of this disclosure as represented by the appended claims. Therefore, the specification and drawings are to be considered illustrative rather than restrictive.

[0117] Each of these non-restrictive examples can exist independently, or can be combined with one or more other examples in various permutations or combinations.

[0118] The above detailed description includes reference to the accompanying drawings, which form part of the detailed description. The drawings illustrate specific embodiments in which the invention can be practiced. These embodiments are also referred to herein as “examples.” Such examples may include elements other than those shown or described. However, the inventors have also contemplated examples that provide only those elements shown or described. Furthermore, the inventors have contemplated examples of any combination or arrangement of those elements (or one or more aspects thereof) shown or described herein, either with respect to a particular example (or one or more aspects thereof) or to other examples (or one or more aspects thereof) shown or described herein.

[0119] In the event of any inconsistency between the usage of this document and any other document incorporated by reference, the usage in this document shall prevail.

[0120] In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more, independent of any other instance or use of “at least one” or “one or more.” In this document, the term “or” is used to mean non-exclusive or such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise stated. In this document, the terms “including” and “in which” are used as simple English equivalents to the corresponding terms “comprising” and “wherein.” Furthermore, in the appended claims, the terms “comprising” and “including” are open-ended, meaning that a system, apparatus, article, composition, formulation, or process that includes elements other than those listed after such terms in the claim is still considered to fall within the scope of that claim. Additionally, in the appended claims, the terms “first,” “second,” and “third,” etc., are used merely as labels and are not intended to impose numerical requirements on their objects.

[0121] The method examples described herein, such as the motor control example, can be implemented at least in part by a machine or computer. Some examples may include computer-readable or machine-readable media encoded with instructions operable to configure electronic devices to perform the methods described in the examples above. Implementations of these methods may include code, such as microcode, assembly language code, high-level language code, etc. Such code may include computer-readable instructions for performing multiple methods. The code may form part of a computer program product. Furthermore, in the examples, the code may be tangibly stored on one or more volatile, non-transitory, or non-volatile tangible computer-readable media, such as during execution or at other times. Examples of such tangible computer-readable media may include, but are not limited to, hard disks, removable disks, removable optical discs (e.g., optical discs and digital video discs), magnetic tape cassettes, memory cards or sticks, random access memory (RAM), read-only memory (ROM), etc.

[0122] The above description is intended to be illustrative and not restrictive. For example, the examples described above (or one or more aspects thereof) may be used in combination with each other. Other embodiments may be used, such as those that can be used by one of ordinary skill in the art upon review of the above description. To comply with U.S. Regulation 37 CFR §1.72(b), an abstract (if provided) is included to allow the reader to quickly determine the nature of the technical disclosure. It is to be understood that the abstract is submitted only insofar as it is not intended to interpret or limit the scope or meaning of the claims. Furthermore, in the above description, multiple features may be combined together to simplify this disclosure. This should not be construed as meaning that any unstated disclosed feature is essential to any claim. Rather, the subject matter of the invention may be less than all the features of a particular disclosed embodiment. Therefore, the appended claims are incorporated into the detailed description as examples or embodiments, wherein each claim is independently as a separate embodiment, and it is contemplated that these embodiments may be combined with each other in various combinations or arrangements. The scope of the invention should be determined by reference to the appended claims and the full scope of their equivalents.

Claims

1. A motor control method comprising: receiving, using a processor circuit coupled to a drive system including a motor, a signal indicative of an input battery voltage provided to the motor; calculating a threshold voltage by determining a voltage at which the motor is capable of producing a selected speed when operating at 100% duty cycle with a constant operating load; comparing, using the processor circuit, the input battery voltage to the threshold voltage to determine whether the input battery voltage exceeds the threshold voltage; controlling, using the processor circuit, the motor within the drive system to produce a first operating characteristic corresponding to operation of the motor at a first operating voltage when it is determined that the input battery voltage exceeds the threshold voltage; and controlling the motor to produce a second operating characteristic corresponding to operation of the motor at a second operating voltage when it is determined that the input battery voltage does not exceed the threshold voltage.

2. The motor control method according to claim 1, wherein the first operating characteristic and the second operating characteristic are selected from a set of operating characteristics including: speed; and torque.

3. The motor control method of claim 1, wherein, the drive system is subject to a constant load.

4. The motor control method of claim 1, wherein, the first operating voltage corresponds to a voltage higher than the threshold voltage.

5. The motor control method of claim 1, wherein, the first operating voltage is equal to the threshold voltage.

6. The motor control method of claim 1, wherein, the second operating voltage corresponds to a voltage lower than the threshold voltage.

7. The motor control method of claim 6, wherein, the second operating voltage corresponds to a minimum effective operating voltage associated with the drive system.

8. The motor control method of claim 1, wherein, if the input battery voltage is higher than the first operating voltage, operating the motor includes regulating a voltage provided to the motor to cause the motor to operate with the first operating characteristic corresponding to operation of the motor at the first operating voltage with a constant load at 100% duty cycle.

9. A motor control method comprising: calculating a threshold voltage by determining a voltage at which the motor is capable of producing a selected speed when operating at 100% duty cycle with a constant operating load; determining a first target speed for operating the motor when a voltage provided to the motor is higher than the threshold voltage; determining a second target speed for operating the motor when the voltage provided to the motor is lower than the threshold voltage; measuring a first voltage provided by a battery; operating the motor at the first target speed based on determining that the first voltage is at or above the threshold voltage; and operating the motor at the second target speed based on determining that the first voltage is below the threshold voltage.

10. A motor control system comprising: a battery having an operating voltage range; a motor having a drive system; and a processor circuit including a processor and a memory device containing instructions that, when executed by the processor circuit, cause the motor control system to perform operations including: calculating a threshold voltage by determining a voltage at which the motor is capable of producing a selected speed when operating at 100% duty cycle with a constant operating load; receiving a signal indicative of an input battery voltage provided to the motor by the battery; ​ comparing the input battery voltage to the threshold voltage to determine whether the input battery voltage exceeds the threshold voltage; controlling the motor within the drive system to produce a first output speed corresponding to operation of the motor at a first operating voltage when it is determined that the input battery voltage exceeds the threshold voltage; and controlling the motor to produce a second output speed corresponding to operation of the motor at a second operating voltage when it is determined that the input battery voltage does not exceed the threshold voltage.

11. The motor control system of claim 10, wherein, the drive system is subject to a constant load.

12. The motor control system of claim 10, wherein, the first operating voltage corresponds to a voltage that is higher than the threshold voltage.

13. The motor control system of claim 10, wherein, the first operating voltage is equal to the threshold voltage.

14. The motor control system of claim 10, wherein, the second operating voltage corresponds to a voltage that is lower than the threshold voltage.

15. The motor control system of claim 14, wherein, the second operating voltage corresponds to a minimum effective operating voltage associated with the drive system.

16. The motor control system of claim 10, wherein, if the input battery voltage is higher than the first operating voltage, operating the motor includes regulating the voltage provided to the motor to cause the motor to operate at the first output speed, the first output speed corresponding to operation of the motor at the first operating voltage at 100% duty cycle with the constant load.

17. A non-transitory computer-readable medium comprising instructions that, when executed by a motor controller, cause the motor controller to perform operations comprising: calculating a threshold voltage by determining a voltage at which the motor is capable of producing a selected speed when operating at 100% duty cycle with a constant operating load; receiving a signal indicative of an input battery voltage provided to a motor by a battery; comparing the input battery voltage to the threshold voltage to determine whether the input battery voltage exceeds the threshold voltage; controlling the motor to produce a first output speed corresponding to operation of the motor at a first operating voltage when it is determined that the input battery voltage exceeds the threshold voltage; and controlling the motor to produce a second output speed corresponding to operation of the motor at a second operating voltage when it is determined that the input battery voltage does not exceed the threshold voltage.

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