Coaxial generator module for a fitness machine with flywheel

Abstract

Coaxial generator module for a fitness machine with a flywheel, comprising: a clutch disc (10) having a flat end face on its outer surface, wherein a projecting ring body (11) is located in the axial direction, which forms a through first bearing hole (12) with the center of the clutch disc (10), wherein several ring-shaped first fastening bores (13) are located near the edge of the clutch disc (10); a pulley (20) which is arranged on the end face of the outer surface of the ring body (11) and has a second bearing hole (21) whose diameter is smaller than that of the first bearing hole (12), wherein at least two bearings (22) are inserted into the second bearing hole (21); an auxiliary flywheel (30) which is arranged on the inside of the clutch disc (10), wherein its outer diameter is smaller than the area of ​​the first mounting holes (13) so that these are not covered by the auxiliary flywheel (30), and wherein the auxiliary flywheel (30) has a third bearing hole (31) in the axial direction and has an open receiving space (32) on its inner side, on the inner circumference of which several permanent magnets (33) are arranged in a ring shape, whereby the clutch disc (10), the pulley (20) and the auxiliary flywheel (30) together form a rotor unit (40A, 40B); an anchor core (50) which is provided with a central fourth bearing hole (51), wherein several coils (52) are attached to its outer circumference, and wherein several first axial screws (53) are located along the circumference of the fourth bearing hole (51); a bushing (60) which is provided with a central fifth bearing hole (61), wherein a section of its outer circumference can be inserted into the fourth bearing hole (51) and a further section with a larger diameter forms a flange section (62) in which first threaded bores (63) are provided which are associated with the first axial screws (53), so that the bushing (60) is fixed in the fourth bearing hole (51) of the armature core (50) via the screws (53) and the armature core (50) together with the bushing (60) forms a stator unit (50A); a central shaft (70) passing through the second bearing hole (21) of the rotor unit (40A, 40B) and extends through the fifth bearing hole (61) of the stator unit (50A) to form the coaxial generator module (80A); and a large flywheel (90A) having a central sixth bearing hole (91) whose inner diameter (φ2) is matched to the outer diameter (φ1) of the ring body (11) of the clutch disc (10) such that the large flywheel (90A, 90B) can be mounted on the ring body (11) and the pulley (20) protrudes from the front end of the sixth bearing hole (91) of the large flywheel (90A, 90B), wherein the large flywheel (90A, 90B) has a planar contact surface on its inner side facing the generator module, which rests against the clutch disc (10) and in which several second mounting holes (93) are provided, corresponding to the first mounting holes (13) of the clutch disc (10), so that the coaxial generator module (80A, 80B) can be connected to the second mounting holes (13) by means of several third axial screws (41) via the first mounting holes (13). The large flywheel (90A, 90B) is screwed into the mounting holes (93), thereby securing the generator module (80A,80B) together with the large flywheel (90A, 90B) forms a self-generating flywheel unit (100A, 100B).

Description

[0001] The present invention relates to a coaxial generator module for a fitness device with a flywheel, and in particular to a generator module which is designed in the form of a single modular component and which can be combined with flywheels of different sizes and shapes depending on customer requirements.

[0002] It is known from current technology that conventional fitness equipment, such as exercise bikes, rowing machines, or elliptical trainers, is often equipped with control units (e.g., LCD displays) to show training data, allowing users to adjust their training intensity and track their progress. Furthermore, such devices may be equipped with additional features like fans for air circulation or TV modules. However, these additional features typically require an external power supply via the mains or batteries, which increases operating costs and leads to higher energy consumption. Since a considerable amount of human energy is expended during training anyway, this represents inefficient energy use.

[0003] Against this background, so-called self-generating flywheel modules for fitness equipment were developed, based on the principle of a permanent magnet AC generator. During training, the flywheel is set in rotation, with rotating permanent magnets generating a magnetic field. This field, in turn, creates a relative motion in an opposing armature core, inducing an electrical voltage in the coils arranged on the armature core. The electrical energy generated in this way can be transmitted via cables to various electrical consumers within the fitness equipment. Simultaneously, the flywheel also serves as mechanical resistance to generate the training load, thus enabling multiple uses. Examples of such devices can be found, among others, in the applicant's previous patent applications, such as German patent applications DE 20 2013 007 635.6 and DE 20 2012 007 256.0, in which the use of permanent magnets rotating with the flywheel in combination with stationary armature cores with coils is disclosed.

[0004] However, the aforementioned patent applications show that certain shortcomings still exist in the combination of components. As in Fig. As shown in Figure 1A, a conventional fitness device 200 has a flywheel generator unit 210 attached to its front or back, which serves both as training resistance or load and for the self-generation of electrical energy. As shown in Fig. 1A and Fig. As shown in Figure 1B, the flywheel-generator unit 210 comprises a flywheel 211 and an armature core 213. Permanent magnets 212 are arranged on the inner circumferential surface of the flywheel 211, while the armature core 213 is equipped with a coil 214. When the flywheel 211 is set in rotation, the magnets 212 move with it and thereby induce an electrical voltage in the coil 214 of the armature core 213. However, the requirements regarding the size or design of the flywheel 211 used vary considerably among different fitness devices, so the manufacturer must produce suitable armature cores 213 and coil assemblies 214 for each application. This results in a complex manufacturing process that complicates production and negatively impacts economic efficiency.

[0005] The invention is based on the objective of creating a coaxial generator module for a fitness device with a flywheel, which is designed in such a way that a single generator module can be flexibly combined with different flywheel sizes according to customer requirements, thereby improving production and assembly efficiency.

[0006] This problem is solved according to the invention by a coaxial generator module for a fitness device with a flywheel, which has the features specified in claim 1. Further advantageous embodiments of the invention will become apparent from the features of the dependent claims.

[0007] According to the invention, a coaxial generator module for a fitness device with a flywheel is provided, designed such that a single generator module can be flexibly combined with different flywheel sizes according to customer requirements, thereby improving production and assembly efficiency. To achieve this, the invention comprises a clutch disc, a pulley, an auxiliary flywheel, an armature core, a bushing, and a shaft, which together form a coaxial generator module. Additionally, a large flywheel is provided, the inner surface of which, facing the generator module, is provided with a planar contact surface that rests against the clutch disc. This contact surface is provided with several secondary mounting holes that correspond to the primary mounting holes in the clutch disc.The generator module is screwed to the second mounting holes of the large flywheel via the first mounting holes using several second axial screws, so that the generator module together with the large flywheel forms a self-generating flywheel unit.

[0008] The invention and its embodiments are explained in more detail below with reference to the drawing. The drawing shows: Fig. 1A a perspective view of a conventional fitness device; Fig. 1B a perspective, partially separated view of a conventional generator module with an attachable flywheel; Fig. 2 a perspective exploded view of the coaxial generator module according to a first embodiment of the invention; Fig. 3 a perspective assembly view of the coaxial generator module according to the first embodiment of the invention; Fig. 4 a section through the coaxial generator module according to the first embodiment of the invention; Fig. 5 a perspective exploded view of the first self-generating flywheel unit, which is formed by the coaxial generator module according to the invention and the first large flywheel; Fig. 6 a sectional view of the first self-generating flywheel unit, wherein the first large flywheel and the coaxial generator module according to the invention are shown in an axially separated manner; Fig. 7 a perspective view of the first self-generating flywheel unit formed by the coaxial generator module according to the invention and the first large flywheel; Fig. 8 a section through the first self-generating flywheel unit formed by the coaxial generator module according to the invention and the first large flywheel; Fig. 9 a perspective exploded view of the coaxial generator module according to a second embodiment of the invention; Fig. 10 a perspective assembly view of the coaxial generator module according to the second embodiment of the invention; Fig. 11 a section through the coaxial generator module according to the second embodiment of the invention; Fig. 12A a section through the first self-generating flywheel unit formed by the second coaxial generator module according to the invention and the first large flywheel; Fig. 12B a section through the second self-generating flywheel unit formed by the second coaxial generator module and the second large flywheel according to the invention; Fig. 13A a perspective view showing the state in which the first self-generating flywheel unit according to the present invention is mounted on a fitness device; and Fig. Figure 13B shows a perspective view of use, showing the state in which the second self-generating flywheel unit according to the present invention is mounted on a fitness device.

[0009] As in Fig. 2 to Fig. Figure 4 shows a first embodiment of a coaxial generator module according to the invention for a fitness device with flywheel comprising a clutch disc 10, a pulley 20, an auxiliary flywheel 30, a rotor unit 40A, an armature core 50, a bushing 60 and a central shaft 70.

[0010] The clutch disc 10 has a flat end face on its outer surface, with an annularly projecting section, namely a protruding ring body 11, extending along the central XX axis. An axially through first bearing hole 12 is formed in this ring body, which is in through-through with the center of the clutch disc 10. A plurality of first mounting holes 13 are arranged in a ring near the outer edge of the clutch disc 10.

[0011] The pulley 20 is arranged on the end face of the projecting ring body 11 and has a central second bearing hole 21, the diameter of which is smaller than that of the first bearing hole 12. Two or more bearings 22 are inserted into the second bearing hole 21. As in Fig. As shown in Figure 4, in this embodiment two bearings 22 are provided - one on the front side, the other on the rear side.

[0012] The auxiliary flywheel 30 is arranged on the inside of the clutch disc 10. Its outer diameter is smaller than the radius area in which the first mounting holes 13 are located, so that these holes are not covered by the auxiliary flywheel 30. A third bearing hole 31 extends axially through the auxiliary flywheel 30. A receiving chamber 32 with an opening is formed on the side of the flywheel facing the clutch body. A plurality of permanent magnets 33 are arranged in a ring on the inner circumferential surface of this receiving chamber 32.

[0013] The components described above - clutch disc 10, pulley 20 and auxiliary flywheel 30 - together form the rotor unit 40A.

[0014] The armature core 50 is provided with a central fourth bearing hole 51. A plurality of coil windings 52 are attached to its outer circumference. Several first axial screws 53 are provided around the fourth bearing hole 51.

[0015] The bushing 60 has a fifth bearing hole 61 centrally located. A section of the outer circumference of this bushing 60 is dimensioned to fit into the fourth bearing hole 51. Another section of the circumference has a larger diameter than the fourth bearing hole 51 and forms a flange section 62. This flange section 62 has several threaded bores 63, which are associated with the first axial screws 53. The bushing 60 can be securely screwed into the fourth bearing hole 51 of the armature core 50 by means of the first axial screws 53, so that the armature core 50 and the bushing 60 together form the stator unit 50A.

[0016] In the present embodiment, the construction of the rotor unit 40A is such that a tubular element 23 is located on the inside of the pulley 20, which is inserted coaxially into the first bearing hole 12 of the clutch disc 10 and is fixedly connected there. Furthermore, a plurality of second threaded bores 34 are formed on the outer circumference of the third bearing hole 31 of the auxiliary flywheel 30. Correspondingly, several third threaded bores 14 are provided on the outer circumference of the projecting ring body 11 of the clutch disc 10. The auxiliary flywheel 30 is fixedly fastened to the inside of the clutch disc 10 by means of several second axial screws 15, which pass through the second threaded bores 34 and engage in the third threaded bores 14.

[0017] The central shaft 70 extends through the second bearing hole 21 of the rotor unit 40A and the fifth bearing hole 61 of the stator unit 50A, so that the two units are coaxially aligned and together form the coaxial generator module 80A.

[0018] As in Fig. 5 to Fig. As shown in Figure 8, the fully assembled coaxial generator module 80A can be combined with a large flywheel 90A of different size and shape. The flywheel 90A described here is merely an exemplary embodiment and does not limit the invention. The large flywheel 90A is centrally provided with a sixth bearing hole 91. As can be seen in particular from Figure 8, the flywheel 90A is designed to be a single, larger flywheel. Fig. As can be seen in Figure 6, this sixth bearing hole 91 has an inner diameter φ2 that corresponds to the outer diameter φ1 of the projecting ring body 11 of the clutch disc 10. This allows the flywheel 90A to be fitted precisely onto the projecting ring body 11. The pulley 20 projects beyond the front section of the sixth bearing hole 91. On the side of the flywheel 90A facing the generator module 80A, there is a planar contact surface 92 [see Figure 6]. Fig. 6] provided, which directly abuts the end face of the clutch disc 10. Several second mounting holes 93 are provided in this mounting surface 92, which correspond in position and arrangement to the first mounting holes 13 of the clutch disc 10. The generator module 80A is bolted to the second mounting holes 93 of the flywheel 90A via the first mounting holes 13 using several third axial screws 41. In this way, the coaxial generator module 80A and the large flywheel 90A together form a first self-generating flywheel unit 100A.

[0019] As in Fig. 9 to Fig. Figure 11 shows the second embodiment of the invention, comprising another coaxial generator module 80B. Components whose structure is identical to that of the first embodiment are identified by the same reference numerals and are not described in detail here. The essential difference lies in the design of the rotor unit 40B. In this embodiment, the clutch disc 10, the pulley 20, and the auxiliary flywheel 30 are combined into a single, uniformly shaped component. This means that the clutch disc 10 does not require third threaded holes 14 or second axial screws 15, and the auxiliary flywheel 30 does not have second threaded holes 34. Furthermore, the tubular element 23 of the pulley 20 is formed directly in one piece with the projecting ring body 11. This simplifies the overall design and makes the assembly more compact.Apart from this difference, the structure and function are otherwise completely identical to the first embodiment, so a further detailed description is unnecessary here.

[0020] In Fig. Figure 12A shows the combination of the coaxial generator module 80B disclosed in the second embodiment with the large flywheel 90A to form a self-generating flywheel unit 100A. This combination is thus essentially identical in content and function to the one shown in Figure 12A. Fig. 9 configuration shown, in which the coaxial generator module 80A is combined with the same large flywheel 90A to form a self-generating flywheel unit 100A.

[0021] In Fig. Figure 12B shows a section through a second self-generating flywheel unit 100B, which is formed from the coaxial generator module 80B [alternatively also the coaxial generator module 80A] and an alternative large flywheel 90B. As can be seen from the illustration, the outer diameter φ1 of the projecting ring body 11 of the generator module 80B or 80A is designed such that it exactly matches the inner diameter φ2 of the sixth bearing hole 91 of the large flywheel 90B or 90A and can therefore be positively fitted. The inner surface of the flywheel 90B, 90A facing the generator module is provided with a planar contact surface 92 that bears against the clutch disc 10 over its entire surface. Furthermore, the second mounting holes 93 provided on the flywheel 90B are arranged in such a way that they correspond exactly to the position of the first mounting holes 13 of the clutch disc 10.In this way, the 90B flywheel can be flexibly adapted to different customer requirements in terms of size and geometry. Regardless of the dimensions or external shape of the respective flywheel, e.g., 90B or 90A, the coaxial generator module 80A or 80B can be used unchanged. In other words, a single generator module 80A or 80B of a fixed size can be modularly combined with different sized flywheels, e.g., 90A, 90B, etc., to form different configurations, such as the first self-generating flywheel unit 100A or the second self-generating flywheel unit 100B.

[0022] As in Fig. Figure 13A shows an example of the use of the first self-generating flywheel unit 100A, which is mounted on a fitness machine 200. In the version shown, the large flywheel used corresponds to the 90A design. Fig.Figure 13B shows an additional example in which the second self-generating flywheel unit 100B - consisting of a generator module 80B or 80A and a large flywheel of design 90B - is installed on an identical fitness device 200.

[0023] With the technical features described above, the present invention allows the use of a single coaxial generator module 80A or 80B, wherein the outer diameter φ1 of the projecting ring body 11 is precisely matched to the inner diameter φ2 of the sixth bearing hole 91 of a large flywheel 90A or 90B, enabling them to be connected precisely. Furthermore, the inner surface of the large flywheel 90A or 90B facing the generator module is provided with a planar contact surface 92 that bears against the clutch disc 10. Based on these essential design features, the size and shape of the large flywheel 90A or 90B can be flexibly adapted to market requirements or individual customer specifications without requiring any modifications to the generator module itself.This increases both production and assembly efficiency, as well as significantly improving the diversity and adaptability of the resulting self-generating flywheel units. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] DE 20 2012 007 256.0

[0003]

Claims

[1] Coaxial generator module for a fitness machine with a flywheel, comprising: a clutch disc (10) having a flat end face on its outer surface, wherein a projecting ring body (11) is located in the axial direction, which forms a through first bearing hole (12) with the center of the clutch disc (10), wherein several ring-shaped first fastening bores (13) are located near the edge of the clutch disc (10); a pulley (20) which is arranged on the end face of the outer surface of the ring body (11) and has a second bearing hole (21) whose diameter is smaller than that of the first bearing hole (12), wherein at least two bearings (22) are inserted into the second bearing hole (21); an auxiliary flywheel (30) which is arranged on the inside of the clutch disc (10), wherein its outer diameter is smaller than the area of ​​the first mounting holes (13) so that these are not covered by the auxiliary flywheel (30), and wherein the auxiliary flywheel (30) has a third bearing hole (31) in the axial direction and has an open receiving space (32) on its inner side, on the inner circumference of which several permanent magnets (33) are arranged in a ring shape, whereby the clutch disc (10), the pulley (20) and the auxiliary flywheel (30) together form a rotor unit (40A, 40B); an anchor core (50) which is provided with a central fourth bearing hole (51), wherein several coils (52) are attached to its outer circumference, and wherein several first axial screws (53) are located along the circumference of the fourth bearing hole (51); a bushing (60) which is provided with a central fifth bearing hole (61), wherein a section of its outer circumference can be inserted into the fourth bearing hole (51) and a further section with a larger diameter forms a flange section (62) in which first threaded bores (63) are provided which are associated with the first axial screws (53), so that the bushing (60) is fixed in the fourth bearing hole (51) of the armature core (50) via the screws (53) and the armature core (50) together with the bushing (60) forms a stator unit (50A); a central shaft (70) passing through the second bearing hole (21) of the rotor unit (40A, 40B) and extends through the fifth bearing hole (61) of the stator unit (50A) to form the coaxial generator module (80A); and a large flywheel (90A) having a central sixth bearing hole (91) whose inner diameter (φ2) is matched to the outer diameter (φ1) of the ring body (11) of the clutch disc (10) such that the large flywheel (90A, 90B) can be mounted on the ring body (11) and the pulley (20) protrudes from the front end of the sixth bearing hole (91) of the large flywheel (90A, 90B), wherein the large flywheel (90A, 90B) has a planar contact surface on its inner side facing the generator module, which rests against the clutch disc (10) and in which several second mounting holes (93) are provided, corresponding to the first mounting holes (13) of the clutch disc (10), so that the coaxial generator module (80A, 80B) can be connected to the second mounting holes (13) by means of several third axial screws (41) via the first mounting holes (13). The large flywheel (90A, 90B) is screwed into the mounting holes (93), thereby securing the generator module (80A,80B) together with the large flywheel (90A, 90B) forms a self-generating flywheel unit (100A, 100B). [2] Coaxial generator module for a fitness device with flywheel according to claim 1, characterized by, that the rotor unit (40A) is designed such that a tubular element (23) is arranged on the inside of the pulley (20), which is inserted into the first bearing hole (12) of the clutch disc (10) and is firmly connected there, that several second threaded bores (34) are provided on the outer circumference of the third bearing hole (31) of the auxiliary flywheel (30), to which third threaded bores (14) arranged accordingly on the outside of the projecting ring body (11) of the clutch disc (10) are assigned, and that the auxiliary flywheel (30) is firmly connected to the inside of the clutch disc (10) by means of several second axial screws (15) which are screwed through the second threaded bores (34) into the third threaded bores (14). [3] Coaxial generator module for a fitness device with flywheel according to claim 1, characterized by, that the rotor unit (40B) is designed such that the clutch disc (10), the pulley (20) and the auxiliary flywheel (30) are designed as a single, integral component.

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