Force-measuring pulley apparatus and method thereof

Abstract

A force-measuring pulley apparatus (200), comprising a pulley wheel (202) having a rotating portion configured to support an elongate flexible member (208) on at least a portion of a peripheral region thereof, a fixed support (206) configured to bear the pulley wheel (202) at a central region thereof, a force-measuring device (212) arranged within the rotating portion of the pulley wheel (202), wherein the force-measuring device (212) rotates with the pulley wheel (202) and is configured to determine a force applied to the rotating portion as the elongate flexible member (208) passes over the pulley wheel (202).

Description

[0001] FORCE-MEASURING PULLEY APPARATUS AND METHOD THEREOF

[0002] TECHNICAL FIELD

[0003] The present disclosure relates to force-measuring pulley systems, and more particularly to a force-measuring pulley apparatus and method for measuring force or tension applied by an elongate flexible member, such as a rope, belt, or chain.

[0004] BACKGROUND

[0005] Pulleys have been known for hundreds of years and have long served a vital role in mechanical systems by redirecting forces, transferring power, and altering the direction of applied loads. A typical pulley includes a wheel with a rounded peripheral edge and guiding sidewalls that allows in guiding a rope, belt, or chain, which rotates around the pulley wheel. Moreover, in many mechanical systems utilizing pulleys, monitoring the tension in the rope, belt, or chain is required in order to monitor the overall operations of the mechanical systems.

[0006] Conventionally, the tension has been inferred by measuring reaction forces at the pin or axle and determining the angle of redirection of the rope, belt or the chain. However, conventional systems and methods fail to provide an accurate and reliable determination of the tension. Additionally, certain attempts have been made to provide an accurate and reliable determination of tension. For example, in Chinese Patent CN102507068B, titled "Internal cable tension measuring device for tension attenuation winch," a system is described in which an internal cable tension measuring device includes a tension pulley, bearing, force-exerting sleeve, and force sensor arranged in a flange sleeve. The force exerted on the tension pulley is transmitted to the force sensor along a resultant direction by the force-exerting sleeve. The configuration ensures stable tension measurement, is not affected by the weight of the device, and accommodates variations in cable wrap angles. However, the system still presents limitations related to its installation complexity and specificity to certain setups. Similarly, U.S. Patent US10107699B2, titled "Wireless enabled tension meter," describes a system involving a pulley arrangement through which a guiding member passes. The system includes a tension force sensor, a wireless network interface, and a control module to capture and transmit data corresponding to the measured tension. However, despite its wireless data capabilities, the system still requires a physical tether to supply power to the sensor and the wireless module, which can restrict its applicability in environments where such connections are impractical or undesirable. As a result, there exists a technical problem of how to provide a reliable and accurate measurement of tension with reduced complexity.

[0007] Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks associated with the conventional systems and the conventional methods for measuring the tension.

[0008] SUMMARY

[0009] The present disclosure provides a force-measuring pulley apparatus and a method for the force-measuring pulley apparatus. The present disclosure provides a solution to the existing problem of how to provide a reliable and accurate measurement of tension with reduced complexity.

[0010] An objective of the present disclosure is to provide a solution that overcomes at least partially the problems encountered in the prior art and provides an improved force-measuring pulley apparatus and a method for the forcemeasuring pulley apparatus.

[0011] One or more objectives of the present disclosure are achieved by the solutions provided in the enclosed independent claims. Advantageous implementations of the present disclosure are further defined in the dependent claims.

[0012] In one aspect, the present disclosure provides a force-measuring pulley apparatus including a pulley wheel having a rotating portion configured to support an elongate flexible member on at least a portion of a peripheral region thereof, a fixed support configured to bear the pulley wheel at a central region thereof, and a force-measuring device arranged within the rotating portion of the pulley wheel, where the force-measuring device rotates with the pulley wheel and is configured to determine a force applied to the rotating portion as the elongate flexible member passes over the pulley wheel.

[0013] Advantageously, the force-measuring pulley apparatus is configured to provide an accurate, real-time tension measurement without requiring modification to the pulley's fixed support or surrounding structure. Moreover, the forcemeasuring pulley apparatus is configured to allow retrofitting into existing mechanical systems and eliminates the need for external power sources or cumbersome wiring, thereby enhancing installation flexibility and operational safety. Additionally, the installation of the one or more strain sensors in the rotating body of the pulley allows for the use of compact, cost-effective bearings and improves measurement accuracy by directly capturing forces exerted by the elongate flexible member. Hence, the force-measuring pulley apparatus is configured to enhance the adaptability and precision of the system across a variety of industrial and recreational applications.

[0014] In another aspect, there is provided a method for measuring force using a pulley apparatus, the method comprising supporting an elongate flexible member on a rotating portion of a pulley wheel, bearing the pulley wheel at a central region thereof using a fixed support, and determining, using a force-measuring device arranged within the rotating portion of the pulley wheel, a force applied to the rotating portion as the elongate flexible member passes over the pulley wheel, where the force-measuring device rotates with the pulley wheel.

[0015] The method achieves all the advantages and technical effects of the forcemeasuring pulley apparatus of the present disclosure.

[0016] It is to be appreciated that all the aforementioned implementation forms can be combined. It is to be noted that all devices, elements, circuitry, units, and means described in the present application could be implemented in the software or hardware elements or any kind of combination thereof. All steps which are performed by the various entities described in the present application, as well as the functionalities described to be performed by the various entities, are intended to mean that the respective entity is adapted to or configured to perform the respective steps and functionalities. Even if, in the following description of specific embodiments, a specific functionality or step to be performed by external entities is not reflected in the description of a specific detailed element of that entity that performs that specific step or functionality, it should be clear for a skilled person that these methods and functionalities can be implemented in respective software or hardware elements, or any kind of combination thereof. It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.

[0017] Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative implementations construed in conjunction with the appended claims that follow.

[0018] BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.

[0020] Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:

[0021] FIG. 1 illustrates a conventional pulley wheel arrangement;

[0022] FIG. 2 illustrates a force-measuring pulley apparatus of the present disclosure, in accordance with an embodiment of the present disclosure; FIG. 3 illustrates a pulley wheel of the force-measuring pulley apparatus, in accordance with an embodiment of the present disclosure;

[0023] FIG. 4 illustrates an implementation scenario of the force-measuring pulley apparatus, in accordance with an embodiment of the present disclosure;

[0024] FIG. 5 illustrates an exploded view of the force-measuring pulley apparatus, in accordance with an embodiment of the present disclosure;

[0025] FIG. 6A and FIG. 6B depicts another implementation scenario of the force-measuring pulley apparatus, in accordance with an embodiment of the present disclosure; and

[0026] FIG. 7 illustrates a flowchart of the method for the force-measuring pulley apparatus, in accordance with an embodiment of the present disclosure.

[0027] In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the nonunderlined number is used to identify a general item at which the arrow is pointing.

[0028] DETAILED DESCRIPTION OF EMBODIMENTS

[0029] The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practising the present disclosure are also possible.

[0030] FIG. 1 illustrates a conventional pulley wheel arrangement. With reference to FIG. 1, the conventional pulley wheel arrangement includes a force-measuring pulley apparatus 100 that includes a wheel 102 having a round peripheral edge and two guiding sidewalls 104. Furthermore, the guiding sidewalls 104 are configured to guide an elongate flexible member, such as a rope, belt, or chain 106, around at least a portion of the peripheral edge of wheel 102. The wheel 102 is configured to be rotationally supported about a central pin or axle 108. In one implementation, wheel 102 rotates about a fixed central pin or axle 108 when the pin or axle is held stationary. In an alternative implementation, pin or axle 108 is integral with wheel 102 and rotates within a bearing support. The rotational configuration of wheel 102 enables redirection of tension forces applied to an elongate flexible member 110 during mechanical operation. Moreover, in many mechanical applications, measurement of tension developed in elongate flexible member 110 is desired. Examples of such applications include physical exercise equipment where effort exerted by a user is monitored and lifting systems such as cranes where the weight of a suspended object is determined.

[0031] One known approach for tension measurement includes incorporation of a forcemeasurement sensor inline within elongate flexible member 110. However, placement of the sensor inline may compromise the load-bearing capacity and safety of elongate flexible member 110. An alternative approach involves measurement of reaction forces at pin or axle 108 using strain gauge arrangements. Implementation of such strain-based measurement generally necessitates a complex mounting configuration for wheel 102 and may not be compatible with existing equipment without significant structural alteration.

[0032] FIG. 2 illustrates a force-measuring pulley apparatus of the present disclosure, in accordance with an embodiment of the present disclosure. With reference to FIG. 2, there is shown a force-measuring apparatus 200 that includes a pulley wheel 202, an inner wheel 204, a fixed support 206, an elongate flexible member 208, an energy-harvesting arrangement 210, a force-measuring device 212, a transmission unit 214, a wireless transmitter 216, a wireless receiver 218, and a processor 220.

[0033] There is provided the force-measuring pulley apparatus 200, which includes the pulley wheel 202 having a rotating portion configured to support an elongate flexible member 208 on at least a portion of a peripheral region thereof. The force-measuring pulley apparatus 200 allows to integrate directly into existing mechanical systems for measuring tension without disrupting the original system structure. Unlike conventional solutions that require modifications to existing mounting arrangements, this design enables users to simply replace a standard pulley with the force-measuring pulley for immediate tension measurement capabilities.

[0034] Furthermore, the force-measuring pulley apparatus 200 includes a fixed support 206 configured to bear the pulley wheel 202 at a central region thereof. The fixed support 206 functions as a structural anchor that holds the pulley wheel 202 in position by engaging with the central hub or inner wheel 204, thereby enabling controlled and stable rotation of the pulley wheel 202 around a fixed axis. By maintaining precise alignment and rotational integrity, the fixed support 206 allows the force-measuring device 212, which is co-rotating with the pulley wheel 202, to accurately determine the force applied by the elongate flexible member 208 passing over the pulley. The fixed support 206 may include low-friction elements such as bearings to minimize mechanical resistance, thereby enhancing the sensitivity and response time of the force measurement. In a real-world application, such as a cable-based strength training machine, the fixed support 206 ensures that the pulley wheel 202 remains correctly aligned under dynamic loads, enabling the system to capture precise tension data that can be used to monitor user effort or performance in real time.

[0035] Furthermore, the force-measuring pulley apparatus 200 includes the forcemeasuring device 212 arranged within the rotating portion of the pulley wheel 202, wherein the force-measuring device 212 rotates with the pulley wheel 202 and is configured to determine a force applied to the rotating portion as the elongate flexible member 208 passes over the pulley wheel 202. In an example, the force applied to the rotating portion is determined based on detecting strain generated in body of the pulley wheel 202. In other words, the force-measuring pulley apparatus 200 includes a force-measuring device 212 arranged within the rotating portion of the pulley wheel 202, such that the force-measuring device 212 rotates in unison with the pulley wheel 202. The force-measuring device 212 is structurally integrated within the rotating region to directly experience the mechanical forces exerted during operation. The force-measuring device 212 is configured to determine the force applied to the rotating portion of the pulley wheel 202 as the elongate flexible member 208 moves over the peripheral region of the pulley. Force determination is achieved by detecting strain generated within the body of the pulley wheel 202, which translates mechanical tension into measurable deformation signals. The arrangement of the force-measuring device 212 within the rotating portion ensures that measurements are taken in real-time at the point of contact, thereby improving the accuracy and dynamic responsiveness of the system. As a result, the force-measuring device 212 in the rotating structure is the elimination of indirect or delayed force sensing, which enables continuous and precise monitoring without signal loss due to rotational position or lag. For example, in a load-lifting cable crane application, the force-measuring device 212 allows real-time monitoring of cable tension as the pulley rotates, ensuring safe handling of variable loads and providing critical feedback for automated control systems.

[0036] Furthermore, the force-measuring pulley apparatus 200 includes the transmission unit 214, operably coupled with the force-measuring device 212 and the processor 220 is configured to transmit the determined force to the processor 220. In an implementation, the transmission unit 214 serves as the communication bridge between the sensing mechanism and the data processing system, enabling the transfer of real-time force measurements without interrupting the operation of the rotating pulley wheel 202. This coupling may be achieved through either a wired or wireless connection, depending on design constraints and mobility requirements, and is often implemented with integrated circuitry that filters, formats, and forwards the strain-derived force data. As a result, the transmission unit 214 directly within the rotating or adjacent structure, latency reduces and signal integrity is preserved, ensuring that the processor 220 receives accurate and timely information for further analysis. The technical advantage of incorporating the transmission unit 214 lies in its ability to support continuous data flow from a rotating, mobile environment to a fixed processing unit, which is essential in applications where real-time feedback or automation is required. For example, in a conveyor-based industrial system where varying loads must be tracked dynamically, the transmission unit 214 ensures that force data is instantly relayed to the processor 220, enabling precise control of load balancing, system alerts, or performance analytics.

[0037] In accordance with an embodiment, the force-measuring pulley apparatus 200 further comprises an energy-harvesting arrangement 210 arranged within the rotating portion of the pulley wheel 202 to generate electrical energy from rotation of the pulley wheel 202 relative to the fixed support 206. Moreover, the energy-harvesting arrangement 210 is configured to provide power to the force-measuring device 212 and the transmission unit 214. The energyharvesting arrangement 210 functions as a self-sustaining power source by converting mechanical rotational energy into usable electrical power, typically through electromagnetic induction or similar energy conversion methods. Moreover, electrical energy generated by the energy-harvesting arrangement 210 is directed to power the force-measuring device 212 and the transmission unit 214, thereby eliminating the need for external wiring or battery replacement. Additionally, the energy-harvesting arrangement 210 ensures that power is continuously generated during pulley operation, maintaining uninterrupted functionality of the sensing and data transmission systems. Since the energy-harvesting arrangement 210 is incorporated into the rotating portion, a compact and autonomous sensing unit capable of operating in remote or mobile environments is possible without reliance on fixed power infrastructure.

[0038] In accordance with an embodiment, the elongate flexible member 208 comprises at least one of: a rope, a belt, or a chain. In an implementation, the elongate flexible member 208 includes the rope. In another implementation, the elongate flexible member 208 is the belt. In yet another implementation, the elongate flexible member 208 is the chain. The elongate flexible member 208 serves as the primary load-bearing element that transmits mechanical force across the pulley wheel 202 during operation. Selection of the flexible member may depend on the specific application and load requirements, for example, a rope may be used in fitness or climbing applications, a belt in automotive or industrial machinery, and a chain in heavy-duty lifting or conveyor systems. The force-measuring device 212 is configured to detect strain induced in the body of the pulley wheel 202 as it moves over the pulley wheel 202, enabling accurate measurement of applied tension. The ability to accommodate various types of flexible members enhances the versatility of the apparatus and allows seamless integration into existing mechanical systems. For example, in a cable-driven robotic arm used in manufacturing, replacing a worn-out belt with a chain or rope does not compromise sensing accuracy or mechanical compatibility, making the system resilient, upgradeable, and easy to maintain.

[0039] The processor 220 may comprise any suitable processing device, such as a microprocessor, microcontroller, programmable logic device, applicationspecific integrated circuit (ASIC), field-programmable gate array (FPGA), or any combination thereof. The processor may include one or more processing cores and may be configured to execute computer-readable instructions stored in a memory.

[0040] The memory may comprise any suitable storage medium, such as random access memory (RAM), read-only memory (ROM), flash memory, electrically erasable programmable read-only memory (EEPROM), or other suitable storage devices. The memory may store computer-readable instructions that, when executed by the processor, cause the processor to perform the operations described herein. The processor 220 may be operably coupled to various components of the force-measuring pulley apparatus via suitable communication interfaces, which may include, but are not limited to, serial interfaces, parallel interfaces, bus interfaces, wireless interfaces, or any combination thereof. The processor may be configured to receive data from various sensors and devices, process the received data, and transmit processed data to output devices or external systems.

[0041] In some embodiments, the processor 220 may be implemented as a distributed processing system, with processing capabilities distributed across multiple physical locations or devices. The processor 220 may also be implemented in a cloud computing environment, wherein at least some processing operations are performed remotely from the force-measuring pulley apparatus 200. In accordance with an embodiment, the force-measuring device 212 comprises a planar plate having one or more strain sensors mounted thereon, wherein the one or more strain sensors are configured to provide strain measurement in two substantially mutually orthogonal axes, the force-measuring device 212 includes a planar plate embedded with strain sensors arranged along two substantially orthogonal axes. Moreover, the dual-axis setup enables detection of multi-directional forces acting on the pulley system. For example, in gym equipment like adjustable cable crossovers, users often pull cables at various angles, which means forces are rarely applied in a single direction. The strain sensors detect linear deformation along both axes, and these signals are used to compute the resulting force vector, which leads to enhanced accuracy in measuring complex, multi-directional efforts during exercises like standing cable woodchoppers or unilateral cable pulls.

[0042] In accordance with an embodiment, the planar plate is configured such that strains resulting from the force applied to the rotating portion are linear strains. The planar plate is configured to produce linear strains in response to forces applied through the pulley's rotating portion. This means the mechanical design channels applied tension in a straight-line path, avoiding torsional or shear- induced distortions, such as in pulldown machines where consistent vertical tension must be captured without artifacts from lateral cable sway. As a result, by ensuring a linear strain profile, the system improves signal fidelity, reduces the need for filtering, and enhances the accuracy of load tracking under dynamic workout conditions.

[0043] In accordance with an embodiment, the tension in the elongate flexible member 208 is computed as a vector sum of two substantially orthogonal measurements of strain. In other words, the force-measuring device 212 is configured to compute total cable tension as the vector sum of orthogonal strain measurements. This approach provides accurate tension values even when force is applied off-axis, which is common in machines like dual-handle cable fly stations. For example, during a cable rear delt fly, the user pulls in a backward and outward arc, and the force direction changes throughout the rep. Moreover, by resolving sensor data into a resultant vector, the force-measuring pulley apparatus 200 is configured to maintain a precise force tracking despite these dynamic shifts, which helps trainers and athletes monitor output consistency and detect muscular imbalances.

[0044] In accordance with an embodiment, the force-measuring device 212 comprises capacitive displacement-sensing sensors whose capacitances vary as a function of changes in the force applied to the rotating portion. In other words, the capacitive displacement-sensing sensors are embedded within the forcemeasuring device 212 to detect small displacements caused by force-induced strain. As the pulley rotates under load, the change in spacing between internal electrodes alters the capacitance, which is correlated to the applied force. Moreover, the capacitive sensing is ideal for high-resolution measurements, making it particularly effective in applications like resistance-assisted pull-up machines where very light loads are gradually increased over time. This allows for fine-tuned progress tracking, especially for beginners or during rehab workouts.

[0045] In accordance with an embodiment, the transmission unit 214 comprises a wireless transmitter 216 configured to wirelessly transmit the determined force to a wireless receiver 218 operably connected to the processor 220. In other words, the transmission unit 214 features a wireless transmitter 216 that sends measured force data to a wireless receiver 218 paired with the processor, which eliminates the need for wiring between moving parts and allows seamless integration with smart gym systems. In practice, this means real-time force data from a cable row station can be displayed on a wall-mounted tablet or mirrored to a trainer's device for live coaching. In other words, the wireless architecture simplifies the process of upgrading older gym equipment with smart monitoring capabilities, as it eliminates the need to install physical cables through existing pulley frames.

[0046] In accordance with an embodiment, the force-measuring pulley apparatus 200 further comprising an energy storage device configured to store excess electrical energy generated by the energy-harvesting arrangement 210 and provide power when the pulley wheel 202 is stationary. For example, for static cable holds or isometric biceps curls, where the user maintains tension without moving. Since the pulley isn't rotating, energy harvesting stops, but stored energy keeps the sensors and transmitter powered and ensures uninterrupted force tracking even during pause reps or muscle contraction holds, where users aim to build strength through time-under-tension techniques.

[0047] In accordance with an embodiment, the force-measuring pulley apparatus 200 further comprising a calibration module configured to account for a deflection angle of the elongate flexible member 208. In an implementation, the calibration module is configured to compensate for variations in the deflection angle of the elongate flexible member 208. In real-world gym applications, exercises like standing overhead triceps extensions may cause the cable to move off-centre. Moreover, the angle change can distort force readings if uncorrected. The calibration module uses pre-defined or adaptive correction models to normalize these effects, allowing consistent force measurement regardless of user posture or machine setup, which is particularly useful for group training setups or circuits.

[0048] In accordance with an embodiment, the calibration unit comprises a programmable calibration arrangement configured to account for one or more deflection angles of the elongate flexible member 208 relative to the fixed support 206. The calibration module is programmable, allowing users or gym staff to preset calibration profiles for different machine positions or exercise modes. For example, on a dual adjustable pulley machine, the cable angle may be steeper for overhead presses and flatter for low rows. As a result, the calibration module is configured to enable stored calibration settings to be applied automatically or selected via software, ensuring accurate measurement across a variety of exercise types without manual recalibration between sessions.

[0049] In accordance with an embodiment, the energy-harvesting arrangement 210 comprises an electromagnetic generator driven by a gear mechanism coupled to the fixed support. The energy-harvesting arrangement 210 includes an electromagnetic generator that converts rotational energy from the pulley wheel 202 into electrical energy using a gear mechanism. As the user performs movements such as cable pulldowns or rows, the pulley rotates, and this motion is converted into usable power. This eliminates the need for external batteries or power sources, reducing maintenance and enabling completely wireless operation, even in facilities without built-in electrical infrastructure at each machine.

[0050] In accordance with an embodiment, the gear mechanism comprises a pulsed motion mechanism configured to increase maximum rotation speed of the electromagnetic generator for enhanced power generation at low rotational speeds of the pulley wheel 202. For example, during slow and controlled cable curls in hypertrophy training, pulley speed is low. Moreover, the pulsed gear converts that limited motion into faster generator rotation, ensuring continuous power delivery to the sensors and processor without requiring the user to speed up, thereby preserving form and safety.

[0051] In accordance with an embodiment, the pulsed motion mechanism comprises at least one of: a Geneva drive or a magnetically coupled gear to provide smooth, efficient rotational translation without slippage that ensure that even with irregular or burst-like user input, such as during explosive reps on a cable squat machine energy is harvested reliably without mechanical wear, maintaining system longevity and reducing servicing needs.

[0052] In accordance with an embodiment, the force-measuring pulley apparatus 200 is configured for use in at least one of: measuring a physical effort exerted by an athlete when using a cable strength training machine, measuring a weight of a load when being lifted by a cable crane, measuring a tension on a halliard of a sailing yacht, measuring a tension in a drive belt in an automotive engine, or measuring a tension of a catenary wire in an electrified railway. In an implementation, the force-measuring pulley apparatus 200 is configured for measuring a physical effort exerted by an athlete when using a cable strength training machine. In another implementation, the force-measuring pulley apparatus 200 is configured for measuring a weight of a load when being lifted by a cable crane. In yet another implementation, the force-measuring pulley apparatus 200 is configured for measuring a tension on a halliard of a sailing yacht. In another implementation, the force-measuring pulley apparatus 200 is configured for measuring a tension in a drive belt in an automotive engine. In yet another implementation, the force-measuring pulley apparatus 200 is configured for measuring a tension of a catenary wire in an electrified railway. As a result, the force-measuring pulley apparatus 200 is optimized for gym environments where it is used to monitor the physical effort of athletes on machines like functional trainers, cable row machines, or assisted dip stations. By measuring real-time force output, the apparatus provides objective feedback for strength progress tracking, helps identify weaknesses, and assists in customizing resistance levels, such as for personal training programs and rehabilitation clinics that rely on data-driven progress monitoring.

[0053] Furthermore, the force-measuring device 212 is configured to determine the force applied to the rotating portion of the pulley wheel 202 based on detecting strain generated in the elongate flexible member 208 as it passes over the pulley wheel. Moreover, the processor 220 also rotates with the pulley wheel 202 in order to receive the strain measurement data from the force-measuring device 212 and performs initial processing to determine the applied force. Subsequently, the processed force data is then transmitted by the transmission unit 214 to the processor 220 via the wireless receiver 218. By performing initial data processing within the rotating portion before transmission, the forcemeasurement pulley apparatus 200 is configured to maintain an improved accuracy and reduces the bandwidth requirements for wireless transmission.

[0054] In accordance with an embodiment, the processor 220 is configured to calculate tension in the elongate flexible member 208 based on the determined force and a deflection angle. The processor 220 calculates the true cable tension by factoring in both strain data and the measured or known deflection angle, for example, in gym machines like incline cable chest presses or decline cable flys where the cable's pull angle influences the actual load experienced. By integrating angular correction, the processor 220 ensures the displayed or logged tension reflects the true effort exerted by the user, allowing precise load management and progression planning.

[0055] Furthermore, the processor 220 is operably coupled with an imaging system positioned in the vicinity of the force-measuring pulley apparatus 200. Moreover, the imaging system is configured to capture imaging data of the area surrounding the apparatus and transmit said imaging data to the processor. The processor 220 implements image processing techniques to identify the user operating the force-measuring pulley apparatus based on the received imaging data. Upon identification of the user, the processor is further configured to retrieve a user profile associated with the identified user from a database. The user profile may contain historical force measurement data, exercise patterns, physical parameters, health metrics, and other relevant user-specific information. In a preferred embodiment, the processor comprises an artificial intelligence module or machine learning module configured to analyse the determined force data in conjunction with the user profile data. Based on this analysis, the processor generates personalised recommendations for the user. These recommendations may include, but are not limited to, suggestions for healthy lifestyle modifications, exercise regimen adjustments, or specific measures to prevent or ameliorate health conditions. The artificial intelligence module or machine learning module is advantageously designed to utilise historical force measurement data and user feedback to continuously improve its recommendation algorithms, thereby creating a closed feedback loop. This self-improving system enhances the accuracy and relevance of the recommendations provided to the user over time.

[0056] In one implementation, the recommendations generated by the processor are transmitted to the user device in real-time during exercise sessions involving the force-measuring pulley apparatus. The user device may comprise at least one of: a smartphone, a tablet computer, a wearable device, a dedicated display unit mounted on exercise equipment, or any other suitable electronic device capable of presenting information to the user. The force-measuring pulley apparatus 200 may further comprise a network interface enabling the processor to access external databases containing medical knowledge, exercise science data, or other relevant information to enhance the quality of the recommendations provided to the user.

[0057] In accordance with an embodiment, the force-measuring pulley apparatus 200 is configured to be installed as a direct replacement for a standard pulley without requiring modification to existing mounting arrangements. In other words, the force-measuring pulley apparatus 200 is directly compatible with industrystandard pulley mounting formats, allowing it to replace conventional pulleys without any structural modification, which enables fitness centres to upgrade existing cable machines, such as pulldowns or seated rows, with force-sensing capability quickly and cost-effectively, without needing new frames, wiring, or housing components.

[0058] In accordance with an embodiment, the force-measuring device 212 provides strain measurement data that is processed to determine a tension value regardless of the rotational position of the pulley wheel 202. In other words, the force-measuring device 212 is configured to provide an accurate tension values regardless of the rotational orientation of the pulley wheel 202, such as in cable face pulls or rotational torso pulls, where the pulley can spin freely and change angle during a rep. As a result, by compensating for rotational position, the force-measuring pulley apparatus 200 is configured to ensure consistent force readings throughout the motion path, enabling reliable analysis of movement quality and effort across the entire range of motion.

[0059] Furthermore, the force-measurement pulley apparatus 200 further includes the transmission unit 214 that serves as the communication interface between the force-measuring device 212 and external processing systems. The transmission unit 214 is operably coupled with the force-measuring device 212 and configured to process and format the strain measurement data for wireless transmission. Moreover, the processed data is then sent via the wireless transmitter 216, which is integrated within the rotating portion of the pulley wheel 202 and rotates during operation. The wireless transmitter 216 employs standard wireless communication protocols, such as Bluetooth®, to reliably transmit the force measurement data without requiring physical connections that would impede rotation. The transmitted data is received by a wireless receiver 218, which is positioned remotely from the rotating pulley wheel 202 in a stationary location. Moreover, the wireless receiver 218 is operably connected to the processor 220, which performs additional calculations to determine the actual tension in the elongate flexible member 208 based on the received force data and applicable deflection angles. This wireless transmission architecture enables continuous data flow from the rotating components to stationary processing systems without mechanical interference, ensuring reliable operation even during continuous or high-speed rotation of the pulley wheel.

[0060] Advantageously, the force-measuring pulley apparatus 200 is configured to provide an accurate, real-time tension measurement without requiring modification to the pulley's fixed support or surrounding structure. Moreover, the force-measuring pulley apparatus 200 is configured to allow retrofitting into existing mechanical systems and eliminates the need for external power sources or cumbersome wiring, thereby enhancing installation flexibility and operational safety. Additionally, the installation of the one or more strain sensors in the rotating body of the pulley wheel 202 allows for the use of compact, cost- effective bearings and improves measurement accuracy by directly capturing forces exerted by the elongate flexible member. Hence, the force-measuring pulley apparatus 200 is configured to enhance the adaptability and precision of the system across a variety of industrial and recreational applications.

[0061] FIG. 3 illustrates a pulley wheel of the force-measuring pulley apparatus, in accordance with an embodiment of the present disclosure. In an implementation scenario, the pulley wheel 202 is depicted as a circular disc that serves as the primary rotating component of the apparatus. At the central region of the pulley wheel is a fixed support 206, shown as a bolt or pin that secures the pulley wheel while allowing it to rotate freely. The fixed support 206 is depicted with a hexagonal head, indicating its function as a non-rotating anchoring component that bears the pulley wheel at its central region. Moreover, the elongate flexible member 208 is shown passing over a portion of the peripheral region of the pulley wheel 202, which may be a rope, belt, or chain, approaches the pulley wheel from one direction, wraps around a portion of the pulley wheel's periphery, and then extends away in another direction, creating a deflection angle. This deflection angle is a critical parameter for calculating the actual tension in the elongate flexible member based on the forces measured at the pulley wheel. The inner wheel 204 is configured to interface with the fixed support 206. This component remains stationary while the pulley wheel 202 rotates around it. The arrangement illustrates how the elongate flexible member 208 applies force to the rotating portion of the pulley wheel as it passes over, which is then detected by the force-measuring device (not explicitly shown in this simplified diagram) that is arranged within the rotating portion of the pulley wheel 202. As a result, the force-measuring pulley apparatus 200 operates as tension is applied to the elongate flexible member 208, it creates measurable strain in the rotating pulley wheel 202, which can be detected and quantified by sensors integrated within the rotating structure.

[0062] FIG. 4 illustrates an implementation scenario of the force-measuring pulley apparatus, in accordance with an embodiment of the present disclosure. In an implementation scenario, the pulley wheel 202 have an outer rim 210A that forms the peripheral region which supports the elongate flexible member 208. The elongate flexible member 208 is shown passing over the pulley wheel, approaching and departing at different angles, creating a partial wrap around the pulley's circumference. Moreover, the inner structure of the pulley shows a central hub region 210B that houses the mounting system for the fixed support. Surrounding this central hub 210C that represent the mounting positions for the force-measuring device elements, such as strain sensors. These components are strategically placed within the rotating portion of the pulley wheel to provide accurate strain measurements in multiple axes as the pulley rotates. This circular arrangement ensures that force measurements can be taken regardless of the rotational position of the pulley wheel.

[0063] FIG. 5 illustrates an exploded view of the force-measuring pulley apparatus, in accordance with an embodiment of the present disclosure. In an implementation, the outer rim 202B is the outer rim of the pulley wheel 202 that engages with the elongate flexible member 208. The central hub region 210B shows the central hub structure that interfaces with the fixed support. The inner rim 202C includes the strain sensors or other force measurement devices.

[0064] FIG. 6A and FIG. 6B depicts another implementation scenario of the forcemeasuring pulley apparatus, in accordance with an embodiment of the present disclosure. In an implementation, the outer rim 202B forms the peripheral edge of the pulley wheel that guides the elongate flexible member. When in operation, projecting members 604 support an annular rigid circuit board 602. The annular rigid circuit board 602 may be manufactured from fibreglass, a ceramic material or similar. Capacitive plates on the annular rigid circuit board 602 form corresponding capacitors with an inside edge or spokes of the pulley wheel 202. Forces acting on the pulley wheel 202 cause strain movement (namely deformation) of the pulley wheel 202 that causes capacitances of the capacitors to vary that is detected by electronic components included on the annular rigid circuit board 602. For example, the capacitors may be configured in a differential excited Wheatstone bridge arrangement, although other configuration are feasible without affecting the scope of the present disclosure Referring to FIG. 6B, there is shown a front view of the assembled alternative implementation of the force-measuring pulley apparatus 200, which depicts the engagement of the elongate flexible member 208 with the outer rim 210A of the pulley wheel 202.

[0065] FIG. 7 illustrates a flowchart of the method for the force-measuring pulley apparatus, in accordance with an embodiment of the present disclosure. The method 700 includes steps 702 to 710.

[0066] At step 702, the method 700 includes supporting the elongate flexible member 208 on a rotating portion of a pulley wheel 202. At step 702, the method 700 includes bearing the pulley wheel 202 at a central region thereof using a fixed support. At step 704, the method 700 includes determining, using a forcemeasuring device 212 arranged within the rotating portion of the pulley wheel 202, a force applied to the rotating portion as the elongate flexible member 208 passes over the pulley wheel, wherein the force-measuring device rotates with the pulley wheel 202. At step 706, the method 700 includes transmitting the determined force to a processor 220 using a transmission unit operably coupled with the force-measuring device 212 and the processor 220 and powering the force-measuring device 212 and the transmission unit 214 using electrical energy generated by an energy-harvesting arrangement 210 arranged within the rotating portion of the pulley wheel 202 and the electrical energy is generated from rotation of the pulley wheel 202 relative to the fixed support.

[0067] Advantageously, the method 700 is used to provide an accurate, real-time tension measurement without requiring modification to the pulley's fixed support or surrounding structure. Moreover, the method 700 is used to allow retrofitting into existing mechanical systems and eliminates the need for external power sources or cumbersome wiring, thereby enhancing installation flexibility and operational safety. Additionally, the installation of the one or more strain sensors in the rotating body of the pulley wheel 202 allows for the use of compact, cost-effective bearings and improves measurement accuracy by directly capturing forces exerted by the elongate flexible member. Hence, the method 700 is used to enhance the adaptability and precision of the system across a variety of industrial and recreational applications.

[0068] There is further provided a computer program product comprising program instructions for performing the method 700 when executed by one or more processors in the force-measuring pulley apparatus 200. The computer program product is implemented as an algorithm, embedded in a software stored in the non-transitory computer-readable storage medium having program instructions stored thereon, the program instructions are executable by the one or more processors in the computer system to execute the method 700. The non- transitory computer-readable storage means may include, but are not limited to, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination of the foregoing. Examples of implementation of computer-readable storage medium, but are not limited to, Electrically Erasable Programmable Read-Only Memory (EEPROM), Random Access Memory (RAM), Read Only Memory (ROM), Hard Disk Drive (HDD), Flash memory, a Secure Digital (SD) card, Solid-State Drive (SSD), a computer-readable storage medium, and / or CPU cache memory.

[0069] Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe, and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural. The word "exemplary" is used herein to mean "serving as an example, instance or illustration". Any embodiment described as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments or to exclude the incorporation of features from other embodiments. The word "optionally" is used herein to mean "is provided in some embodiments and not provided in other embodiments". It is appreciated that certain features of the present disclosure, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable combination or as suitable in any other described embodiment of the disclosure.

Claims

CLAIMS1. A force-measuring pulley apparatus (200), comprising: a pulley wheel (202) having a rotating portion configured to support an elongate flexible member (208) on at least a portion of a peripheral region thereof; a fixed support (206) configured to bear the pulley wheel (202) at a central region thereof; and a force-measuring device (212) arranged within the rotating portion of the pulley wheel (202), wherein the force-measuring device (212) rotates with the pulley wheel (202) and is configured to determine a force applied to the rotating portion as the elongate flexible member (208) passes over the pulley wheel (202).

2. The force-measuring pulley apparatus (200) as claimed in claim 1, wherein the force-measuring apparatus (200) further comprises an energy-harvesting arrangement (210) arranged within the rotating portion of the pulley wheel (202) to generate electrical energy from rotation of the pulley wheel (202) relative to the fixed support, wherein the energy-harvesting arrangement (210) is configured to provide power to the force-measuring device (212) and the transmission unit (214).

3. The force-measuring pulley apparatus (200) as claimed in claim 1, wherein the elongate flexible member (110) comprises at least one of: a rope, a belt, or a chain.

4. The force-measuring pulley apparatus (200) as claimed in claim 1, wherein the force-measuring device (212) comprises a planar plate having one or more strain sensors mounted thereon, wherein the one or more strain sensors are configured to provide strain measurement in two substantially mutually orthogonal axes.

5. The force-measuring pulley apparatus (200) as claimed in claim 4, wherein the planar plate is configured such that strains resulting from the force applied to the rotating portion are linear strains.

6. The force-measuring pulley apparatus (200) as claimed in claim 4, wherein tension in the elongate flexible member (208) is computed as a vector sum of two substantially orthogonal measurements of strain.

7. The force-measuring pulley apparatus (200) as claimed in claim 1, wherein the force-measuring device (212) comprises capacitive displacement-sensing sensors whose capacitances vary as a function of changes in the force applied to the rotating portion.

8. The force-measuring pulley apparatus (200) as claimed in claim 6, further comprising a capacitance measurement circuit configured to measure the capacitances by determining discharge rate of pre-charged electrodes.

9. The force-measuring pulley apparatus (200) as claimed in claim 1, further comprising a transmission unit (214) operably coupled with the forcemeasuring device (212) and a processor (220), the transmission unit (214) comprising a wireless transmitter (216) configured to transmit the determined force to the processor (220).

10. The force-measuring pulley apparatus (200) as claimed in claim 1, further comprising an energy storage device configured to store excess electrical energy generated by the energy-harvesting arrangement and provide power when the pulley wheel (202) is stationary.

11. The force-measuring pulley apparatus (200) as claimed in claim 1, further comprising a calibration module configured to account for a deflection angle of the elongate flexible member (208).

12. The force-measuring pulley apparatus (200) as claimed in claim 10, wherein the calibration module comprises a programmable calibration arrangement configured to account for one or more deflection angles of the elongate flexible member (208) relative to the fixed support (206).

13. The force-measuring pulley apparatus (200) as claimed in claim 1, wherein the processor (220) is configured to calculate tension in theelongate flexible member (208) based on the determined force and a deflection angle.

14. The force-measuring pulley apparatus (200) as claimed in claim 1, wherein the energy-harvesting arrangement (210) comprises an electromagnetic generator driven by a gear mechanism coupled to the fixed support (206).

15. The force-measuring pulley apparatus (200) as claimed in claim 13, wherein the gear mechanism comprises a pulsed motion mechanism configured to increase maximum rotation speed of the electromagnetic generator for enhanced power generation at low rotational speeds of the pulley wheel (202).

16. The force-measuring pulley apparatus (200) as claimed in claim 14, wherein the pulsed motion mechanism comprises at least one of: a Geneva drive or a magnetically coupled gear.

17. The force-measuring pulley apparatus (200) as claimed in claim 1, wherein the force-measuring pulley apparatus (200) is configured for use in at least one of: measuring a physical effort exerted by an athlete when using a cable strength training machine, measuring a weight of a load when being lifted by a cable crane, measuring a tension on a halliard of a sailing yacht, measuring a tension in a drive belt in an automotive engine, or measuring a tension of a catenary wire in an electrified railway.

18. The force-measuring pulley apparatus (200) as claimed in claim 1, wherein the force-measuring pulley apparatus (200) is configured to be installed as a direct replacement for a standard pulley without requiring modification to existing mounting arrangements.

19. The force-measuring pulley apparatus (200) as claimed in claim 1, wherein the force-measuring device (212) provides strain measurement data that is processed to determine a tension value regardless of the rotational position of the pulley wheel (202).

20. A method (700) for measuring force using a force-measuring pulley apparatus (200), the method (700) comprising: supporting an elongate flexible member (208) on a rotating portion of a pulley wheel (202); bearing the pulley wheel (202) at a central region thereof using a fixed support (206); and determining, using a force-measuring device (212) arranged within the rotating portion of the pulley wheel (202), a force applied to the rotating portion as the elongate flexible member (208) passes over the pulley wheel (202), wherein the force-measuring device (212) rotates with the pulley wheel (202).

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