Exercise Apparatus having Bidirectional Resistance Movements with Active Load Regulation

Abstract

The exercise apparatus has a user interface operable to perform active resistance with bidirectional movements. A directional control valve selectively positions a double-acting, pneumatic cylinder between extended and retracted positions. An engagement switch disposed on the exercise tool engages the directional control valve to switch the pneumatic cylinder between extension and retraction. An air pressure regulator fluidly connected with the pneumatic cylinder adjusts a continuous supply of air from a powered air source to maintain active resistance upon the exercise tool at a constant force. The air pressure regulator adjusts air pressure in response to a reactive resistance applied to the exercise tool by a user of the exercise apparatus. Upon disengagement of the engagement switch by the user, the directional control valve defaults the pneumatic cylinder into the retracted position.

Description

CROSS REFERENCES

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 780,760 filed 31 Mar. 2025, which is incorporated by reference herein in its entirety.REFERENCE TO RESEARCH

[0002] Not Applicable.REFERENCE TO CDS

[0003] Not Applicable.FIELD OF THE INVENTION

[0004] The present disclosure relates to an exercise apparatus that uses pneumatics to continuously maintain an active resistance at a constant force for working a body.BACKGROUND

[0005] In weightlifting, weights are typically added or removed from a bar (e.g., a barbell) as with free weights, or are part of a weight stack in which the number of weight plates resisting movement of a handle or a bar can be varied. Resistance experienced by the body of a user during concentric or eccentric movements depends upon the amount of the weight.

[0006] Pneumatic exercise equipment has been developed in attempts to simulate exercise weights and is typically configured similarly to weight stack equipment. However, for many weightlifters, pneumatic exercise equipment does not provide the simulated feeling of free weights to which they are accustomed.SUMMARY

[0007] The exercise apparatus performs bidirectional resistance movements with active load regulation by way of a pneumatic system. The pneumatic system may comprise a first pneumatic cylinder that is double-acting. The pneumatic cylinder has an extension chamber and a retraction chamber. A directional control valve fluidly connected with the pneumatic cylinder is structured to be selectively engaged between a first position and a second position. In the first position, the extension chamber is permitted to charge. As a result, the pneumatic cylinder extends and applies active resistance in a first direction upon an exercise tool user interface. In the second position, the retraction chamber is permitted to charge. As a result, the first pneumatic cylinder may retract and apply active resistance in a second direction upon the exercise tool user interface.

[0008] A second pneumatic cylinder that is double acting may be disposed laterally adjacent and vertically oriented and parallel with the first pneumatic cylinder. The exercise tool user interface may be connected perpendicularly between bottom ends of the first pneumatic cylinder and the second pneumatic cylinder. The directional control valve may be operable to permit both the first pneumatic cylinder and the second pneumatic cylinder act simultaneously together to perform bidirectional resistance movements with active load regulation.

[0009] An air pressure regulator may be fluidly connected to the pneumatic cylinder. The air pressure regulator may be structured to adjust a continuous active supply of air to the pneumatic cylinder. The continuous supply of air may be directly transferred to the pneumatic cylinder from a powered air source with regulation provided by the air pressure regulator. The air pressure regulator maintains the active resistance upon the exercise tool user interface at a constant force, even in response to a reactive resistance applied to the exercise tool user interface by a user of the exercise apparatus.

[0010] An engagement switch may be operably connected with the controller to engage the directional control valve. The engagement may be disposed on the exercise tool user interface for direct engagement by a user of the exercise apparatus. Disengagement of the engagement switch by the user may engage the directional control valve into a default position. The default position may correlate with the second position, which results in the pneumatic cylinder being retracted.

[0011] The above advantages and features are of representative embodiments only, and are presented only to assist in understanding the invention. It should be understood that they are not to be considered limitations on the invention as defined by the claims. Additional features and advantages of embodiments of the invention will become apparent in the following description, from the drawings, and from the claims.BRIEF DESCRIPTION OF DRAWINGS

[0012] Aspects are illustrated by way of example, and not by way of limitation, in the accompanying drawings, wherein:

[0013] FIG. 1 depicts a front perspective view of an exercise apparatus structured in a power rack type configuration.

[0014] FIG. 2 depicts a front perspective view of the exercise apparatus installed with a control system and an engagement switch.

[0015] FIG. 3 depicts a structural layout of the control system showing component elements.

[0016] FIG. 4 depicts an operational schematic of an exercise apparatus showing electrical and pneumatic components.

[0017] FIG. 5 depicts a pneumatic schematic of an exercise apparatus showing proportional and directional control valves.

[0018] FIG. 6 depicts an electrical schematic of an exercise apparatus showing proportional and directional control valves powered by converters and an electric power source.

[0019] FIG. 7 depicts an operational flowchart for maintaining a regulated load by the exercise apparatus at a constant force relative to a difference between an established reference force and an actual force applied.

[0020] FIG. 8 depicts an operational flowchart for safely returning the regulated load to a start position by release of an engagement switch of the exercise apparatus.

[0021] FIG. 9A shows a first frame in a series of chronological depictions of the exercise apparatus being used by a user during an exercise cycle.

[0022] FIG. 9B shows a second frame in a series of chronological depictions of the exercise apparatus being used by a user during an exercise cycle.

[0023] FIG. 9C shows a third frame in a series of chronological depictions of the exercise apparatus being used by a user during an exercise cycle.

[0024] FIG. 9D shows a fourth frame in a series of chronological depictions of the exercise apparatus being used by a user during an exercise cycle.

[0025] FIG. 9E shows a fifth frame in a series of chronological depictions of the exercise apparatus being used by a user during an exercise cycle.

[0026] FIG. 9F shows a sixth frame in a series of chronological depictions of the exercise apparatus being used by a user during an exercise cycle.

[0027] FIG. 10 shows a directional control valve powered by an electric power source through a relay solenoid valve.DETAILED DESCRIPTION

[0028] The exercise apparatus is operable to perform bidirectional resistance movements with active load regulation. The exercise apparatus derives the load from actuators that are actively regulated to assert an active resistance (e.g., pressure) that equalizes with reactive resistance asserted by a user. The exercise apparatus maintains the load at a constant force based on a selected reference force and resistance applied by a user's reactive force. An example of the exercise apparatus 10 structured to provide bidirectional resistance movements during weightlifting exercising is shown in FIG. 1. The exercise apparatus 10 comprises a frame 12. The frame 12 may define at least one exercise station. A user can sit, stand, or recline at the exercise station. In the example of sitting, an exercise bench (not shown) may be used with the exercise apparatus 10.

[0029] The frame 12, if not mounted directly to a floor, may comprise a sub-assembly 16. The sub-assembly 16 may be formed by a base 18 having a first base member 20 and a second base member 22. The base 18 may be rectangular in shape and serve as a platform for a user of the exercise apparatus 10. The base 18 may be attached to a side or an end of each base member. The base 18 may be disposed between the base members 20, 22. Portions of each base member may extend beyond the rectangular frame structure at both ends of the respective base 18. Brace structures may be used between the base 18 and the base members 20, 22 to secure them firmly together. Base components may be made of steel, aluminum, rubber, or other supporting material.

[0030] Each base member may include one or more mounting flanges, brackets, or plates that are mounted and positioned to support the frame 12. A first mounting plate 24 and a second mounting plate 26 are shown. The base members 20, 22 may include mounting holes through which a suitable fastener (e.g., a bolt) can pass to anchor the mounting plates 24, 26 and frame 12 in place.

[0031] The assembly of the frame 12 may comprise a plurality of vertical support members and cross braces. Together, the vertical supports and the cross braces may form a rectangular, frame-like structure that resembles a power rack for performing barbell power exercises like squats, deadlifts, bench presses, alternative rows, lateral pulls, etc. The structure and functionality of the exercise apparatus 10 eliminates potential injury risks associated with barbell weightlifting exercises that utilize free weights. Alternative weightlifting platform configurations are possible as racks may be designed for presses such as bench, military, front, and / or other push / pull exercise movements.

[0032] As shown in FIG. 1 and FIG. 2, two vertically oriented upright members extend upward from each base member. A first upright member 28 and a second upright member 32 are positioned on each side of the frame 12. The upright members 28, 32 may terminate at or be generally respective of a cross-brace member. Each upright member may be directly connected with the cross-brace member.

[0033] As illustrated, at least one cross-brace member 34, that may be horizontal, connects the upper ends of the two upright members 28, 32 that are disposed laterally adjacent and parallel with one another. The cross-brace member 34 may extend transversely between the two upright members 28, 32 to form a generally supportive rectangular frame structure. The pair of upright members 28, 32 and cross-brace member 34 may include a series of apertures 30 that extend over a length of the upright members 28, 32 and cross-brace member 34.

[0034] An angled member 36 may lie generally at a 45° angle with respect to an upright member and a base member. Each angled member 36 may extend upward at about a 45° angle from the respective base member. A plurality of angled members may be mounted between the upright members 28, 32 and the base members 20, 22 via fasteners disposed through the apertures 30 to provide structural support to the frame 12.

[0035] An angled member 36 may lie generally at a 45° angle with respect to an upright member and a cross-brace member 34. Each angled member 36 may extend downward at about a 45° angle from the respective cross-brace member. A plurality of angled members may be mounted between the upright members 28, 32 and the cross-brace member 34 via fasteners disposed through the apertures 30 to provide structural support to the frame 12.

[0036] Additionally, apertures 30 may be structured to cooperate with fasteners to mount components to the frame 12 of the exercise apparatus 10. Components may include a control system, a resistance assembly, sensors, or other accessories. Thus, components may be positioned, mounted, and readjusted vertically or horizontally to accommodate different sized users as well as to accommodate different exercises (e.g., moving from a lower position for bench press to a higher position for squats).

[0037] The base 18, base members 20, 22, upright members 28, 32, and the cross-brace member 34 may be formed of a suitably rigid material, such as, for example, cold rolled tube steel having a suitable wall thickness. Assembling the frame structure of the exercise apparatus 10 may be a simple process. Components of the frame structure may be unpacked and organized in accordance with parts listed in a manual. The sub-assembly 16 may be assembled by attaching the base members 20, 22 to the base 18. Fasteners may include bolts and washers. The upright members 28, 32 may be connected to the base members 20, 22 and securely fastened with mounting plates 24, 26. Transverse cross-brace members may be installed to upper and lower ends of the upright members 28, 32, and / or anywhere along the length of the upright member 28, 32 to provide stability to the frame 12. Components, such as the control system, resistance assembly, sensors, or other accessories may be added to the frame 12 by mounting with bolts through the apertures 30 disposed through the upright members 28, 32 and the cross-brace member 34.

[0038] Members of the frame 12 may be welded together, along with mounting plates 24, 26, and other brackets and braces. The frame 12 may be painted and / or powder coat painted. Some portions of the frame 12 may be coated or overlaid with plastic, foam, rubber guards, or shields. The illustrated frame configuration is but one example, and the frame may be formed with other suitable materials, be assembled using other suitable fasteners, connectors, or methods, and may be finished using other suitable materials and techniques.

[0039] With reference to FIGS. 1, 2, and 3, the exercise apparatus 10 includes a resistance assembly 80 having one or more resistance modules, such as actuators attached to the frame 12. An actuator may be secured to one or more mounting platforms 66 that are structured to mount the respective actuator utilizing apertures 30 disposed through the frame 12. The actuator may provide one or more sources of motive power to cause an actuating unit to extend or retract. For example, an electrical linear motor, electrical stepper motor, an electric solenoid, etc., may act upon by pulling or pushing the actuating unit. Alternatively, the actuator may be a piston that is pneumatically, fluidically, mechanically, electrically, or hydraulically positioned to act upon the actuating unit so that the exercise apparatus 10 provides active resistance at a constant force or variable force. Actuators utilized to perform the bidirectional actuating movements may include linear actuators, rotary actuators, gripper actuators, diaphragm actuators, screws, worm gears, springs, cams, levers, and / or other force transmitter.

[0040] As illustrated, the exercise apparatus 10 includes two actuators. A first actuator 52 is attached to a left-hand side of the frame 12 and a second actuator 54 is attached to a right-hand side of the frame 12. Actuators 52, 54 may be located on the frame 12 at a location generally aside where a user would stand, sit or recline when using the exercise apparatus 10. Actuators 52, 54 are shown located on the inner sides of upright members 28, 32, but could just as easily be disposed on another side. Actuators 52, 54 descend downwardly from the ends of the cross-brace member 34. Actuators 52, 54 that are vertically oriented and parallel may be supported by one of the respective upright members 28, 32 and / or cross-brace member 34 via the mounting platforms 66.

[0041] Each actuator includes an elongated, vertically oriented, and linearly extending actuating unit, such as a piston rod. However, the actuating unit may have other orientations (e.g., inclined) and other shapes (e.g., curved) depending upon the exercise motion relative to the frame 12. As illustrated, the first actuator 52 cooperates with a first actuating unit 56 and the second actuator 54 cooperates with a second actuating unit 58. Housings 84 may support and enclose the actuators 52, 54, and at least a portion of the actuating units 56, 58.

[0042] The actuators 52, 54 preferably cooperate together in order to apply the same level of active resistance upon an exercise tool user interface, such as an engagement tool or a plurality of engagement tools. However, in some applications, actuators 52, 54 may operate independently of each other to apply varying levels of active resistance upon ends of the exercise tool user interface. In such cases, a user balances the exercise tool user interface against the varying levels of active resistance. In the example shown, the exercise tool user interface is connected perpendicularly between the bottom ends of actuators 52, 54.

[0043] Continuing reference to FIGS. 1, 2, and 3, the first actuating unit 56 includes a first coupler 76, and the second actuating unit 58 includes a second coupler 78. Couplers 76, 78 may couple actuating units 56, 58 with the exercise tool user interface, such as a steel weightlifting bar, which is also known as a “weight bar” or “barbell”. A first end 13 and a second end 15 of weight bar 14 may be connected between the actuating units 56, 58, with or without free weights. Couplers 76, 78 may provide a range of rotational and / or pivotal movement between ends of the actuating units 56, 58 and the weight bar 14 by inclusion of a hinge, ball-socket, clip, linkage, or other connection device.

[0044] A plurality of actuators 52, 54 respectively position the plurality of actuating units 56, 58 by selectively extending or retracting the couplers 76, 78 between a retracted state where the weight bar 14 is at a “zeroed start position” and an extended state where the weight bar 14 is at a fully extended position relative to the zeroed start position. Actuating units 56, 58 operably connected on each side of the weight bar 14 may restrict the user's movement of the weight bar 14 to a particular course of travel. As shown, actuating units 56, 58 may allow for relatively vertical movement of the weight bar 14 within a single vertical plane. In alternative configurations, the user may move the weight bar 14 through a variety of paths within the frame 12.

[0045] As seen in FIG. 2, each of the couplers 76, 78 take the form of a yoke that cooperatively pins ends of the weight bar 14. Couplers 76, 78, however, can take other forms, such as a receptive collar, and may couple the actuating units 56, 58 to other types of exercise tool user interfaces or directly to a body of the user. For example, the coupler may be a band (preferably of an adjustable size) that is sized to fit around a portion of the user's body, e.g., a waistband or an ankle band. The coupler may be structured to couple to a bar, a foot pedal, or other tool used with weightlifting equipment. Thus, the coupler may be any type of connector that couples to an article or mechanism that a user acts against or interacts with and that is attached, either directly or indirectly, to one of, or both of, the actuating units 56, 58.

[0046] Couplers 76, 78 may be moved by actuating resistance between two positions during an exercise. Couplers 76, 78 may be moved from one extended position to another extended position. Couplers 76, 78 may be moved from one retracted position to another retracted position. Couplers 76, 78 may be moved from a retracted position to an extended position, and vice versa.

[0047] As illustrated in FIG. 1 and FIG. 2, couplers 76, 78 are in a retracted position 82, which may include the zeroed start position. Couplers 76, 78 may normally reside in a retracted position 82 with the attached weight bar 14. A user can apply their own reactive resistance force to overcome the active resistance force applied by actuators to the weight bar 14 to move the couplers 76, 78 from a retracted position 82 to an extended position 86 in which the actuating units 56, 58 are extended further out from within the housings 84. Alternatively, the user can apply their own reactive resistance force to overcome the active resistance force applied by actuators to the weight bar 14 to move the couplers 76, 78 from an extended position 86 to a retracted position 82 in which the actuating units 56, 58 are retracted further into the housings 84. Exercise movements may involve variable movements between any two of these positions, possibly including a fully retracted position and a fully extended position, in order to accommodate different exercises and different sized weight lifters. The travel distance the exercise tool user interface is independently moved towards and away from a stationary portion of the exercise apparatus 10 may be regulated to provide safety for the user.

[0048] Arrangement of the actuator 52, 54 components within the housing 84 may have identical layout or be mirror images of each other. Fasteners (not shown) may connect the removable housing 84. As a result, the interior of the actuators 52, 54 may be accessed for servicing or inspection by removing the fasteners and removing the housing 84 or cover panel of the housing.

[0049] A lower base and an upper base of the housing 84 of the first actuator 52 may be attached to a corresponding platform 66 on the left side of the frame 12. Similarly, a lower base and an upper base of the housing 84 of the second actuator 54 may be attached to a corresponding mounting platform 66 on the right side of the frame 12. In this manner, actuators 52, 54 and associated housings 84 may be sold or shipped apart from the frame 12, and subsequently, easily, and rigidly affixed to the frame 12. Suitable fasteners or fastening techniques (e.g., bolts, welding, etc.) may be used to attach, either permanently or removably, the actuators 52, 54 to the frame 12. Actuating units 56, 58 reside, in part, within housings 84 and are extendable from and retractable into the housing 84 during actuating exercise strokes.

[0050] The resistance assembly 80 may include a single resistance unit, dual resistance units, or more. As noted above, the exercise apparatus 10 may include at least one resistance unit, such as an actuator, which may be a pneumatic actuator. In the example shown in FIG. 4, the resistance unit is a pneumatic actuator 150 that provides linear actuation. In the example shown in FIG. 5, the dual resistance units are a pair of pneumatic actuators 252, 254. A pneumatic actuator utilized in the resistance assembly 80 may be a double-acting, pneumatic cylinder that is structured to perform bidirectional resistance movements upon the exercise tool user interface so that a user can reactively work against the live actuating resistance.

[0051] An electro-pneumatic system of the exercise apparatus 10 may include at least one resistance unit. The resistance unit may apply pneumatic resistance via a continuous live flow of pressurized gas, such as air, from the pneumatic power source 350. The pneumatic system may or may not include an accumulator. The exercise apparatus 10 may transmit active resistance to the exercise tool user interface via pressurized gas that operates under a dynamic kinetic energy principle, rather than a static potential energy principle. The functional design of the exercise apparatus 10 may eliminate the elastic feel of a pneumatic system that features air compressibility as the source of the resistance force. The layout and components of the pneumatic system are configured so that pressurized gas within the system has a more incompressible, hydraulic-like feeling during exercise use. In this way, live transmission of pressurized gas allows the exercise apparatus 10 to be highly responsive without delay in movement and application of resistance force. As a result, use of the exercise apparatus 10 more naturally mimics the resistance feeling of free weights under the continuous force of gravity.

[0052] As illustrated in FIG. 4, the pneumatic actuator 150 is a linear actuator that includes a cylinder 152 and a piston rod 154. The piston rod 154 may be an extension of an actuating unit as discussed and shown previously. The cylinder 152 includes a cylinder body 156 in which a piston head 158 slides within a bore of the cylinder body 156. The piston head 158 divides the cylinder body 156 into two variable volume chambers. As a naming convention, the divided cylinder body 156 may be referred to as having a retraction chamber 162 and an extension chamber 164.

[0053] At least one, or both, of the chambers may selectively communicate with a compressed air supply source, thereby providing active pneumatic resistance against the piston head 158 from one direction or two directions. At least one, or both, or none, of the chambers may open to the atmosphere. Both chambers may be pressurized (e.g., be of equal or variable pressure), and selectively communicate with the atmosphere and / or communicate with each other. In the example shown in FIG. 4, both of the chambers communicate with the compressed air supply source so as to be provided with a constant supply of compressed air for movement of the piston to form active resistance upon the exercise tool user interface bidirectionally.

[0054] The piston rod 154 is connected to the piston head 158 and extends through the variable volume chambers. A distal end cap 170 may close the end of the cylinder body 156 opposite the end through which the piston rod 154 extends. The piston rod 154 moves linearly along a stroke axis as the piston slides within the cylinder bore. The length of the piston rod 154 may be sufficient to provide the desired stroke length for exercise movements by the couplers 76, 78.

[0055] At least one, several, or all components of the pneumatic actuator 150 may be formed of a polymer (e.g., plastic), aluminum (e.g., metal), and / or other durable, light material in order to lighten the overall weight of the resistance assembly 80 and to decrease production costs. Such components made of lightweight but durable material may include the cylinder body 156, the piston, and one or more of the end caps of the cylinder.

[0056] The retraction chamber 162 and the extension chamber 164 may communicate with at least one powered resistance source. The powered resistance source may be a pneumatic power source 350 that has a compressed air supply, as seen in FIG. 4. The pneumatic power source 350 may include an air compressor 380 and an air tank 390 reservoir, which may be mounted at a location near the exercise apparatus 10, as seen in FIG. 3. Alternatively, the pneumatic power source 350 may be remotely disposed relative to the exercise apparatus 10 with a separator, such as a wall 50, as seen in FIG. 5. A powered line, such as a hydraulic, electrical, or pneumatic hose may connect with the powered resistance source to power the resistance assembly 80. As shown in FIG. 4, a pneumatic hose 160 connects the pneumatic power source 350 with the pneumatic actuator 150 so as to pressurize either one of the two variable volume chambers, that is the retraction chamber 162 and the extension chamber 164. Thus, air pressure may be actively applied to either of the two variable volume chambers via the pneumatic hose 160 that is bifurcated to move the piston head 158 and the piston rod 154 together, bidirectionally.

[0057] A directional control valve 200 with an inlet port 205 may serve as a bifurcated juncture in the pneumatic hose 160 of a pneumatic system 70. The pneumatic system 70 may provide a linear pathway for the flow of pressurized gas from the pneumatic power source 350 to a pneumatic actuator. The directional control valve 200 may be fluidly connected with one or more pneumatic actuators. The directional control valve 200 regulates the flow path of a compressed fluid, such as the pressurized gas or fluid, towards and away from a bidirectional actuator, such as a double-acting pneumatic cylinder.

[0058] The directional control valve 200 may have a plurality of ports and positions that permit fluids, such as air, to be directed to either side of the cylinder for charging either of the dual variable chambers. When the directional control valve 200 is activated, compressed air may be channeled into one side of the cylinder, causing the piston to move in one direction. Simultaneously, the directional control valve 200 may allow air from the opposite side to exhaust, which enables the piston to extend or retract. By switching the directional control valve 200 between positions, the flow direction is reversed, causing the piston to move in the opposite direction. This bidirectional control allows for precise and reversible linear motion of the bidirectional actuator.

[0059] The pneumatic power source 350 may communicate with a single, pneumatic actuator 150 through a directional control valve 200, as seen in FIG. 4. As shown in FIG. 4, the directional control valve 200 is fluidly connected between the pneumatic power source 350 and the pneumatic actuator 150. The directional control valve 200 serves as the bifurcation point of the pneumatic hose 160. The retraction chamber 162 and extension chamber 164 of the pneumatic actuator 150 fluidly communicate with the pneumatic power source 350 through the directional control valve 200 to receive an active supply of pressurized gas and / or to communicate with the atmosphere.

[0060] The pneumatic power source 350 may communicate with a pair of pneumatic actuators 252, 254 through the directional control valve 200, as seen in FIG. 5. An example configuration for ports and pathways of a directional control valve is shown in FIG. 5. This example configuration of a three-position, four-way valve is utilized for description purposes that follow. However, the directional control valve 200 may be structured with alternative valve port configurations and operating positions, which may include two-positions, three-positions, or more valve ways for control of the pneumatic actuator(s). In one preferred example of the exercise apparatus, a two-position, four-way valve was utilized for the directional control valve 200 to eliminate a middle position that may fix the weight bar 14 in a static position.

[0061] As shown in FIG. 4, the directional control valve 200 may be operable to selectively engage the pneumatic actuator 150 for extension and retraction in response to a continuous live supply of pressurized gas. The directional control valve 200 is shown fluidly connected between the retraction chamber 162 and extension chamber 164 of pneumatic actuator 150 via pneumatic hoses 172, 174 and flow-through ports 171, 173 of the cylinder 152, respectively. A regulated flow of pressurized gas may be delivered to the directional control valve 200 via the pneumatic hose 160.

[0062] The directional control valve 200 can be selectively engaged in a first position 202 so that extension chamber 164 is permitted to charge with an increase of air pressure. In the first position 202, the directional control valve 200 may direct the flow of pressurized gas towards the extension chamber 164 side of the pneumatic actuator 150 through a first flow-through port 176 of the valve via pneumatic hose 172. Charging the extension chamber 164 with pressurized gas may result in increased volume of said chamber. In response to extension chamber 164 being charged, piston head 158 will extend piston rod 154 to apply active resistance upon an exercise tool user interface in a first direction, as shown by movement arrow 166.

[0063] The directional control valve 200 can also be selectively engaged in a second position 204 so that the retraction chamber 162 is permitted to charge with an increase of air pressure. In the second position 204, the directional control valve 200 may direct the flow of pressurized gas towards the retraction chamber 162 side of the pneumatic actuator 150 through a second flow-through port 178 of the valve via pneumatic hose 174. Charging the retraction chamber 162 with pressurized gas may result in increased volume of said chamber. In response to the retraction chamber 162 being charged, piston head 158 will retract piston rod 154 to apply active resistance upon the exercise tool user interface in a second direction, as shown by movement arrow 168.

[0064] An uncharged chamber may decrease in volume in response to piston movement when air in the uncharged chamber is permitted to exhaust to the surrounding atmosphere. In the first position 202, the directional control valve 200 may permit the retraction chamber 162 to exhaust air resulting in decreased volume of said chamber. The directional control valve 200 may direct the flow of exhausted air received from pneumatic hose 174 via flow-through port 178 towards a first exhaust valve 220. Exhausted air may discharge from the exhaust valve 220 via a first exhaust port 210 disposed in the directional control valve 200. In the second position 204, the directional control valve 200 may permit the extension chamber 164 to exhaust air resulting in decreased volume of said chamber. The directional control valve 200 may direct the flow of exhausted air received from pneumatic hose 172 via flow-through port 176 towards a second exhaust valve 240. Exhausted air may discharge from exhaust valve 240 via a second exhaust port 230 disposed in the directional control valve 200.

[0065] Thereby, the directional control valve 200 is operable to have active control of bidirectional resistance movements of the piston rod 154 and piston head 158. Bidirectional movements may include movement of the piston rod 154 and piston head 158 toward the distal end cap 170 (see movement arrow 168) and away from the distal end cap 170 (see movement arrow 166). The piston rod 154 may be operably connected to an actuating unit, which may be an integral rod, to control the stroke movement of a coupler at a distal end of the actuating unit.

[0066] As shown in FIG. 5, the directional control valve 200 may be structured to be slidably engaged between the first position 202 and the second position 204. The directional control valve 200 engaged in the first position 202 permits the flow of pressurized gas towards extension chambers 262, 264 to charge pneumatic actuators 252, 254 so they extend and apply active resistance in a first direction upon an exercise tool user interface. The directional control valve 200 engaged in the second position 204 permits the flow of pressurized gas towards retraction chambers 272, 274 to charge pneumatic actuators 252, 254 so that they retract and apply active resistance in a second direction upon the exercise tool user interface. Please note that reversing orientation of one of the pneumatic actuators 252, 254 in the pneumatic system 70 can result in a scenario where the pneumatic actuators 252, 254 extend and retract inversely from one another, rather than together.

[0067] Optionally, the directional control valve 200 may be structured to be selectively engaged into a third position 206 that is centrally disposed between the first position 202 and the second position 204. The directional control valve 200 engaged in the third position 206 prevents the flow of pressurized gas between the pneumatic power source 350 and the pneumatic actuators 252, 254. As a result of the directional control valve 200 being placed in this neutral position, the pneumatic actuators 252, 254 are not allowed to further extend or retract, but may be fixed in place mid-stroke at any position at, or between, full extension and full retraction.

[0068] With reference still to FIG. 5, a first T-valve connection 182 may be disposed in pneumatic hose 172. T-valve connection 182 divides the supply of compressed air delivered to charge extension chambers 262, 264 of the pair of pneumatic actuators 252, 254. T-valve connection 182 may allow extension chamber 262, 264 sides of the pair of pneumatic actuators 252, 254 to be charged simultaneously, proportionally, or independently from one another. A second T-valve connection 184 may be disposed in pneumatic hose 174. T-valve connection 184 divides the supply of compressed air delivered to charge retraction chambers 272, 274 of the pair of pneumatic actuators 252, 254. T-valve connection 184 may allow retraction chamber 272, 274 sides of the pair of pneumatic actuators 252, 254 to be charged simultaneously, proportionally, or independently from one another. Shared valves and pneumatic hoses extending between the two resistance units may be utilized. However, in other applications, separate valves and pneumatic hoses may be used for each resistance unit.

[0069] The directional control valve 200 is fluidly connected to a pneumatic power source 350 via a pneumatic hose 160. The pneumatic power source 350 may include the air compressor 380 and the air tank 390 which may have a capacity range of between 15 gallons to 100 gallons of pressurized air. Alternatively, other pneumatic power sources may be utilized, such as a compressed air tank, a pneumatic pump, a blower, a vacuum pump, or a fixed displacement pump or a variable displacement pump that may be pressure-compensated or non-pressure compensated.

[0070] In the examples shown, the air compressor 380 is operable to generate a pressurized flow of air to a pneumatic system 70 of the exercise apparatus 10. The pneumatic system 70 may be operated by a control system 60 so that the resistance assembly 80 applies and maintains the active resistance at a constant force. The control system 60 dynamically controls each of the plurality of actuators to cause the respective one of the plurality of actuating units to extend and retract dynamically. The control system 60 may be connected downstream of the air compressor 380 and air tank 390 via a first portion 160A of the pneumatic hose 160. The control system 60 may be electrically powered by an electric power source 360 such as an electrical outlet, generator, battery, or other electrical output source via a power line 370.

[0071] The control system 60 may include a filter, regulator, and lubricator (F.R.L.) unit 300 which comprises an air filter, a pneumatic regulator, and a lubricant valve. The F.R.L. unit 300 may also comprise an on / off switch, output ports, and air pressure gauges. The pneumatic regulator may protect a pneumatic system 70 of the exercise apparatus 10 from over pressurization.

[0072] The control system 60 may include a force regulating device such as a pressure regulator 250 that controls downstream pressure of gas within the pneumatic system 70 so that the actuator's pressure is maintained near or at the reference force setpoint. The pressure regulator 250 may be structured with a solenoid valve to proportionally adjust a continuous supply of pressurized gas from the pneumatic power source 350 to the remainder of the pneumatic system 70. The pressure regulator 250 may be electrically operated in response to an output signal received from the control system 60. Output signals received from the control system 60 may adjust the pressure regulator 250 proportionally between a plurality of positions to dictate and modulate air pressure in the pneumatic system 70 downstream. An inlet port 245 of the pressure regulator 250 may be connected to the pneumatic system 70 to receive pressurized gas from the pneumatic power source 350. A pressure port side 225 and a return port 275 side of the pressure regulator 250 may be proportionally adjusted between a fully open position and a fully closed position. The continuous supply of adjusted air may be directly transferred to the directional control valve 200 from an outlet port 255 of the pressure regulator 250.

[0073] As shown in FIGS. 4, 5, 6, and 7, the pressure regulator 250 may be fluidly connected with the pneumatic hose 160 between the directional control valve 200 and F.R.L. unit 300 via a second portion 160B and a third portion 160C of pneumatic hose 160. Alternatively, the pressure regulator 250 may be fluidly connected with the pneumatic hose 160 between the pneumatic power source 350 and a pneumatic actuator. In this configuration, the continuous supply of adjusted air may be directly transferred to the pneumatic actuator by the pressure regulator 250. The pressure regulator 250 is operable to continuously and proportionally adjust the pressurized flow of air received upstream via the second portion 160B of the pneumatic hose 160 so that the pneumatic actuator downstream can maintain active resistance at a constant force, even in response to reactive force of resistance applied to the exercise tool user interface by a user of the exercise apparatus 10.

[0074] The control system 60 may include an electronic controller, such as a microprocessor or microcontroller 500. The microcontroller 500 may access a computer-readable medium to perform operations by the actuator(s) via one or more actuator interfaces / drivers. The microcontroller 500 may respond to a user input made on a user-interface display, such as a selection of a weight load amount. The microcontroller 500 may include a Central Processing Unit (CPU) along with other components such as memory and input / output interfaces that are integrated as a system on a single chip. The microcontroller 500 may be further integrated for connection with an outside interface 550 such as network-controlled devices connected to ethernet, Wi-Fi, or Bluetooth that may interact with the user and / or other systems. Optionally, the control system 60 may be remotely controlled by the outside interface 550. The microcontroller 500 may be embedded as a part of the control system 60 by way of an embedded electronic system such as a Raspberry Pi 5. The microcontroller 500 may be operable to process data signals and execute instructions to electronically activate and control the pressure regulator 250 and the directional control valve 200 as shown in FIG. 6.

[0075] In one aspect, the control system 60 may be mounted on a control panel 100 with the user-interface display that permits selection or input of a reference force by a user. The user may input a reference force (e.g., weight value) into the microcontroller that ranges from between 0 pounds to 1,000 pounds in weight. Precise weight values, even to the tenth or hundredth of a pound, may be selected by the user with the press of a button. Programming within the microcontroller 500 may convert the reference force to a corresponding air pressure by the pressure regulator 250. The control system 60 may accurately supply the active resistance force within a tenth of a pound of the user input reference force. The plurality of actuators charge with a regulated supply of pressurized air based on a power rating that corresponds to the input reference force. The actuators then achieve an output amount of an active resistance force that corresponds to the input reference force, which may occur within a range of between 1 second to 5 seconds. The amount of active resistance force applied by actuators of the exercise apparatus 10 may be within a range of + / −0.02 pounds to 2 pounds from the reference force input into the control system 60.

[0076] In an additional aspect, the control system 60 may selectively command a pressure value of a respective one of the plurality of actuators to achieve an output amount of an active resistance force that corresponds to the input reference force. In another aspect, the control system 60 may selectively command the respective pressure regulator 250 to proportionally control the active resistance force based on a linear conversion scale of a voltage command signal versus an amount of gas pressure applied in pounds per square inch (i.e., 1 volt=10 psi (40 lbs. of active resistance), 5 volts=50 psi (200 lbs. of active resistance force), 10 volts=100 psi (400 lbs. of active resistance)). Adjusting the active resistance force of each actuator, independently or in combination with each other, in correspondence with the voltage command signal may be achieved by one or more of sizing the respective pressure values for an amount of voltage command signal that corresponds to the input reference force. Selecting a power rating of each actuator to correspond to the input reference force, or adjusting a commanded pressure value of actuation by the control system 60 to correspond to the input reference force may be considered to convert the user input reference force into an equivalent air pressure (e.g., psi) using the pressure regulator 250 and directional control valve 200.

[0077] The control system 60 may include a Digital-to-Analog Converter (DAC) that is operable to step-up voltage from the microcontroller 500 in order to provide sufficient downstream operational control of a pressure regulator and directional or proportional control valves. For a valve having a voltage operating range of between 0 volts minimum to 10 volts maximum, a converter that provides a step-up voltage of 5 volts may be used for a microcontroller 500 that has a maximum operational voltage of 5 volts.

[0078] As shown in FIG. 4, a first converter 400 is electrically connected between the pressure regulator 250 and the microcontroller 500 via a first converter line 420 and a first processor line 435, respectively. The converter utilized in this example is a MCP4725 12-bit DAC which may be used where precise analog output is warranted, such as in signal generation, sensor interfacing, and control systems. This particular converter provides 0-volt min. to 10-volt max. control signals. The pressure regulator 250 may be electronically controlled by the microcontroller 500 via the first converter 400.

[0079] A second converter 450 is electrically connected between the microcontroller 500 and the directional control valve 200 via a second processor line 475 and a second converter line 425, respectively. The directional control valve 200 may be electronically controlled by the microcontroller 500 via the second converter 450 at connection 405. As shown in FIG. 6, the first converter 400 and the second converter 450 may be switched positionally, vice versa, with the pressure regulator 250 and directional control valve 200. The electric power source 360 may be electrically connected with the directional control valve 200 and the pressure regulator 250 to provide operational power control.

[0080] The control system 60 may include any acceptable sensor, such as a proximity or electrical conductivity sensor, a load cell, a flow sensor, an actuator position sensor, a level sensor, a proximity sensor, a presence sensor, a pressure sensor including strain-gauge, piezoresistive, capacitive, piezoelectric, diaphragm-based, absolute, differential, or transducer types, or a plurality of pressure sensors to read actual pressure within the pneumatic system 70 as shown in FIG. 4. A first pressure sensor 180 may be operably disposed in a pneumatic hose between the directional control valve 200 and the actuator 150. A T-valve connection 179 may be disposed in pneumatic hose 172 and / or pneumatic hose 174 for connection of the pressure sensor 180. Sensor 180 may generate a first output signal that the microcontroller 500 receives to determine a charge parameter and / or an amount of pressure supplied in the pneumatic hose. A second pressure sensor 186 may be operably disposed in the wall or at a proximal end of the pneumatic cylinder 152 of the actuator 150. Sensor 186 may generate a second output signal that the microcontroller 500 receives to determine an amount of pressure charged within the retraction chamber 162 of the actuator 150. A third pressure sensor 188 may be operably disposed in the wall or the distal end cap 170 of the cylinder 152 of the actuator 150. Sensor 188 may generate a third output signal that the microcontroller 500 receives to determine an amount of pressure charged within the extension chamber 164. Therefore, the control system 60 may calculate a pressure differential between the retraction chamber 162 and the extension chamber 164 in order to modulate air pressure within the pneumatic system 70 for maintaining application of active resistance by the actuator at a constant force during an exercise cycle conducted by a user.

[0081] A display unit 90 may be included as a part of the exercise apparatus 10, preferably in a heads-up type display. As seen in FIG. 2, the display unit 90 is positioned above and centrally mounted to the cross-brace member 34. Preferably, the face of the display unit 90 is positioned to face toward a user so easily visible while the user is in an exercise position. The display unit 90 displays information representing the sensed pressure control signal, which is indicative of the resistance force applied to the weight bar 14 by the resistance assembly 80 as adjusted by the pressure regulator 250. For example, but without limitation, the display unit 90 may also display information such as a target number of repetitions, number of repetitions performed, and / or the number of exercise sets to be completed in an exercise cycle.

[0082] An unregulated flow of pressurized gas through the pneumatic system 70 may be back fed through the pressure regulator 250 via the third portion 160C of the pneumatic hose 160. This occurs when a reactive resistance force overcomes the active resistance force delivered from actuation by the exercise apparatus 10. A user of the exercise apparatus 10 may apply enough reactive resistance force through the exercise tool user interface to overcome the active resistance force.

[0083] During exercise use of the exercise apparatus 10, a charged chamber may decrease in volume in response to piston movement when a force of gas pressure within the charged chamber is overcome by the user's reactive resistance force. In response to charged extension chamber 164 being overcome by a user's reactive resistance force, piston rod 154 will move piston head 158 towards the distal end cap 170 in a second direction, as shown by movement arrow 168. As a result, the directional control valve 200 in first position 202 may permit gas from the charged extension chamber 164 to back feed through flow-through port 171 of cylinder 152 resulting in decreased volume of said chamber. The directional control valve 200 may direct the flow of back fed gas received from pneumatic hose 172 via flow-through port 176 back towards the pressure regulator 250. Back fed gas may be proportionally adjusted and exhaust vented from the pressure regulator 250 to the atmosphere via the return port side 275 to maintain a constant active resistance force by actuation relative to the reference force.

[0084] In response to charged retraction chamber 162 being overcome by a user's reactive resistance force, piston rod 154 will move piston head 158 towards the proximal end of cylinder 152 in a first direction, as shown by movement arrow 166. As a result, the directional control valve 200 in second position 204 may permit gas from charged retraction chamber 162 to back feed through flow-through port 173 of cylinder 152 resulting in decreased volume of said chamber. The directional control valve 200 may direct the flow of back fed gas received from pneumatic hose 174 via flow-through port 178 back towards the pressure regulator 250. Back fed gas may be proportionally adjusted and exhaust vented from the pressure regulator 250 to the atmosphere via the return port side 275 to maintain a constant active resistance force by actuation relative to the reference force.

[0085] With reference to FIG. 7 now, an operational cycle is shown by flowchart 700 for maintaining a regulated load by the exercise apparatus 10. The regulated load is maintained at a constant force relative to variable differences identified between an established reference force and an actual force applied. According to step 710, the weight bar 14 is positioned in a retracted position 82 to begin an exercise cycle. The weight bar 14 may start, by default, in a retracted position 82 for user safety. According to step 720, a reference force is established by the user in which the pressure regulator 250 will seek to maintain. Upon user engagement of a switch or detection by sensors, the exercise cycle will begin. According to step 730, a directional control valve 200 is opened so that actuators extend to bear down upon the user an actuated load. According to step 740, an actual force value is measured by a pressure sensor 180 disposed in the pneumatic system 70. According to step 750, the pressure in the pneumatic system 70 may be proportionally adjusted if the actual force value measured is not in agreement with the reference force established. According to step 760, the active resistance force is supplied in correspondence with the reference force. The operational cycle may be repeated as the user continues the exercise cycle.

[0086] With reference to FIG. 8 now, an operational exercise cycle is shown by flowchart 800 for safely returning the regulated load to a retracted position 82, which may be a zeroed start position, by release of an engagement switch 74 of the exercise apparatus 10. As shown between FIG. 8 and FIGS. 9A-F, a user 5 who has selected a reference force (e.g., weight value) on the control panel 100 may position oneself in the exercise station of the exercise apparatus 10 in order to perform an exercise squat, according to step 810. As depicted in FIG. 9A, the user 5 is positioned in a standing position below the weight bar 14 disposed in the zeroed start position 82. In the zeroed start position 82, the retraction chambers of the actuators may be charged so that the forces acting on the weight bar are balanced between the pressurized air pushing on the piston head and the distal end cap fixed at the distal end of the air piston. Movement arrow 815 shows a first transition between step 810 and step 820. According to step 820, the engagement switch 74 has been engaged to actuate the weight bar 14 to come down from the start position and bear a regulated load downwardly upon the user 5. In response, an operational signal is sent through operation line 72 to the control system 60. The control system 60 engages the pneumatic power source 350 to provide an active supply of pressurized air to the pneumatic system 70 so that actuators initiate an active resistance force 822 that corresponds with the selected reference force. As seen by the downwardly projecting spot-filled arrow in FIG. 9B, the active resistance force 822 has a great magnitude causing extension of the actuators so that the weight bar 14 begins to move downwardly. As seen in FIG. 9C, the active resistance force 822 (see arrow with spotted shading) has a greater magnitude than a reactive resistance force 824 (see arrow with diagonal hatching) applied by the user 4 so that the weight bar 14 continues to move downwardly. Movement arrow 825 shows a second transition between step 820 and step 830. According to step 830, the user 5 that maintains engagement with the engagement switch 74 will continue the operational exercise cycle in accordance with step 840 via a third transition as shown by movement arrows 835, 845. As seen in FIG. 9D, the active resistance force 822 applied by the actuators and the reactive resistance force 824 applied by the user 5 are substantially equal so that the weight bar 14 begins to halt and transition to an upward motion as seen in FIG. 9E. The pressure regulator continues to seek the reference force by modulating the continuous supply of pressurized air so that the actual force equals the reference force as discussed in FIG. 7. Movement arrow 855 shows a fourth transition between step 840 and step 850. According to step 850, the user 5 pushes with the reactive resistance force 824 against the active resistance force 822 bearing down. If the user's active reactive resistance force 824 pushing up is greater than the exercise apparatus's active resistance force 822 pushing down, then the weight bar 14 will move upwardly due to the imbalance between forces. As seen in FIG. 9E, the reactive resistance force 824 applied by the user 5 has a greater magnitude than the active resistance force 822 applied by the actuators so that the weight bar 14 moves upwardly. The user 5 may continue to maintain engagement of the engagement switch 74 to repeat repetitions of the squat exercise movement. When the user 5 decides to end the exercise cycle, the user 5 may release the engagement switch 74 and the weight bar 14 will return to the zeroed start position 82, according to step 860 via a fifth transition as shown by movement arrow 865. Disengagement of the engagement switch 74 will initiate the directional control valve 200 to return to a safety position so that retraction chambers of the actuators charge, and retraction of the load occurs. The weight bar 14 may return to the starting position within a range of between 1 second to 5 seconds. As seen by the upwardly projecting hatch-filled arrow in FIG. 9F, the active resistance force 822 has switched causing retraction of the actuators so that the weight bar 14 begins to move upwardly towards the zeroed start position 82.

[0087] As shown in FIG. 2, operation of the directional control valve 200 may be partially or fully administered by the engagement switch 74. The engagement switch 74 may be operably connected with the directional control valve 200 via an operation line 72. The operation line 72 may be disposed externally to or internally within the exercise user tool interface. The engagement switch 74 may be structured to detect the presence of a user interfaced with the exercise apparatus 10 via a presence sensor as discussed above. In the example shown, the engagement switch 74 is directly engaged by direct contact from the user with the exercise tool user interface. The engagement switch 74 may be disposed upon one end of the exercise tool user interface for direct engagement by the user.

[0088] As shown in FIG. 2, the engagement switch 74 is an electronic push button (e.g., start / stop operation) disposed on the first end 13 of the weight bar 14 to be manually accessible by a hand or foot of the user placed upon the weight bar 14. Alternatively, the engagement switch 74 may be a lever, pedal, pressure switch, remote control, or sensor, such as a proximity or electrical conductivity sensor. Engagement of the directional control valve 200 by engagement switch 74 may switch directional flow of supplied air to charge a different chambered side of the cylinder 152 with increased air pressure. Engagement of the directional control valve 200 by engagement switch 74 may also start and stop operation of the pneumatic system 70 of the exercise apparatus 10. The control system 60 may switch the directional control valve 200 between diversion control positions. A high voltage signal (e.g., 10 volts) may be sensed by the control system 60 with engagement of the engagement switch 74. A medium voltage signal (e.g., 5 volts) may be sensed by the control system 60 with release of the engagement switch 74. A low voltage signal (e.g., 0 volts) may be sensed by the control system 60 with disengagement of the engagement switch 74 or loss of electrical power to serve as a fail-safe.

[0089] The microcontroller 500 may be operationally configured so that upon disengagement of the engagement switch 74 by a user of the exercise apparatus 10, the microcontroller 500 will switch the directional control valve 200 into a safety default or zero position. In the examples shown, the directional control valve 200 is structured to be automatically switched into second position 204 by default upon the engagement switch 74 being released by the user. In response, retraction chamber(s) of the pneumatic cylinder(s) are charged, and the actuating unit(s) are retracted along with the coupler(s) connected to the exercise user tool interface.

[0090] In different configurations of the exercise apparatus 10, the directional control valve 200 may be structured to be automatically switched into first position 202, by default, upon the engagement switch 74 being released by the user. In response, extension chamber(s) of the pneumatic cylinder(s) are charged, and the actuating unit(s) are extended along with the coupler(s) connected to the exercise user tool interface. Alternatively, the directional control valve 200 may be structured to be automatically centered into the third position 206, by default, upon the engagement switch 74 being released by the user. In response, the supply of pressurized gas is restricted through the directional control valve 200 and the actuating unit(s) of the pneumatic cylinder(s) are placed into a fixed position.

[0091] In further consideration of methods employed by use of the exercise apparatus, a user may input a weight amount into a controller. The controller may convert the weight amount into a simulated weight force. The simulated weight force may be applied upon a weightless barbell of the exercise apparatus to move the weightless barbell. The weightless barbell installed with a presence sensor may sense engagement by a user and initiate application of the simulated weight force. The simulated weight force may be increased to a reference value within a time range of between one second to five seconds. Upon engagement of the presence sensor by the user, a control valve may be slowly opened and closed to adjust the simulated weight force in dynamic proportion to a counter force applied to the weightless barbell by the user. The simulated weight force may be maintained at the reference value within a weight range of between a hundredth of a pound to two pounds. The simulated weight force may be actively balanced with the counter force by the controller's adjustment of the control valve. Upon disengagement of the presence sensor by the user, the weightless barbell may be retracted into a start position due to signal communication between the presence sensor and the controller.

[0092] Rather than maintain a constant force throughout the stroke movement of the actuators, the techniques described herein may be modified so that proportional control of the pneumatic system can produce variable resistance force curves that increase and decrease throughout the exercise stroke. For example, when exercising muscles or muscle groups, the resistance force may increase towards the middle of the stroke and then decrease towards the end of the stroke. The initial orientation of the pneumatic actuator(s), the degree of inclination, the initial position of the exercise user tool interface, and / or the guidance profile embedded in the microcontroller may be used to produce the desired force curve.

[0093] Now referring to FIG. 10, an example electrical schematic of a control system 1060 is depicted that may be utilized with the exercise apparatus. The control system 1060 may be electrically powered by a power source 1360 by direct connection to an electrical outlet, generator, battery, or other electrical output source via a power line. The power source 1360 device shown has 24-volt power that may be compatible with either alternating current (AC) or direct current (DC). A 24-volt power source for the control system 1060 may allow for low-voltage power control when using step-down voltage from a standard wall outlet. The power source 1360 may be electrically connected to a pneumatic control valve, such as a directional control valve 1200. The directional control valve 1200 may be an AVS-5313, 5-port, 2-way positional, single spring return solenoid valve. A relay solenoid 1100 may be disposed between the power source 1360 and the directional control valve 1200 via a first ancillary electrical circuit. The relay solenoid 1100 may be operable to control the directional control valve 1200 electromagnetically as an on / off relay switch to provide operational control of the directional control valve 1200.

[0094] A step-down converter 1600 may be integrated into the circuitry of the control system 1060. The step-down converter 1600 utilized may be a Buck-type Converter, such as a LM2596 that is configured to convert higher input voltage (i.e., 24-volt) to an adjusted lower voltage output (i.e., 5-volt). The step-down converter 1600 may be operably connected between the power source 1360 and the microcontroller 1500 that operates at a lower voltage. The step-down converter 1600 may receive input of electrical power directly from the power source 1360.

[0095] The control system 1060 may include an electronic controller, such as a microprocessor or microcontroller 1500. The microcontroller 1500 may access a computer-readable medium to perform operations by the pneumatic actuator(s) via one or more actuator interfaces / drivers. The microcontroller 1500 may respond to a user input made on a user-interface display 1550, such as a touch screen display that is mounted on a control panel. The control panel may be a Printed Circuit Board (PCB) that is a flat board that physically supports and carries control circuitry that electrically interconnects the electronic components of the control system 1060.

[0096] The microcontroller 1500 may include a Central Processing Unit (CPU) along with other components such as memory and input / output interfaces that are integrated as a processing system on a single chip. The microcontroller 1500 may be further integrated for connection with an outside interface such as a network-controlled device(s) connected to ethernet, Wi-Fi, or Bluetooth that may interact with the user and / or other systems. Optionally, the control system 1060 may be remotely controlled by the outside interface.

[0097] The microcontroller 1500 may be a part of the control system 1060 by way of an embedded Proportional-Integral-Derivative (PID) controller, such as a Raspberry Pi. A PID controller may be used to automatically regulate the directional control valve 1200 so that output of actuator(s) pressure is maintained near or at the reference force setpoint. The microcontroller 1500 may be operable to process data signals and execute instructions to electronically activate and control the directional control valve 1200 by the relay solenoid 1100 with on / off functionality. The PID controller may allow for more programmer control, thereby requiring less input control by a user.

[0098] In one aspect, the control system 1060 may be mounted on the control panel with the user-interface display 1550 to permit selection or input of a reference force by a user. The user-interface display 1550 may be operable connected between the step-down converter 1600 and the microcontroller 1500. The user may input a reference force (e.g., weight value) that may range from between 0 pounds to 1,000 pounds in weight into the microcontroller 1500. Precise weight values, even to the tenth or hundredth of a pound, may be selected by the user with the press of a touchscreen button on the user-interface display 1550. Programming within the microcontroller 1500 may convert the reference force to a corresponding air pressure applied to the pneumatic system.

[0099] A Digital-to-Analog Converter (DAC) converter may be electrically connected between the microcontroller 1500 and a pressure regulator 1402 via a second ancillary electrical circuit. The pressure regulator 1402, may be a pneumatic transducer, such as model NCP2-20-3120D by AutomationDirect having a 4 milliampere (mA) to 20 mA input range. The pressure regulator 1402 may be electrically connected to the DAC converter 1400 via the first ancillary electrical circuit to convert the electrical control input signal into a proportional pneumatic pressure output for controlling the pneumatic system.

[0100] The DAC converter 1400 shown may be a first control module electrically connected between the microcontroller 1500 and the pressure regulator 1402 via a first primary electrical pathway. As shown in FIG. 10, the control system 1060 including the DAC converter 1400 is operable to step-up voltage from the microcontroller 1500 in order to provide sufficient downstream operational control. The DAC converter 1400 may provide a step-up voltage of 24-volts when used with the microcontroller 1500 operating on lower voltage. The DAC converter 1400 may provide 0-volt minimum to 24-volt maximum control signals for operation of the pressure regulator 1402. The DAC converter 1400 utilized in this example may be used where precise analog output is warranted, such as in signal generation, sensor interfacing, and control systems.

[0101] An Analog-to-Digital (ADC) converter 1450 shown may be a second control module electrically connected between the microcontroller 1500 and a pressure sensor 1452 via a second primary electrical pathway. The ADC converter 1450 may be an ADS1115 by AutomationDirect being a 16-bit, 4-channel ADC type converter that is utilized in place of the second DAC converter and pressure regulator as in the control system previously shown in FIG. 6. The ADC converter 1450 may be operable to step-up voltage from the microcontroller 1500 in order to provide sufficient downstream operational control. The ADC converter 1450 may provide a step-up voltage of 24-volts when used with the microcontroller 1500 operating on lower voltage. The ADC converter 1450 may provide 0-volt minimum to 24-volt maximum control signals. The ADC converter 1450 utilized in this example may be used where precise digital output is warranted, such as in signal generation, sensor interfacing, and control systems.

[0102] The control system 1060 may include a sensor, such as the pressure sensor 1452, or a plurality of pressure sensors. The pressure sensor 1452 may be a pressure transmitter, such as a SPTD25-20-0200H by AutomationDirect, having a fluid pressure sensing range of 0-200 psi. The pressure sensor 1452 may be operably connected to the ADC converter 1450 via the second primary electrical pathway. The pressure sensor 1452 may be operably disposed between the ADC converter 1450 within the second primary electrical pathway. The ADC converter 1450 may receive 4 mA to 20 mA signals from the pressure sensor 1452 and provide readouts to the CPU. The supply voltage for the pressure sensor 1452 may be 24-volts.

[0103] The pressure sensor 1452 may read an output of fluid pressure within the pneumatic system for the control system 1060. Pressure sensor 1452 may generate an input signal based on the output of the fluid pressure. The electrical current of the input signal and / or output signal from the pressure sensor 1452 may range between 4 mA to 20 mA. The actual fluid pressure may be determined based on the input signal relayed to the ADC converter 1450. The microcontroller 1500 receiving the input signal via the ADC converter 1450 may determine a charge parameter and / or an amount of pressure being supplied in the pneumatic system. As a result, the control system 1060 may modulate fluid pressure within the pneumatic system to maintain application of active resistance by the actuator(s) at a constant force during an exercise cycle conducted by a user.

[0104] An engagement switch 1074 may be operably connected with the microcontroller 1500 via a second ancillary electrical pathway to engage the directional control valve 1200. The engagement switch 1074 may be disposed on the exercise tool user interface for direct engagement by a user of the exercise apparatus. Disengagement of the engagement switch 1074 by the user may engage the directional control valve 1200 into a default off position. The default off position may correlate with the directional control valve 1200 being retracted. Engagement of the engagement switch 1074 by the user may engage the directional control valve 1200 into a manual on position. The manual on position may correlate with the directional control valve 1200 being extended.

[0105] The microcontroller 1500 may be operationally configured so that upon disengagement of the engagement switch 1074 by a user of the exercise apparatus, the microcontroller 1500 will switch the directional control valve 1200 into a safety default, zero, or retracted position. The directional control valve may be structured to be automatically switched into the retracted position by default upon the engagement switch being released by the user. In response, retraction chamber(s) of the pneumatic cylinder(s) are charged, and the actuating unit(s) are retracted along with the coupler(s) connected to the exercise user tool interface. The directional control valve 1200 may be structured to be switched into an extended position upon the engagement switch 1074 being engaged by the user. In response, extension chamber(s) of the pneumatic cylinder(s) are charged, and the actuating unit(s) are extended along with the coupler(s) connected to the exercise user tool interface.

[0106] It is understood that the invention is not confined to the particular construction and arrangement of parts herein described. That although the drawings and specification set forth a preferred embodiment, and although specific terms are employed, they are used in a description sense only and embody all such forms as come within the scope of the following claims.

[0107] The present disclosure is not to be limited in terms of the particular embodiments described in this application, which are intended as illustrations of various aspects. Many modifications and variations can be made without departing from its spirit and scope. Functionally equivalent methods and apparatuses within the scope of the disclosure, in addition to those enumerated herein, are possible from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the appended claims.

[0108] For the convenience of the reader, the above description has focused on a representative sample of all possible embodiments, a sample that teaches the principles of the invention and conveys the best mode contemplated for carrying it out. Throughout this application and its associated file history, when the term “invention” is used, it refers to the entire collection of ideas and principles described; in contrast, the formal definition of the exclusive protected property right is set forth in the claims, which exclusively control. The description has not attempted to exhaustively enumerate all possible variations. Other undescribed variations or modifications may be possible. Where multiple alternative embodiments are described, in many cases it will be possible to combine elements of different embodiments, or to combine elements of the embodiments described here with other modifications or variations that are not expressly described. A list of items does not imply that any or all of the items are mutually exclusive, nor that any or all of the items are comprehensive of any category, unless expressly specified otherwise. In many cases, one feature or group of features may be used separately from the entire apparatus or methods described. Many of those undescribed variations, modifications and variations are within the literal scope of the following claims, and others are equivalent.

Examples

Embodiment Construction

[0028]The exercise apparatus is operable to perform bidirectional resistance movements with active load regulation. The exercise apparatus derives the load from actuators that are actively regulated to assert an active resistance (e.g., pressure) that equalizes with reactive resistance asserted by a user. The exercise apparatus maintains the load at a constant force based on a selected reference force and resistance applied by a user's reactive force. An example of the exercise apparatus 10 structured to provide bidirectional resistance movements during weightlifting exercising is shown in FIG. 1. The exercise apparatus 10 comprises a frame 12. The frame 12 may define at least one exercise station. A user can sit, stand, or recline at the exercise station. In the example of sitting, an exercise bench (not shown) may be used with the exercise apparatus 10.

[0029]The frame 12, if not mounted directly to a floor, may comprise a sub-assembly 16. The sub-assembly 16 may be formed by a bas...

CROSS REFERENCES

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 780,760 filed 31 Mar. 2025, which is incorporated by reference herein in its entirety.REFERENCE TO RESEARCH

[0002] Not Applicable.REFERENCE TO CDS

[0003] Not Applicable.FIELD OF THE INVENTION

[0004] The present disclosure relates to an exercise apparatus that uses pneumatics to continuously maintain an active resistance at a constant force for working a body.BACKGROUND

[0005] In weightlifting, weights are typically added or removed from a bar (e.g., a barbell) as with free weights, or are part of a weight stack in which the number of weight plates resisting movement of a handle or a bar can be varied. Resistance experienced by the body of a user during concentric or eccentric movements depends upon the amount of the weight.

[0006] Pneumatic exercise equipment has been developed in attempts to simulate exercise weights and is typically configured similarly to weight stack equipment. However, for many weightlifters, pneumatic exercise equipment does not provide the simulated feeling of free weights to which they are accustomed.SUMMARY

[0007] The exercise apparatus performs bidirectional resistance movements with active load regulation by way of a pneumatic system. The pneumatic system may comprise a first pneumatic cylinder that is double-acting. The pneumatic cylinder has an extension chamber and a retraction chamber. A directional control valve fluidly connected with the pneumatic cylinder is structured to be selectively engaged between a first position and a second position. In the first position, the extension chamber is permitted to charge. As a result, the pneumatic cylinder extends and applies active resistance in a first direction upon an exercise tool user interface. In the second position, the retraction chamber is permitted to charge. As a result, the first pneumatic cylinder may retract and apply active resistance in a second direction upon the exercise tool user interface.

[0008] A second pneumatic cylinder that is double acting may be disposed laterally adjacent and vertically oriented and parallel with the first pneumatic cylinder. The exercise tool user interface may be connected perpendicularly between bottom ends of the first pneumatic cylinder and the second pneumatic cylinder. The directional control valve may be operable to permit both the first pneumatic cylinder and the second pneumatic cylinder act simultaneously together to perform bidirectional resistance movements with active load regulation.

[0009] An air pressure regulator may be fluidly connected to the pneumatic cylinder. The air pressure regulator may be structured to adjust a continuous active supply of air to the pneumatic cylinder. The continuous supply of air may be directly transferred to the pneumatic cylinder from a powered air source with regulation provided by the air pressure regulator. The air pressure regulator maintains the active resistance upon the exercise tool user interface at a constant force, even in response to a reactive resistance applied to the exercise tool user interface by a user of the exercise apparatus.

[0010] An engagement switch may be operably connected with the controller to engage the directional control valve. The engagement may be disposed on the exercise tool user interface for direct engagement by a user of the exercise apparatus. Disengagement of the engagement switch by the user may engage the directional control valve into a default position. The default position may correlate with the second position, which results in the pneumatic cylinder being retracted.

[0011] The above advantages and features are of representative embodiments only, and are presented only to assist in understanding the invention. It should be understood that they are not to be considered limitations on the invention as defined by the claims. Additional features and advantages of embodiments of the invention will become apparent in the following description, from the drawings, and from the claims.BRIEF DESCRIPTION OF DRAWINGS

[0012] Aspects are illustrated by way of example, and not by way of limitation, in the accompanying drawings, wherein:

[0013] FIG. 1 depicts a front perspective view of an exercise apparatus structured in a power rack type configuration.

[0014] FIG. 2 depicts a front perspective view of the exercise apparatus installed with a control system and an engagement switch.

[0015] FIG. 3 depicts a structural layout of the control system showing component elements.

[0016] FIG. 4 depicts an operational schematic of an exercise apparatus showing electrical and pneumatic components.

[0017] FIG. 5 depicts a pneumatic schematic of an exercise apparatus showing proportional and directional control valves.

[0018] FIG. 6 depicts an electrical schematic of an exercise apparatus showing proportional and directional control valves powered by converters and an electric power source.

[0019] FIG. 7 depicts an operational flowchart for maintaining a regulated load by the exercise apparatus at a constant force relative to a difference between an established reference force and an actual force applied.

[0020] FIG. 8 depicts an operational flowchart for safely returning the regulated load to a start position by release of an engagement switch of the exercise apparatus.

[0021] FIG. 9A shows a first frame in a series of chronological depictions of the exercise apparatus being used by a user during an exercise cycle.

[0022] FIG. 9B shows a second frame in a series of chronological depictions of the exercise apparatus being used by a user during an exercise cycle.

[0023] FIG. 9C shows a third frame in a series of chronological depictions of the exercise apparatus being used by a user during an exercise cycle.

[0024] FIG. 9D shows a fourth frame in a series of chronological depictions of the exercise apparatus being used by a user during an exercise cycle.

[0025] FIG. 9E shows a fifth frame in a series of chronological depictions of the exercise apparatus being used by a user during an exercise cycle.

[0026] FIG. 9F shows a sixth frame in a series of chronological depictions of the exercise apparatus being used by a user during an exercise cycle.

[0027] FIG. 10 shows a directional control valve powered by an electric power source through a relay solenoid valve.DETAILED DESCRIPTION

[0028] The exercise apparatus is operable to perform bidirectional resistance movements with active load regulation. The exercise apparatus derives the load from actuators that are actively regulated to assert an active resistance (e.g., pressure) that equalizes with reactive resistance asserted by a user. The exercise apparatus maintains the load at a constant force based on a selected reference force and resistance applied by a user's reactive force. An example of the exercise apparatus 10 structured to provide bidirectional resistance movements during weightlifting exercising is shown in FIG. 1. The exercise apparatus 10 comprises a frame 12. The frame 12 may define at least one exercise station. A user can sit, stand, or recline at the exercise station. In the example of sitting, an exercise bench (not shown) may be used with the exercise apparatus 10.

[0029] The frame 12, if not mounted directly to a floor, may comprise a sub-assembly 16. The sub-assembly 16 may be formed by a base 18 having a first base member 20 and a second base member 22. The base 18 may be rectangular in shape and serve as a platform for a user of the exercise apparatus 10. The base 18 may be attached to a side or an end of each base member. The base 18 may be disposed between the base members 20, 22. Portions of each base member may extend beyond the rectangular frame structure at both ends of the respective base 18. Brace structures may be used between the base 18 and the base members 20, 22 to secure them firmly together. Base components may be made of steel, aluminum, rubber, or other supporting material.

[0030] Each base member may include one or more mounting flanges, brackets, or plates that are mounted and positioned to support the frame 12. A first mounting plate 24 and a second mounting plate 26 are shown. The base members 20, 22 may include mounting holes through which a suitable fastener (e.g., a bolt) can pass to anchor the mounting plates 24, 26 and frame 12 in place.

[0031] The assembly of the frame 12 may comprise a plurality of vertical support members and cross braces. Together, the vertical supports and the cross braces may form a rectangular, frame-like structure that resembles a power rack for performing barbell power exercises like squats, deadlifts, bench presses, alternative rows, lateral pulls, etc. The structure and functionality of the exercise apparatus 10 eliminates potential injury risks associated with barbell weightlifting exercises that utilize free weights. Alternative weightlifting platform configurations are possible as racks may be designed for presses such as bench, military, front, and / or other push / pull exercise movements.

[0032] As shown in FIG. 1 and FIG. 2, two vertically oriented upright members extend upward from each base member. A first upright member 28 and a second upright member 32 are positioned on each side of the frame 12. The upright members 28, 32 may terminate at or be generally respective of a cross-brace member. Each upright member may be directly connected with the cross-brace member.

[0033] As illustrated, at least one cross-brace member 34, that may be horizontal, connects the upper ends of the two upright members 28, 32 that are disposed laterally adjacent and parallel with one another. The cross-brace member 34 may extend transversely between the two upright members 28, 32 to form a generally supportive rectangular frame structure. The pair of upright members 28, 32 and cross-brace member 34 may include a series of apertures 30 that extend over a length of the upright members 28, 32 and cross-brace member 34.

[0034] An angled member 36 may lie generally at a 45° angle with respect to an upright member and a base member. Each angled member 36 may extend upward at about a 45° angle from the respective base member. A plurality of angled members may be mounted between the upright members 28, 32 and the base members 20, 22 via fasteners disposed through the apertures 30 to provide structural support to the frame 12.

[0035] An angled member 36 may lie generally at a 45° angle with respect to an upright member and a cross-brace member 34. Each angled member 36 may extend downward at about a 45° angle from the respective cross-brace member. A plurality of angled members may be mounted between the upright members 28, 32 and the cross-brace member 34 via fasteners disposed through the apertures 30 to provide structural support to the frame 12.

[0036] Additionally, apertures 30 may be structured to cooperate with fasteners to mount components to the frame 12 of the exercise apparatus 10. Components may include a control system, a resistance assembly, sensors, or other accessories. Thus, components may be positioned, mounted, and readjusted vertically or horizontally to accommodate different sized users as well as to accommodate different exercises (e.g., moving from a lower position for bench press to a higher position for squats).

[0037] The base 18, base members 20, 22, upright members 28, 32, and the cross-brace member 34 may be formed of a suitably rigid material, such as, for example, cold rolled tube steel having a suitable wall thickness. Assembling the frame structure of the exercise apparatus 10 may be a simple process. Components of the frame structure may be unpacked and organized in accordance with parts listed in a manual. The sub-assembly 16 may be assembled by attaching the base members 20, 22 to the base 18. Fasteners may include bolts and washers. The upright members 28, 32 may be connected to the base members 20, 22 and securely fastened with mounting plates 24, 26. Transverse cross-brace members may be installed to upper and lower ends of the upright members 28, 32, and / or anywhere along the length of the upright member 28, 32 to provide stability to the frame 12. Components, such as the control system, resistance assembly, sensors, or other accessories may be added to the frame 12 by mounting with bolts through the apertures 30 disposed through the upright members 28, 32 and the cross-brace member 34.

[0038] Members of the frame 12 may be welded together, along with mounting plates 24, 26, and other brackets and braces. The frame 12 may be painted and / or powder coat painted. Some portions of the frame 12 may be coated or overlaid with plastic, foam, rubber guards, or shields. The illustrated frame configuration is but one example, and the frame may be formed with other suitable materials, be assembled using other suitable fasteners, connectors, or methods, and may be finished using other suitable materials and techniques.

[0039] With reference to FIGS. 1, 2, and 3, the exercise apparatus 10 includes a resistance assembly 80 having one or more resistance modules, such as actuators attached to the frame 12. An actuator may be secured to one or more mounting platforms 66 that are structured to mount the respective actuator utilizing apertures 30 disposed through the frame 12. The actuator may provide one or more sources of motive power to cause an actuating unit to extend or retract. For example, an electrical linear motor, electrical stepper motor, an electric solenoid, etc., may act upon by pulling or pushing the actuating unit. Alternatively, the actuator may be a piston that is pneumatically, fluidically, mechanically, electrically, or hydraulically positioned to act upon the actuating unit so that the exercise apparatus 10 provides active resistance at a constant force or variable force. Actuators utilized to perform the bidirectional actuating movements may include linear actuators, rotary actuators, gripper actuators, diaphragm actuators, screws, worm gears, springs, cams, levers, and / or other force transmitter.

[0040] As illustrated, the exercise apparatus 10 includes two actuators. A first actuator 52 is attached to a left-hand side of the frame 12 and a second actuator 54 is attached to a right-hand side of the frame 12. Actuators 52, 54 may be located on the frame 12 at a location generally aside where a user would stand, sit or recline when using the exercise apparatus 10. Actuators 52, 54 are shown located on the inner sides of upright members 28, 32, but could just as easily be disposed on another side. Actuators 52, 54 descend downwardly from the ends of the cross-brace member 34. Actuators 52, 54 that are vertically oriented and parallel may be supported by one of the respective upright members 28, 32 and / or cross-brace member 34 via the mounting platforms 66.

[0041] Each actuator includes an elongated, vertically oriented, and linearly extending actuating unit, such as a piston rod. However, the actuating unit may have other orientations (e.g., inclined) and other shapes (e.g., curved) depending upon the exercise motion relative to the frame 12. As illustrated, the first actuator 52 cooperates with a first actuating unit 56 and the second actuator 54 cooperates with a second actuating unit 58. Housings 84 may support and enclose the actuators 52, 54, and at least a portion of the actuating units 56, 58.

[0042] The actuators 52, 54 preferably cooperate together in order to apply the same level of active resistance upon an exercise tool user interface, such as an engagement tool or a plurality of engagement tools. However, in some applications, actuators 52, 54 may operate independently of each other to apply varying levels of active resistance upon ends of the exercise tool user interface. In such cases, a user balances the exercise tool user interface against the varying levels of active resistance. In the example shown, the exercise tool user interface is connected perpendicularly between the bottom ends of actuators 52, 54.

[0043] Continuing reference to FIGS. 1, 2, and 3, the first actuating unit 56 includes a first coupler 76, and the second actuating unit 58 includes a second coupler 78. Couplers 76, 78 may couple actuating units 56, 58 with the exercise tool user interface, such as a steel weightlifting bar, which is also known as a “weight bar” or “barbell”. A first end 13 and a second end 15 of weight bar 14 may be connected between the actuating units 56, 58, with or without free weights. Couplers 76, 78 may provide a range of rotational and / or pivotal movement between ends of the actuating units 56, 58 and the weight bar 14 by inclusion of a hinge, ball-socket, clip, linkage, or other connection device.

[0044] A plurality of actuators 52, 54 respectively position the plurality of actuating units 56, 58 by selectively extending or retracting the couplers 76, 78 between a retracted state where the weight bar 14 is at a “zeroed start position” and an extended state where the weight bar 14 is at a fully extended position relative to the zeroed start position. Actuating units 56, 58 operably connected on each side of the weight bar 14 may restrict the user's movement of the weight bar 14 to a particular course of travel. As shown, actuating units 56, 58 may allow for relatively vertical movement of the weight bar 14 within a single vertical plane. In alternative configurations, the user may move the weight bar 14 through a variety of paths within the frame 12.

[0045] As seen in FIG. 2, each of the couplers 76, 78 take the form of a yoke that cooperatively pins ends of the weight bar 14. Couplers 76, 78, however, can take other forms, such as a receptive collar, and may couple the actuating units 56, 58 to other types of exercise tool user interfaces or directly to a body of the user. For example, the coupler may be a band (preferably of an adjustable size) that is sized to fit around a portion of the user's body, e.g., a waistband or an ankle band. The coupler may be structured to couple to a bar, a foot pedal, or other tool used with weightlifting equipment. Thus, the coupler may be any type of connector that couples to an article or mechanism that a user acts against or interacts with and that is attached, either directly or indirectly, to one of, or both of, the actuating units 56, 58.

[0046] Couplers 76, 78 may be moved by actuating resistance between two positions during an exercise. Couplers 76, 78 may be moved from one extended position to another extended position. Couplers 76, 78 may be moved from one retracted position to another retracted position. Couplers 76, 78 may be moved from a retracted position to an extended position, and vice versa.

[0047] As illustrated in FIG. 1 and FIG. 2, couplers 76, 78 are in a retracted position 82, which may include the zeroed start position. Couplers 76, 78 may normally reside in a retracted position 82 with the attached weight bar 14. A user can apply their own reactive resistance force to overcome the active resistance force applied by actuators to the weight bar 14 to move the couplers 76, 78 from a retracted position 82 to an extended position 86 in which the actuating units 56, 58 are extended further out from within the housings 84. Alternatively, the user can apply their own reactive resistance force to overcome the active resistance force applied by actuators to the weight bar 14 to move the couplers 76, 78 from an extended position 86 to a retracted position 82 in which the actuating units 56, 58 are retracted further into the housings 84. Exercise movements may involve variable movements between any two of these positions, possibly including a fully retracted position and a fully extended position, in order to accommodate different exercises and different sized weight lifters. The travel distance the exercise tool user interface is independently moved towards and away from a stationary portion of the exercise apparatus 10 may be regulated to provide safety for the user.

[0048] Arrangement of the actuator 52, 54 components within the housing 84 may have identical layout or be mirror images of each other. Fasteners (not shown) may connect the removable housing 84. As a result, the interior of the actuators 52, 54 may be accessed for servicing or inspection by removing the fasteners and removing the housing 84 or cover panel of the housing.

[0049] A lower base and an upper base of the housing 84 of the first actuator 52 may be attached to a corresponding platform 66 on the left side of the frame 12. Similarly, a lower base and an upper base of the housing 84 of the second actuator 54 may be attached to a corresponding mounting platform 66 on the right side of the frame 12. In this manner, actuators 52, 54 and associated housings 84 may be sold or shipped apart from the frame 12, and subsequently, easily, and rigidly affixed to the frame 12. Suitable fasteners or fastening techniques (e.g., bolts, welding, etc.) may be used to attach, either permanently or removably, the actuators 52, 54 to the frame 12. Actuating units 56, 58 reside, in part, within housings 84 and are extendable from and retractable into the housing 84 during actuating exercise strokes.

[0050] The resistance assembly 80 may include a single resistance unit, dual resistance units, or more. As noted above, the exercise apparatus 10 may include at least one resistance unit, such as an actuator, which may be a pneumatic actuator. In the example shown in FIG. 4, the resistance unit is a pneumatic actuator 150 that provides linear actuation. In the example shown in FIG. 5, the dual resistance units are a pair of pneumatic actuators 252, 254. A pneumatic actuator utilized in the resistance assembly 80 may be a double-acting, pneumatic cylinder that is structured to perform bidirectional resistance movements upon the exercise tool user interface so that a user can reactively work against the live actuating resistance.

[0051] An electro-pneumatic system of the exercise apparatus 10 may include at least one resistance unit. The resistance unit may apply pneumatic resistance via a continuous live flow of pressurized gas, such as air, from the pneumatic power source 350. The pneumatic system may or may not include an accumulator. The exercise apparatus 10 may transmit active resistance to the exercise tool user interface via pressurized gas that operates under a dynamic kinetic energy principle, rather than a static potential energy principle. The functional design of the exercise apparatus 10 may eliminate the elastic feel of a pneumatic system that features air compressibility as the source of the resistance force. The layout and components of the pneumatic system are configured so that pressurized gas within the system has a more incompressible, hydraulic-like feeling during exercise use. In this way, live transmission of pressurized gas allows the exercise apparatus 10 to be highly responsive without delay in movement and application of resistance force. As a result, use of the exercise apparatus 10 more naturally mimics the resistance feeling of free weights under the continuous force of gravity.

[0052] As illustrated in FIG. 4, the pneumatic actuator 150 is a linear actuator that includes a cylinder 152 and a piston rod 154. The piston rod 154 may be an extension of an actuating unit as discussed and shown previously. The cylinder 152 includes a cylinder body 156 in which a piston head 158 slides within a bore of the cylinder body 156. The piston head 158 divides the cylinder body 156 into two variable volume chambers. As a naming convention, the divided cylinder body 156 may be referred to as having a retraction chamber 162 and an extension chamber 164.

[0053] At least one, or both, of the chambers may selectively communicate with a compressed air supply source, thereby providing active pneumatic resistance against the piston head 158 from one direction or two directions. At least one, or both, or none, of the chambers may open to the atmosphere. Both chambers may be pressurized (e.g., be of equal or variable pressure), and selectively communicate with the atmosphere and / or communicate with each other. In the example shown in FIG. 4, both of the chambers communicate with the compressed air supply source so as to be provided with a constant supply of compressed air for movement of the piston to form active resistance upon the exercise tool user interface bidirectionally.

[0054] The piston rod 154 is connected to the piston head 158 and extends through the variable volume chambers. A distal end cap 170 may close the end of the cylinder body 156 opposite the end through which the piston rod 154 extends. The piston rod 154 moves linearly along a stroke axis as the piston slides within the cylinder bore. The length of the piston rod 154 may be sufficient to provide the desired stroke length for exercise movements by the couplers 76, 78.

[0055] At least one, several, or all components of the pneumatic actuator 150 may be formed of a polymer (e.g., plastic), aluminum (e.g., metal), and / or other durable, light material in order to lighten the overall weight of the resistance assembly 80 and to decrease production costs. Such components made of lightweight but durable material may include the cylinder body 156, the piston, and one or more of the end caps of the cylinder.

[0056] The retraction chamber 162 and the extension chamber 164 may communicate with at least one powered resistance source. The powered resistance source may be a pneumatic power source 350 that has a compressed air supply, as seen in FIG. 4. The pneumatic power source 350 may include an air compressor 380 and an air tank 390 reservoir, which may be mounted at a location near the exercise apparatus 10, as seen in FIG. 3. Alternatively, the pneumatic power source 350 may be remotely disposed relative to the exercise apparatus 10 with a separator, such as a wall 50, as seen in FIG. 5. A powered line, such as a hydraulic, electrical, or pneumatic hose may connect with the powered resistance source to power the resistance assembly 80. As shown in FIG. 4, a pneumatic hose 160 connects the pneumatic power source 350 with the pneumatic actuator 150 so as to pressurize either one of the two variable volume chambers, that is the retraction chamber 162 and the extension chamber 164. Thus, air pressure may be actively applied to either of the two variable volume chambers via the pneumatic hose 160 that is bifurcated to move the piston head 158 and the piston rod 154 together, bidirectionally.

[0057] A directional control valve 200 with an inlet port 205 may serve as a bifurcated juncture in the pneumatic hose 160 of a pneumatic system 70. The pneumatic system 70 may provide a linear pathway for the flow of pressurized gas from the pneumatic power source 350 to a pneumatic actuator. The directional control valve 200 may be fluidly connected with one or more pneumatic actuators. The directional control valve 200 regulates the flow path of a compressed fluid, such as the pressurized gas or fluid, towards and away from a bidirectional actuator, such as a double-acting pneumatic cylinder.

[0058] The directional control valve 200 may have a plurality of ports and positions that permit fluids, such as air, to be directed to either side of the cylinder for charging either of the dual variable chambers. When the directional control valve 200 is activated, compressed air may be channeled into one side of the cylinder, causing the piston to move in one direction. Simultaneously, the directional control valve 200 may allow air from the opposite side to exhaust, which enables the piston to extend or retract. By switching the directional control valve 200 between positions, the flow direction is reversed, causing the piston to move in the opposite direction. This bidirectional control allows for precise and reversible linear motion of the bidirectional actuator.

[0059] The pneumatic power source 350 may communicate with a single, pneumatic actuator 150 through a directional control valve 200, as seen in FIG. 4. As shown in FIG. 4, the directional control valve 200 is fluidly connected between the pneumatic power source 350 and the pneumatic actuator 150. The directional control valve 200 serves as the bifurcation point of the pneumatic hose 160. The retraction chamber 162 and extension chamber 164 of the pneumatic actuator 150 fluidly communicate with the pneumatic power source 350 through the directional control valve 200 to receive an active supply of pressurized gas and / or to communicate with the atmosphere.

[0060] The pneumatic power source 350 may communicate with a pair of pneumatic actuators 252, 254 through the directional control valve 200, as seen in FIG. 5. An example configuration for ports and pathways of a directional control valve is shown in FIG. 5. This example configuration of a three-position, four-way valve is utilized for description purposes that follow. However, the directional control valve 200 may be structured with alternative valve port configurations and operating positions, which may include two-positions, three-positions, or more valve ways for control of the pneumatic actuator(s). In one preferred example of the exercise apparatus, a two-position, four-way valve was utilized for the directional control valve 200 to eliminate a middle position that may fix the weight bar 14 in a static position.

[0061] As shown in FIG. 4, the directional control valve 200 may be operable to selectively engage the pneumatic actuator 150 for extension and retraction in response to a continuous live supply of pressurized gas. The directional control valve 200 is shown fluidly connected between the retraction chamber 162 and extension chamber 164 of pneumatic actuator 150 via pneumatic hoses 172, 174 and flow-through ports 171, 173 of the cylinder 152, respectively. A regulated flow of pressurized gas may be delivered to the directional control valve 200 via the pneumatic hose 160.

[0062] The directional control valve 200 can be selectively engaged in a first position 202 so that extension chamber 164 is permitted to charge with an increase of air pressure. In the first position 202, the directional control valve 200 may direct the flow of pressurized gas towards the extension chamber 164 side of the pneumatic actuator 150 through a first flow-through port 176 of the valve via pneumatic hose 172. Charging the extension chamber 164 with pressurized gas may result in increased volume of said chamber. In response to extension chamber 164 being charged, piston head 158 will extend piston rod 154 to apply active resistance upon an exercise tool user interface in a first direction, as shown by movement arrow 166.

[0063] The directional control valve 200 can also be selectively engaged in a second position 204 so that the retraction chamber 162 is permitted to charge with an increase of air pressure. In the second position 204, the directional control valve 200 may direct the flow of pressurized gas towards the retraction chamber 162 side of the pneumatic actuator 150 through a second flow-through port 178 of the valve via pneumatic hose 174. Charging the retraction chamber 162 with pressurized gas may result in increased volume of said chamber. In response to the retraction chamber 162 being charged, piston head 158 will retract piston rod 154 to apply active resistance upon the exercise tool user interface in a second direction, as shown by movement arrow 168.

[0064] An uncharged chamber may decrease in volume in response to piston movement when air in the uncharged chamber is permitted to exhaust to the surrounding atmosphere. In the first position 202, the directional control valve 200 may permit the retraction chamber 162 to exhaust air resulting in decreased volume of said chamber. The directional control valve 200 may direct the flow of exhausted air received from pneumatic hose 174 via flow-through port 178 towards a first exhaust valve 220. Exhausted air may discharge from the exhaust valve 220 via a first exhaust port 210 disposed in the directional control valve 200. In the second position 204, the directional control valve 200 may permit the extension chamber 164 to exhaust air resulting in decreased volume of said chamber. The directional control valve 200 may direct the flow of exhausted air received from pneumatic hose 172 via flow-through port 176 towards a second exhaust valve 240. Exhausted air may discharge from exhaust valve 240 via a second exhaust port 230 disposed in the directional control valve 200.

[0065] Thereby, the directional control valve 200 is operable to have active control of bidirectional resistance movements of the piston rod 154 and piston head 158. Bidirectional movements may include movement of the piston rod 154 and piston head 158 toward the distal end cap 170 (see movement arrow 168) and away from the distal end cap 170 (see movement arrow 166). The piston rod 154 may be operably connected to an actuating unit, which may be an integral rod, to control the stroke movement of a coupler at a distal end of the actuating unit.

[0066] As shown in FIG. 5, the directional control valve 200 may be structured to be slidably engaged between the first position 202 and the second position 204. The directional control valve 200 engaged in the first position 202 permits the flow of pressurized gas towards extension chambers 262, 264 to charge pneumatic actuators 252, 254 so they extend and apply active resistance in a first direction upon an exercise tool user interface. The directional control valve 200 engaged in the second position 204 permits the flow of pressurized gas towards retraction chambers 272, 274 to charge pneumatic actuators 252, 254 so that they retract and apply active resistance in a second direction upon the exercise tool user interface. Please note that reversing orientation of one of the pneumatic actuators 252, 254 in the pneumatic system 70 can result in a scenario where the pneumatic actuators 252, 254 extend and retract inversely from one another, rather than together.

[0067] Optionally, the directional control valve 200 may be structured to be selectively engaged into a third position 206 that is centrally disposed between the first position 202 and the second position 204. The directional control valve 200 engaged in the third position 206 prevents the flow of pressurized gas between the pneumatic power source 350 and the pneumatic actuators 252, 254. As a result of the directional control valve 200 being placed in this neutral position, the pneumatic actuators 252, 254 are not allowed to further extend or retract, but may be fixed in place mid-stroke at any position at, or between, full extension and full retraction.

[0068] With reference still to FIG. 5, a first T-valve connection 182 may be disposed in pneumatic hose 172. T-valve connection 182 divides the supply of compressed air delivered to charge extension chambers 262, 264 of the pair of pneumatic actuators 252, 254. T-valve connection 182 may allow extension chamber 262, 264 sides of the pair of pneumatic actuators 252, 254 to be charged simultaneously, proportionally, or independently from one another. A second T-valve connection 184 may be disposed in pneumatic hose 174. T-valve connection 184 divides the supply of compressed air delivered to charge retraction chambers 272, 274 of the pair of pneumatic actuators 252, 254. T-valve connection 184 may allow retraction chamber 272, 274 sides of the pair of pneumatic actuators 252, 254 to be charged simultaneously, proportionally, or independently from one another. Shared valves and pneumatic hoses extending between the two resistance units may be utilized. However, in other applications, separate valves and pneumatic hoses may be used for each resistance unit.

[0069] The directional control valve 200 is fluidly connected to a pneumatic power source 350 via a pneumatic hose 160. The pneumatic power source 350 may include the air compressor 380 and the air tank 390 which may have a capacity range of between 15 gallons to 100 gallons of pressurized air. Alternatively, other pneumatic power sources may be utilized, such as a compressed air tank, a pneumatic pump, a blower, a vacuum pump, or a fixed displacement pump or a variable displacement pump that may be pressure-compensated or non-pressure compensated.

[0070] In the examples shown, the air compressor 380 is operable to generate a pressurized flow of air to a pneumatic system 70 of the exercise apparatus 10. The pneumatic system 70 may be operated by a control system 60 so that the resistance assembly 80 applies and maintains the active resistance at a constant force. The control system 60 dynamically controls each of the plurality of actuators to cause the respective one of the plurality of actuating units to extend and retract dynamically. The control system 60 may be connected downstream of the air compressor 380 and air tank 390 via a first portion 160A of the pneumatic hose 160. The control system 60 may be electrically powered by an electric power source 360 such as an electrical outlet, generator, battery, or other electrical output source via a power line 370.

[0071] The control system 60 may include a filter, regulator, and lubricator (F.R.L.) unit 300 which comprises an air filter, a pneumatic regulator, and a lubricant valve. The F.R.L. unit 300 may also comprise an on / off switch, output ports, and air pressure gauges. The pneumatic regulator may protect a pneumatic system 70 of the exercise apparatus 10 from over pressurization.

[0072] The control system 60 may include a force regulating device such as a pressure regulator 250 that controls downstream pressure of gas within the pneumatic system 70 so that the actuator's pressure is maintained near or at the reference force setpoint. The pressure regulator 250 may be structured with a solenoid valve to proportionally adjust a continuous supply of pressurized gas from the pneumatic power source 350 to the remainder of the pneumatic system 70. The pressure regulator 250 may be electrically operated in response to an output signal received from the control system 60. Output signals received from the control system 60 may adjust the pressure regulator 250 proportionally between a plurality of positions to dictate and modulate air pressure in the pneumatic system 70 downstream. An inlet port 245 of the pressure regulator 250 may be connected to the pneumatic system 70 to receive pressurized gas from the pneumatic power source 350. A pressure port side 225 and a return port 275 side of the pressure regulator 250 may be proportionally adjusted between a fully open position and a fully closed position. The continuous supply of adjusted air may be directly transferred to the directional control valve 200 from an outlet port 255 of the pressure regulator 250.

[0073] As shown in FIGS. 4, 5, 6, and 7, the pressure regulator 250 may be fluidly connected with the pneumatic hose 160 between the directional control valve 200 and F.R.L. unit 300 via a second portion 160B and a third portion 160C of pneumatic hose 160. Alternatively, the pressure regulator 250 may be fluidly connected with the pneumatic hose 160 between the pneumatic power source 350 and a pneumatic actuator. In this configuration, the continuous supply of adjusted air may be directly transferred to the pneumatic actuator by the pressure regulator 250. The pressure regulator 250 is operable to continuously and proportionally adjust the pressurized flow of air received upstream via the second portion 160B of the pneumatic hose 160 so that the pneumatic actuator downstream can maintain active resistance at a constant force, even in response to reactive force of resistance applied to the exercise tool user interface by a user of the exercise apparatus 10.

[0074] The control system 60 may include an electronic controller, such as a microprocessor or microcontroller 500. The microcontroller 500 may access a computer-readable medium to perform operations by the actuator(s) via one or more actuator interfaces / drivers. The microcontroller 500 may respond to a user input made on a user-interface display, such as a selection of a weight load amount. The microcontroller 500 may include a Central Processing Unit (CPU) along with other components such as memory and input / output interfaces that are integrated as a system on a single chip. The microcontroller 500 may be further integrated for connection with an outside interface 550 such as network-controlled devices connected to ethernet, Wi-Fi, or Bluetooth that may interact with the user and / or other systems. Optionally, the control system 60 may be remotely controlled by the outside interface 550. The microcontroller 500 may be embedded as a part of the control system 60 by way of an embedded electronic system such as a Raspberry Pi 5. The microcontroller 500 may be operable to process data signals and execute instructions to electronically activate and control the pressure regulator 250 and the directional control valve 200 as shown in FIG. 6.

[0075] In one aspect, the control system 60 may be mounted on a control panel 100 with the user-interface display that permits selection or input of a reference force by a user. The user may input a reference force (e.g., weight value) into the microcontroller that ranges from between 0 pounds to 1,000 pounds in weight. Precise weight values, even to the tenth or hundredth of a pound, may be selected by the user with the press of a button. Programming within the microcontroller 500 may convert the reference force to a corresponding air pressure by the pressure regulator 250. The control system 60 may accurately supply the active resistance force within a tenth of a pound of the user input reference force. The plurality of actuators charge with a regulated supply of pressurized air based on a power rating that corresponds to the input reference force. The actuators then achieve an output amount of an active resistance force that corresponds to the input reference force, which may occur within a range of between 1 second to 5 seconds. The amount of active resistance force applied by actuators of the exercise apparatus 10 may be within a range of + / −0.02 pounds to 2 pounds from the reference force input into the control system 60.

[0076] In an additional aspect, the control system 60 may selectively command a pressure value of a respective one of the plurality of actuators to achieve an output amount of an active resistance force that corresponds to the input reference force. In another aspect, the control system 60 may selectively command the respective pressure regulator 250 to proportionally control the active resistance force based on a linear conversion scale of a voltage command signal versus an amount of gas pressure applied in pounds per square inch (i.e., 1 volt=10 psi (40 lbs. of active resistance), 5 volts=50 psi (200 lbs. of active resistance force), 10 volts=100 psi (400 lbs. of active resistance)). Adjusting the active resistance force of each actuator, independently or in combination with each other, in correspondence with the voltage command signal may be achieved by one or more of sizing the respective pressure values for an amount of voltage command signal that corresponds to the input reference force. Selecting a power rating of each actuator to correspond to the input reference force, or adjusting a commanded pressure value of actuation by the control system 60 to correspond to the input reference force may be considered to convert the user input reference force into an equivalent air pressure (e.g., psi) using the pressure regulator 250 and directional control valve 200.

[0077] The control system 60 may include a Digital-to-Analog Converter (DAC) that is operable to step-up voltage from the microcontroller 500 in order to provide sufficient downstream operational control of a pressure regulator and directional or proportional control valves. For a valve having a voltage operating range of between 0 volts minimum to 10 volts maximum, a converter that provides a step-up voltage of 5 volts may be used for a microcontroller 500 that has a maximum operational voltage of 5 volts.

[0078] As shown in FIG. 4, a first converter 400 is electrically connected between the pressure regulator 250 and the microcontroller 500 via a first converter line 420 and a first processor line 435, respectively. The converter utilized in this example is a MCP4725 12-bit DAC which may be used where precise analog output is warranted, such as in signal generation, sensor interfacing, and control systems. This particular converter provides 0-volt min. to 10-volt max. control signals. The pressure regulator 250 may be electronically controlled by the microcontroller 500 via the first converter 400.

[0079] A second converter 450 is electrically connected between the microcontroller 500 and the directional control valve 200 via a second processor line 475 and a second converter line 425, respectively. The directional control valve 200 may be electronically controlled by the microcontroller 500 via the second converter 450 at connection 405. As shown in FIG. 6, the first converter 400 and the second converter 450 may be switched positionally, vice versa, with the pressure regulator 250 and directional control valve 200. The electric power source 360 may be electrically connected with the directional control valve 200 and the pressure regulator 250 to provide operational power control.

[0080] The control system 60 may include any acceptable sensor, such as a proximity or electrical conductivity sensor, a load cell, a flow sensor, an actuator position sensor, a level sensor, a proximity sensor, a presence sensor, a pressure sensor including strain-gauge, piezoresistive, capacitive, piezoelectric, diaphragm-based, absolute, differential, or transducer types, or a plurality of pressure sensors to read actual pressure within the pneumatic system 70 as shown in FIG. 4. A first pressure sensor 180 may be operably disposed in a pneumatic hose between the directional control valve 200 and the actuator 150. A T-valve connection 179 may be disposed in pneumatic hose 172 and / or pneumatic hose 174 for connection of the pressure sensor 180. Sensor 180 may generate a first output signal that the microcontroller 500 receives to determine a charge parameter and / or an amount of pressure supplied in the pneumatic hose. A second pressure sensor 186 may be operably disposed in the wall or at a proximal end of the pneumatic cylinder 152 of the actuator 150. Sensor 186 may generate a second output signal that the microcontroller 500 receives to determine an amount of pressure charged within the retraction chamber 162 of the actuator 150. A third pressure sensor 188 may be operably disposed in the wall or the distal end cap 170 of the cylinder 152 of the actuator 150. Sensor 188 may generate a third output signal that the microcontroller 500 receives to determine an amount of pressure charged within the extension chamber 164. Therefore, the control system 60 may calculate a pressure differential between the retraction chamber 162 and the extension chamber 164 in order to modulate air pressure within the pneumatic system 70 for maintaining application of active resistance by the actuator at a constant force during an exercise cycle conducted by a user.

[0081] A display unit 90 may be included as a part of the exercise apparatus 10, preferably in a heads-up type display. As seen in FIG. 2, the display unit 90 is positioned above and centrally mounted to the cross-brace member 34. Preferably, the face of the display unit 90 is positioned to face toward a user so easily visible while the user is in an exercise position. The display unit 90 displays information representing the sensed pressure control signal, which is indicative of the resistance force applied to the weight bar 14 by the resistance assembly 80 as adjusted by the pressure regulator 250. For example, but without limitation, the display unit 90 may also display information such as a target number of repetitions, number of repetitions performed, and / or the number of exercise sets to be completed in an exercise cycle.

[0082] An unregulated flow of pressurized gas through the pneumatic system 70 may be back fed through the pressure regulator 250 via the third portion 160C of the pneumatic hose 160. This occurs when a reactive resistance force overcomes the active resistance force delivered from actuation by the exercise apparatus 10. A user of the exercise apparatus 10 may apply enough reactive resistance force through the exercise tool user interface to overcome the active resistance force.

[0083] During exercise use of the exercise apparatus 10, a charged chamber may decrease in volume in response to piston movement when a force of gas pressure within the charged chamber is overcome by the user's reactive resistance force. In response to charged extension chamber 164 being overcome by a user's reactive resistance force, piston rod 154 will move piston head 158 towards the distal end cap 170 in a second direction, as shown by movement arrow 168. As a result, the directional control valve 200 in first position 202 may permit gas from the charged extension chamber 164 to back feed through flow-through port 171 of cylinder 152 resulting in decreased volume of said chamber. The directional control valve 200 may direct the flow of back fed gas received from pneumatic hose 172 via flow-through port 176 back towards the pressure regulator 250. Back fed gas may be proportionally adjusted and exhaust vented from the pressure regulator 250 to the atmosphere via the return port side 275 to maintain a constant active resistance force by actuation relative to the reference force.

[0084] In response to charged retraction chamber 162 being overcome by a user's reactive resistance force, piston rod 154 will move piston head 158 towards the proximal end of cylinder 152 in a first direction, as shown by movement arrow 166. As a result, the directional control valve 200 in second position 204 may permit gas from charged retraction chamber 162 to back feed through flow-through port 173 of cylinder 152 resulting in decreased volume of said chamber. The directional control valve 200 may direct the flow of back fed gas received from pneumatic hose 174 via flow-through port 178 back towards the pressure regulator 250. Back fed gas may be proportionally adjusted and exhaust vented from the pressure regulator 250 to the atmosphere via the return port side 275 to maintain a constant active resistance force by actuation relative to the reference force.

[0085] With reference to FIG. 7 now, an operational cycle is shown by flowchart 700 for maintaining a regulated load by the exercise apparatus 10. The regulated load is maintained at a constant force relative to variable differences identified between an established reference force and an actual force applied. According to step 710, the weight bar 14 is positioned in a retracted position 82 to begin an exercise cycle. The weight bar 14 may start, by default, in a retracted position 82 for user safety. According to step 720, a reference force is established by the user in which the pressure regulator 250 will seek to maintain. Upon user engagement of a switch or detection by sensors, the exercise cycle will begin. According to step 730, a directional control valve 200 is opened so that actuators extend to bear down upon the user an actuated load. According to step 740, an actual force value is measured by a pressure sensor 180 disposed in the pneumatic system 70. According to step 750, the pressure in the pneumatic system 70 may be proportionally adjusted if the actual force value measured is not in agreement with the reference force established. According to step 760, the active resistance force is supplied in correspondence with the reference force. The operational cycle may be repeated as the user continues the exercise cycle.

[0086] With reference to FIG. 8 now, an operational exercise cycle is shown by flowchart 800 for safely returning the regulated load to a retracted position 82, which may be a zeroed start position, by release of an engagement switch 74 of the exercise apparatus 10. As shown between FIG. 8 and FIGS. 9A-F, a user 5 who has selected a reference force (e.g., weight value) on the control panel 100 may position oneself in the exercise station of the exercise apparatus 10 in order to perform an exercise squat, according to step 810. As depicted in FIG. 9A, the user 5 is positioned in a standing position below the weight bar 14 disposed in the zeroed start position 82. In the zeroed start position 82, the retraction chambers of the actuators may be charged so that the forces acting on the weight bar are balanced between the pressurized air pushing on the piston head and the distal end cap fixed at the distal end of the air piston. Movement arrow 815 shows a first transition between step 810 and step 820. According to step 820, the engagement switch 74 has been engaged to actuate the weight bar 14 to come down from the start position and bear a regulated load downwardly upon the user 5. In response, an operational signal is sent through operation line 72 to the control system 60. The control system 60 engages the pneumatic power source 350 to provide an active supply of pressurized air to the pneumatic system 70 so that actuators initiate an active resistance force 822 that corresponds with the selected reference force. As seen by the downwardly projecting spot-filled arrow in FIG. 9B, the active resistance force 822 has a great magnitude causing extension of the actuators so that the weight bar 14 begins to move downwardly. As seen in FIG. 9C, the active resistance force 822 (see arrow with spotted shading) has a greater magnitude than a reactive resistance force 824 (see arrow with diagonal hatching) applied by the user 4 so that the weight bar 14 continues to move downwardly. Movement arrow 825 shows a second transition between step 820 and step 830. According to step 830, the user 5 that maintains engagement with the engagement switch 74 will continue the operational exercise cycle in accordance with step 840 via a third transition as shown by movement arrows 835, 845. As seen in FIG. 9D, the active resistance force 822 applied by the actuators and the reactive resistance force 824 applied by the user 5 are substantially equal so that the weight bar 14 begins to halt and transition to an upward motion as seen in FIG. 9E. The pressure regulator continues to seek the reference force by modulating the continuous supply of pressurized air so that the actual force equals the reference force as discussed in FIG. 7. Movement arrow 855 shows a fourth transition between step 840 and step 850. According to step 850, the user 5 pushes with the reactive resistance force 824 against the active resistance force 822 bearing down. If the user's active reactive resistance force 824 pushing up is greater than the exercise apparatus's active resistance force 822 pushing down, then the weight bar 14 will move upwardly due to the imbalance between forces. As seen in FIG. 9E, the reactive resistance force 824 applied by the user 5 has a greater magnitude than the active resistance force 822 applied by the actuators so that the weight bar 14 moves upwardly. The user 5 may continue to maintain engagement of the engagement switch 74 to repeat repetitions of the squat exercise movement. When the user 5 decides to end the exercise cycle, the user 5 may release the engagement switch 74 and the weight bar 14 will return to the zeroed start position 82, according to step 860 via a fifth transition as shown by movement arrow 865. Disengagement of the engagement switch 74 will initiate the directional control valve 200 to return to a safety position so that retraction chambers of the actuators charge, and retraction of the load occurs. The weight bar 14 may return to the starting position within a range of between 1 second to 5 seconds. As seen by the upwardly projecting hatch-filled arrow in FIG. 9F, the active resistance force 822 has switched causing retraction of the actuators so that the weight bar 14 begins to move upwardly towards the zeroed start position 82.

[0087] As shown in FIG. 2, operation of the directional control valve 200 may be partially or fully administered by the engagement switch 74. The engagement switch 74 may be operably connected with the directional control valve 200 via an operation line 72. The operation line 72 may be disposed externally to or internally within the exercise user tool interface. The engagement switch 74 may be structured to detect the presence of a user interfaced with the exercise apparatus 10 via a presence sensor as discussed above. In the example shown, the engagement switch 74 is directly engaged by direct contact from the user with the exercise tool user interface. The engagement switch 74 may be disposed upon one end of the exercise tool user interface for direct engagement by the user.

[0088] As shown in FIG. 2, the engagement switch 74 is an electronic push button (e.g., start / stop operation) disposed on the first end 13 of the weight bar 14 to be manually accessible by a hand or foot of the user placed upon the weight bar 14. Alternatively, the engagement switch 74 may be a lever, pedal, pressure switch, remote control, or sensor, such as a proximity or electrical conductivity sensor. Engagement of the directional control valve 200 by engagement switch 74 may switch directional flow of supplied air to charge a different chambered side of the cylinder 152 with increased air pressure. Engagement of the directional control valve 200 by engagement switch 74 may also start and stop operation of the pneumatic system 70 of the exercise apparatus 10. The control system 60 may switch the directional control valve 200 between diversion control positions. A high voltage signal (e.g., 10 volts) may be sensed by the control system 60 with engagement of the engagement switch 74. A medium voltage signal (e.g., 5 volts) may be sensed by the control system 60 with release of the engagement switch 74. A low voltage signal (e.g., 0 volts) may be sensed by the control system 60 with disengagement of the engagement switch 74 or loss of electrical power to serve as a fail-safe.

[0089] The microcontroller 500 may be operationally configured so that upon disengagement of the engagement switch 74 by a user of the exercise apparatus 10, the microcontroller 500 will switch the directional control valve 200 into a safety default or zero position. In the examples shown, the directional control valve 200 is structured to be automatically switched into second position 204 by default upon the engagement switch 74 being released by the user. In response, retraction chamber(s) of the pneumatic cylinder(s) are charged, and the actuating unit(s) are retracted along with the coupler(s) connected to the exercise user tool interface.

[0090] In different configurations of the exercise apparatus 10, the directional control valve 200 may be structured to be automatically switched into first position 202, by default, upon the engagement switch 74 being released by the user. In response, extension chamber(s) of the pneumatic cylinder(s) are charged, and the actuating unit(s) are extended along with the coupler(s) connected to the exercise user tool interface. Alternatively, the directional control valve 200 may be structured to be automatically centered into the third position 206, by default, upon the engagement switch 74 being released by the user. In response, the supply of pressurized gas is restricted through the directional control valve 200 and the actuating unit(s) of the pneumatic cylinder(s) are placed into a fixed position.

[0091] In further consideration of methods employed by use of the exercise apparatus, a user may input a weight amount into a controller. The controller may convert the weight amount into a simulated weight force. The simulated weight force may be applied upon a weightless barbell of the exercise apparatus to move the weightless barbell. The weightless barbell installed with a presence sensor may sense engagement by a user and initiate application of the simulated weight force. The simulated weight force may be increased to a reference value within a time range of between one second to five seconds. Upon engagement of the presence sensor by the user, a control valve may be slowly opened and closed to adjust the simulated weight force in dynamic proportion to a counter force applied to the weightless barbell by the user. The simulated weight force may be maintained at the reference value within a weight range of between a hundredth of a pound to two pounds. The simulated weight force may be actively balanced with the counter force by the controller's adjustment of the control valve. Upon disengagement of the presence sensor by the user, the weightless barbell may be retracted into a start position due to signal communication between the presence sensor and the controller.

[0092] Rather than maintain a constant force throughout the stroke movement of the actuators, the techniques described herein may be modified so that proportional control of the pneumatic system can produce variable resistance force curves that increase and decrease throughout the exercise stroke. For example, when exercising muscles or muscle groups, the resistance force may increase towards the middle of the stroke and then decrease towards the end of the stroke. The initial orientation of the pneumatic actuator(s), the degree of inclination, the initial position of the exercise user tool interface, and / or the guidance profile embedded in the microcontroller may be used to produce the desired force curve.

[0093] Now referring to FIG. 10, an example electrical schematic of a control system 1060 is depicted that may be utilized with the exercise apparatus. The control system 1060 may be electrically powered by a power source 1360 by direct connection to an electrical outlet, generator, battery, or other electrical output source via a power line. The power source 1360 device shown has 24-volt power that may be compatible with either alternating current (AC) or direct current (DC). A 24-volt power source for the control system 1060 may allow for low-voltage power control when using step-down voltage from a standard wall outlet. The power source 1360 may be electrically connected to a pneumatic control valve, such as a directional control valve 1200. The directional control valve 1200 may be an AVS-5313, 5-port, 2-way positional, single spring return solenoid valve. A relay solenoid 1100 may be disposed between the power source 1360 and the directional control valve 1200 via a first ancillary electrical circuit. The relay solenoid 1100 may be operable to control the directional control valve 1200 electromagnetically as an on / off relay switch to provide operational control of the directional control valve 1200.

[0094] A step-down converter 1600 may be integrated into the circuitry of the control system 1060. The step-down converter 1600 utilized may be a Buck-type Converter, such as a LM2596 that is configured to convert higher input voltage (i.e., 24-volt) to an adjusted lower voltage output (i.e., 5-volt). The step-down converter 1600 may be operably connected between the power source 1360 and the microcontroller 1500 that operates at a lower voltage. The step-down converter 1600 may receive input of electrical power directly from the power source 1360.

[0095] The control system 1060 may include an electronic controller, such as a microprocessor or microcontroller 1500. The microcontroller 1500 may access a computer-readable medium to perform operations by the pneumatic actuator(s) via one or more actuator interfaces / drivers. The microcontroller 1500 may respond to a user input made on a user-interface display 1550, such as a touch screen display that is mounted on a control panel. The control panel may be a Printed Circuit Board (PCB) that is a flat board that physically supports and carries control circuitry that electrically interconnects the electronic components of the control system 1060.

[0096] The microcontroller 1500 may include a Central Processing Unit (CPU) along with other components such as memory and input / output interfaces that are integrated as a processing system on a single chip. The microcontroller 1500 may be further integrated for connection with an outside interface such as a network-controlled device(s) connected to ethernet, Wi-Fi, or Bluetooth that may interact with the user and / or other systems. Optionally, the control system 1060 may be remotely controlled by the outside interface.

[0097] The microcontroller 1500 may be a part of the control system 1060 by way of an embedded Proportional-Integral-Derivative (PID) controller, such as a Raspberry Pi. A PID controller may be used to automatically regulate the directional control valve 1200 so that output of actuator(s) pressure is maintained near or at the reference force setpoint. The microcontroller 1500 may be operable to process data signals and execute instructions to electronically activate and control the directional control valve 1200 by the relay solenoid 1100 with on / off functionality. The PID controller may allow for more programmer control, thereby requiring less input control by a user.

[0098] In one aspect, the control system 1060 may be mounted on the control panel with the user-interface display 1550 to permit selection or input of a reference force by a user. The user-interface display 1550 may be operable connected between the step-down converter 1600 and the microcontroller 1500. The user may input a reference force (e.g., weight value) that may range from between 0 pounds to 1,000 pounds in weight into the microcontroller 1500. Precise weight values, even to the tenth or hundredth of a pound, may be selected by the user with the press of a touchscreen button on the user-interface display 1550. Programming within the microcontroller 1500 may convert the reference force to a corresponding air pressure applied to the pneumatic system.

[0099] A Digital-to-Analog Converter (DAC) converter may be electrically connected between the microcontroller 1500 and a pressure regulator 1402 via a second ancillary electrical circuit. The pressure regulator 1402, may be a pneumatic transducer, such as model NCP2-20-3120D by AutomationDirect having a 4 milliampere (mA) to 20 mA input range. The pressure regulator 1402 may be electrically connected to the DAC converter 1400 via the first ancillary electrical circuit to convert the electrical control input signal into a proportional pneumatic pressure output for controlling the pneumatic system.

[0100] The DAC converter 1400 shown may be a first control module electrically connected between the microcontroller 1500 and the pressure regulator 1402 via a first primary electrical pathway. As shown in FIG. 10, the control system 1060 including the DAC converter 1400 is operable to step-up voltage from the microcontroller 1500 in order to provide sufficient downstream operational control. The DAC converter 1400 may provide a step-up voltage of 24-volts when used with the microcontroller 1500 operating on lower voltage. The DAC converter 1400 may provide 0-volt minimum to 24-volt maximum control signals for operation of the pressure regulator 1402. The DAC converter 1400 utilized in this example may be used where precise analog output is warranted, such as in signal generation, sensor interfacing, and control systems.

[0101] An Analog-to-Digital (ADC) converter 1450 shown may be a second control module electrically connected between the microcontroller 1500 and a pressure sensor 1452 via a second primary electrical pathway. The ADC converter 1450 may be an ADS1115 by AutomationDirect being a 16-bit, 4-channel ADC type converter that is utilized in place of the second DAC converter and pressure regulator as in the control system previously shown in FIG. 6. The ADC converter 1450 may be operable to step-up voltage from the microcontroller 1500 in order to provide sufficient downstream operational control. The ADC converter 1450 may provide a step-up voltage of 24-volts when used with the microcontroller 1500 operating on lower voltage. The ADC converter 1450 may provide 0-volt minimum to 24-volt maximum control signals. The ADC converter 1450 utilized in this example may be used where precise digital output is warranted, such as in signal generation, sensor interfacing, and control systems.

[0102] The control system 1060 may include a sensor, such as the pressure sensor 1452, or a plurality of pressure sensors. The pressure sensor 1452 may be a pressure transmitter, such as a SPTD25-20-0200H by AutomationDirect, having a fluid pressure sensing range of 0-200 psi. The pressure sensor 1452 may be operably connected to the ADC converter 1450 via the second primary electrical pathway. The pressure sensor 1452 may be operably disposed between the ADC converter 1450 within the second primary electrical pathway. The ADC converter 1450 may receive 4 mA to 20 mA signals from the pressure sensor 1452 and provide readouts to the CPU. The supply voltage for the pressure sensor 1452 may be 24-volts.

[0103] The pressure sensor 1452 may read an output of fluid pressure within the pneumatic system for the control system 1060. Pressure sensor 1452 may generate an input signal based on the output of the fluid pressure. The electrical current of the input signal and / or output signal from the pressure sensor 1452 may range between 4 mA to 20 mA. The actual fluid pressure may be determined based on the input signal relayed to the ADC converter 1450. The microcontroller 1500 receiving the input signal via the ADC converter 1450 may determine a charge parameter and / or an amount of pressure being supplied in the pneumatic system. As a result, the control system 1060 may modulate fluid pressure within the pneumatic system to maintain application of active resistance by the actuator(s) at a constant force during an exercise cycle conducted by a user.

[0104] An engagement switch 1074 may be operably connected with the microcontroller 1500 via a second ancillary electrical pathway to engage the directional control valve 1200. The engagement switch 1074 may be disposed on the exercise tool user interface for direct engagement by a user of the exercise apparatus. Disengagement of the engagement switch 1074 by the user may engage the directional control valve 1200 into a default off position. The default off position may correlate with the directional control valve 1200 being retracted. Engagement of the engagement switch 1074 by the user may engage the directional control valve 1200 into a manual on position. The manual on position may correlate with the directional control valve 1200 being extended.

[0105] The microcontroller 1500 may be operationally configured so that upon disengagement of the engagement switch 1074 by a user of the exercise apparatus, the microcontroller 1500 will switch the directional control valve 1200 into a safety default, zero, or retracted position. The directional control valve may be structured to be automatically switched into the retracted position by default upon the engagement switch being released by the user. In response, retraction chamber(s) of the pneumatic cylinder(s) are charged, and the actuating unit(s) are retracted along with the coupler(s) connected to the exercise user tool interface. The directional control valve 1200 may be structured to be switched into an extended position upon the engagement switch 1074 being engaged by the user. In response, extension chamber(s) of the pneumatic cylinder(s) are charged, and the actuating unit(s) are extended along with the coupler(s) connected to the exercise user tool interface.

[0106] It is understood that the invention is not confined to the particular construction and arrangement of parts herein described. That although the drawings and specification set forth a preferred embodiment, and although specific terms are employed, they are used in a description sense only and embody all such forms as come within the scope of the following claims.

[0107] The present disclosure is not to be limited in terms of the particular embodiments described in this application, which are intended as illustrations of various aspects. Many modifications and variations can be made without departing from its spirit and scope. Functionally equivalent methods and apparatuses within the scope of the disclosure, in addition to those enumerated herein, are possible from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the appended claims.

[0108] For the convenience of the reader, the above description has focused on a representative sample of all possible embodiments, a sample that teaches the principles of the invention and conveys the best mode contemplated for carrying it out. Throughout this application and its associated file history, when the term “invention” is used, it refers to the entire collection of ideas and principles described; in contrast, the formal definition of the exclusive protected property right is set forth in the claims, which exclusively control. The description has not attempted to exhaustively enumerate all possible variations. Other undescribed variations or modifications may be possible. Where multiple alternative embodiments are described, in many cases it will be possible to combine elements of different embodiments, or to combine elements of the embodiments described here with other modifications or variations that are not expressly described. A list of items does not imply that any or all of the items are mutually exclusive, nor that any or all of the items are comprehensive of any category, unless expressly specified otherwise. In many cases, one feature or group of features may be used separately from the entire apparatus or methods described. Many of those undescribed variations, modifications and variations are within the literal scope of the following claims, and others are equivalent.

Examples

Embodiment Construction

[0028]The exercise apparatus is operable to perform bidirectional resistance movements with active load regulation. The exercise apparatus derives the load from actuators that are actively regulated to assert an active resistance (e.g., pressure) that equalizes with reactive resistance asserted by a user. The exercise apparatus maintains the load at a constant force based on a selected reference force and resistance applied by a user's reactive force. An example of the exercise apparatus 10 structured to provide bidirectional resistance movements during weightlifting exercising is shown in FIG. 1. The exercise apparatus 10 comprises a frame 12. The frame 12 may define at least one exercise station. A user can sit, stand, or recline at the exercise station. In the example of sitting, an exercise bench (not shown) may be used with the exercise apparatus 10.

[0029]The frame 12, if not mounted directly to a floor, may comprise a sub-assembly 16. The sub-assembly 16 may be formed by a bas...

Claims

1. An exercise apparatus comprising:a first pneumatic cylinder that is double-acting to perform bidirectional resistance movements, the first pneumatic cylinder having:an extension chamber;a retraction chamber;a directional control valve fluidly connected with the first pneumatic cylinder and structured to be selectively engaged between:a first position, where the extension chamber is permitted to charge, and the first pneumatic cylinder extends to apply active resistance in a first direction upon an exercise tool user interface; anda second position, where the retraction chamber is permitted to charge, and the first pneumatic cylinder retracts to apply active resistance in a second direction upon the exercise tool user interface.

2. The exercise apparatus of claim 1, further comprising:a second pneumatic cylinder that is double-acting, wherein the second pneumatic cylinder is disposed laterally adjacent and vertically parallel with the first pneumatic cylinder.

3. The exercise apparatus of claim 2, wherein the exercise tool user interface is connected perpendicularly between bottom ends of the first pneumatic cylinder and the second pneumatic cylinder.

4. The exercise apparatus of claim 2, wherein the directional control valve is operable to permit the first pneumatic cylinder and the second pneumatic cylinder to perform bidirectional resistance movements with simultaneous action.

5. The exercise apparatus of claim 1, further comprising:an air pressure regulator fluidly connected to the first pneumatic cylinder and structured to adjust a continuous active supply of air to the first pneumatic cylinder.

6. The exercise apparatus of claim 5, where in response to a reactive resistance applied to the exercise tool user interface the air pressure regulator maintains the active resistance at a constant force.

7. The exercise apparatus of claim 1, further comprising:an engagement switch operably connected with the directional control valve.

8. The exercise apparatus of claim 7, wherein disengagement of the engagement switch by a user engages the directional control valve into the second position by default.

9. An exercise apparatus comprising:a pneumatic cylinder structured to apply active resistance upon an exercise tool user interface;an air pressure regulator fluidly connected to the pneumatic cylinder; andwhere in response to a reactive resistance applied to the exercise tool user interface the air pressure regulator maintains the active resistance at a constant force.

10. The exercise apparatus of claim 9, wherein the air pressure regulator is structured to adjust a continuous supply of air to the pneumatic cylinder.

11. The exercise apparatus of claim 10, wherein the continuous supply of air is directly transferred by the air pressure regulator from a powered air source.

12. The exercise apparatus of claim 9, wherein the pneumatic cylinder is double-acting to perform bidirectional resistance movements upon the exercise tool user interface.

13. The exercise apparatus of claim 9, further comprising:a directional control valve fluidly connected with the pneumatic cylinder and structured to be selectively engaged between:a first position, wherein an extension chamber of the pneumatic cylinder is permitted to charge, and the pneumatic cylinder extends to apply active resistance in a first direction upon the exercise tool user interface; anda second position, wherein a retraction chamber of the pneumatic cylinder is permitted to charge, and the pneumatic cylinder retracts to apply active resistance in a second direction upon the exercise tool user interface.

14. The exercise apparatus of claim 13, further comprising:an engagement switch operably connected with the directional control valve.

15. The exercise apparatus of claim 14, wherein disengagement of the engagement switch by a user engages the directional control valve into the second position by default.

16. An exercise apparatus comprising:a pneumatic cylinder that is double-acting to perform bidirectional resistance movements, the pneumatic cylinder having:an extension chamber;a retraction chamber;a directional control valve fluidly connected with the pneumatic cylinder and structured to be selectively engaged between:a first position, wherein the extension chamber is charged;a second position, wherein the retraction chamber is charged; andan engagement switch operably connected with the directional control valve, the engagement switch structured to engage the directional control valve into the second position, by default, upon disengagement of the engagement switch by a user.

17. The exercise apparatus of claim 16, wherein the engagement switch is disposed upon an exercise tool user interface for direct engagement by the user.

18. The exercise apparatus of claim 16, where in the first position the pneumatic cylinder extends to apply active resistance in a first direction upon an exercise tool user interface, and in the second position the pneumatic cylinder retracts to apply active resistance in a second direction upon the exercise tool user interface.

19. The exercise apparatus of claim 16, further comprising:an air pressure regulator fluidly connected to the pneumatic cylinder and structured to adjust a continuous supply of air to the pneumatic cylinder.

20. The exercise apparatus of claim 19, where in response to a reactive resistance applied to an exercise tool user interface the air pressure regulator maintains an active resistance upon the exercise tool user interface at a constant force.

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