Digital Resistance Cable Readiness Control for Assisted Unracking

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Solution Overview

Problem

Strength training at home is often performed alone without trained assistance, posing risks and challenges in managing high weights and varying user abilities.

Innovation Solution

A digital strength trainer using a three-phase brushless DC motor to generate resistance, coupled with sensors and controllers to adjust tension dynamically, allowing for real-time adjustments based on user performance and exercise phase.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional weight stacks are used for strength training, then resistance can be provided, but the user requires trained assistance for safety and cannot easily adjust resistance

Engineering Contradiction:
ImproveEase of resistance adjustmentVSAvoidTraining safety
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The patent replaces traditional mechanical weight stacks with a digital resistance system using a motor and control circuitry. The motor generates resistance forces that are dynamically controlled by a processor based on sensor feedback, eliminating the need for physical weight plates and manual adjustment mechanisms while providing programmable resistance profiles and safety monitoring.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system continuously monitors user performance through sensors that detect cable position, force applied, and movement velocity. This feedback is processed in real-time to adjust resistance levels, provide form correction, and ensure safety by detecting improper technique or excessive strain, replacing the need for a human trainer to monitor and adjust settings.

Inventive Principle:
Principle #23Feedback

2Productivity

If high resistance is applied to provide effective strength training, then training effectiveness improves, but the difficulty of starting and ending the movement increases

Engineering Contradiction:
ImproveTraining effectivenessVSAvoidDifficulty of starting movement
Core Design Contradiction:
ProductivityVSEase of operation

Solution Approach 1:

The resistance profile is dynamically adjusted throughout the range of motion based on real-time sensor data. The system can provide lower resistance during the initiation phase of movement when the user needs to overcome inertia, and progressively increase resistance as the movement progresses, optimizing both effectiveness and ease of execution. The resistance can be modified based on velocity, position, and detected user intent.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The control system modifies multiple parameters including resistance magnitude, resistance curve shape, and movement velocity thresholds based on the exercise phase and user performance. This allows the system to adapt the mechanical characteristics of the resistance to match the physiological capabilities of the user at different points in the movement, making high resistance training more accessible.

Inventive Principle:
Principle #35Parameter changes

3Adaptability or versatility

If a motor is used to generate digital resistance, then resistance can be dynamically adjusted, but the complexity of the system increases

Engineering Contradiction:
ImproveDynamic resistance adjustmentVSAvoidSystem complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The motor assembly serves multiple functions: it generates resistance force, positions the cable, and provides the mechanical interface for force sensing. The control circuitry integrates multiple functions including motor control, sensor data acquisition, resistance profile management, and safety monitoring into a single integrated system, reducing overall complexity despite the added adaptability.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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

Enables safe and effective strength training at home by simulating traditional weight stacks with adjustable resistance, accommodating varying user abilities and providing real-time feedback and coaching.

Implementation Method 1

A digital strength trainer using a three-phase brushless DC motor to generate resistance

Methodology Applied
Scientific EffectElectromagnetic conversion: Electromagnetic Induction

Data Source

PatentUS12453883B2Assisted unracking of digital resistance
Publication Date: 2025.10.28 TONAL SYSTEMS INC
  • US12453883B2 patent drawing
  • US12453883B2 patent drawing
  • US12453883B2 patent drawing

AI summary

Assisted unracking of digital resistance includes detecting a state of a cable. A motor is mechanically coupled to the cable to provide resistance during an exercise by tensioning the cable. It further includes determining a readiness of the user to accept resistance based at least in part on the detected state of the cable. It further includes selectively applying resistance by the motor to the cable according to the determined readiness of the user to accept the resistance.