Brushless DC Motor Weight Loading System for Fitness Equipment
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Solution Overview
Problem
Conventional fitness equipment weight loading systems have complex structures, large volumes, heavy weights, and high costs, making them inconvenient for use and installation, particularly in household settings, and require additional components like reducers and linkage mechanisms to manage torque and resistance effectively.
Innovation Solution
A weight loading system utilizing a permanent magnet brushless DC motor with an external rotor structure, a rally rope, and a motor control unit that includes a torque control unit, current regulating unit, and position sensing circuit, allowing for stepless control of electromagnetic force and simplifying the structure by eliminating the need for additional reducers and linkage mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a motor with gear reducer and linkage mechanism is used to produce resistance, then the torque can be increased, but the structure becomes complicated and the cost increases
Solution Approach 1:
The patent replaces the mechanical gear reducer and linkage mechanism with an electromagnetic motor that directly produces the required torque. The motor's electromagnetic field generates force without mechanical transmission components, eliminating the need for reducers and linkages while maintaining the ability to produce sufficient resistance torque.
Solution Approach 2:
The patent changes the operating parameters of the motor, specifically operating it at low speed with high torque output. By adjusting the motor's current and control parameters, the system achieves the required torque levels without needing mechanical speed reduction devices.
2Force
If a motor with gear reducer is used to increase torque, then the resistance can be increased, but the structure becomes cumbersome and expensive
Solution Approach 1:
The patent substitutes the mechanical resistance transmission system with an electromagnetic system. The motor directly generates the resistance force through electromagnetic interaction, eliminating mechanical reducers and linkage mechanisms that would otherwise be required to transmit and amplify the force.
3Force
If iron blocks are used as weight load, then the resistance is sufficient, but the equipment has large frame and heavy total weight
Solution Approach 1:
The patent replaces physical iron block weights with an electromagnetic motor system that generates resistance through electromagnetic fields. This substitution eliminates the need for heavy physical masses while maintaining the same resistance effect, significantly reducing the equipment's total weight.
4Speed
If motor with high rotating speed is used, then the motor output is sufficient, but the torque is small requiring additional reducers
Solution Approach 1:
The patent changes the motor's operating parameters by controlling it to run at low speed with high torque output. Through electronic control and current regulation, the motor operates in a regime where it produces maximum torque at the required low speeds, eliminating the need for mechanical speed reduction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides a lightweight, cost-effective, and simple structure for fitness equipment, enabling effective muscle training with adjustable resistance and preventing equipment damage, while allowing for efficient control of rotating speed and force during exercise.
Implementation Method 1
a motor (1), which is a permanent magnet brushless DC motor with an external rotor structure... including a stator (11) mounted onto the fitness equipment support (4) and sheathed on the stator (11) and rotatable with respect to an external rotor (12) of the stator (11)
Implementation Method 2
the rally rope (5) is wound around the external rotor (12) of the motor (1)... and the other end of the rally rope (5) is coupled to a power driving mechanism (6) of the fitness equipment
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A weight loading system for fitness equipments includes a fitness equipment support (4), a rally rope (5), a motor (1), a motor driving and a motor control unit. The motor (1) is a permanent magnet brushless DC motor with an external rotor structure, and the motor includes a stator (11) mounted onto the fitness equipment support (4) and an external rotor (12) sheathed on the stator (11) and rotatable with respect to the stator (11), and the rally rope (5) is wound around the external rotor (12) of the motor (1), and an end of the rally rope (5) is coupled to the external rotor of the motor (1), and the other end of the rally rope (5) is coupled to the power driving mechanism (6) of the fitness equipment; the power driving mechanism (6) is provided for driving the external rotor (12) of the motor (1) through the rally rope (5) to rotate and generate a rally, and the motor control unit controls the motor to rotate in an opposite direction through the motor driving module, so as to produce a load force opposite to the rally. The weight loading system for fitness equipments structure is simple, lightweight, and achieves the effect of a stepless weight control.