Electromagnetic Resistance Module With EEPROM-Based 3-Parameter Sensing
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Solution Overview
Problem
Existing fitness equipment resistance devices face challenges in obtaining high-precision rotating speed and torque data without incurring high costs or reducing controller lifespan due to high temperature exposure, and they often require complex balancing and cooling solutions.
Innovation Solution
A rotary electromagnetically controlled resistance device that uses a non-magnetic housing, electromagnetic brake unit, and an EEPROM-based sensor module to independently manage 3-parameter data, allowing for precise control and long-term precision without integrating the controller, thus facilitating flexible mass production and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the controller is integrated into the resistance device, then the 3-parameter data can be directly written into the controller memory, but the controller lifespan is greatly reduced due to high temperature environment
Solution Approach 1:
The patent divides the resistance device into separate modules: the sensor module with EEPROM is separated from the controller. The sensor module collects and stores 3-parameter data locally, while the controller processes data without being exposed to high temperatures, thus extending controller lifespan while maintaining data precision.
Solution Approach 2:
The patent introduces an EEPROM as an intermediary storage device between the sensor and controller. The EEPROM stores 3-parameter data in the sensor module, acting as a buffer that allows the controller to access precise data without being exposed to the high-temperature environment of the resistance device.
2Device complexity
If an iron housing is used as the rotating body, then the structure is simple, but heat accumulation occurs causing high temperature of internal electrical and electronic components
Solution Approach 1:
The patent uses aluminum alloy for the housing instead of traditional iron materials. Aluminum alloy provides both structural integrity and superior heat dissipation properties, reducing internal component temperatures while maintaining structural simplicity.
Solution Approach 2:
The patent utilizes the excellent thermal conductivity of aluminum alloy materials to facilitate heat dissipation from internal components through the housing structure, preventing heat accumulation and reducing operating temperatures.
3Measurement precision
If a torque sensor is used to obtain resistance information, then high-precision torque data can be obtained, but the cost is very high and calibration is required
Solution Approach 1:
The patent replaces mechanical torque sensors with an electromagnetic sensing system. The electromagnetic brake unit with coils and magnetic metal ring generates electromagnetic resistance that can be precisely controlled and measured through electrical parameters, eliminating the need for mechanical strain gauges and their associated calibration requirements.
Solution Approach 2:
The patent measures torque by detecting electrical parameters (current, voltage, resistance) of the electromagnetic brake unit rather than mechanical deformation. By monitoring the electrical characteristics of the electromagnetic coils and their interaction with the magnetic metal ring, the system achieves high-precision torque measurement without mechanical sensors.
4Measurement precision
If the controller is built into the resistance device, then the 3-parameter data can be stored locally, but the flexibility in mass production and maintenance is reduced
Solution Approach 1:
The patent segments the system into independent sensor module and controller units. The sensor module with EEPROM can be manufactured and tested separately, then integrated with different controller configurations for various fitness equipment applications, enhancing manufacturing flexibility and adaptability.
Solution Approach 2:
The patent extracts the data storage function from the controller and places it in a separate EEPROM within the sensor module. This extraction allows the controller to be optimized for different applications while the sensor module maintains consistent high-precision data storage capabilities across all applications.
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 high-precision control of resistance with reduced temperature exposure risks, extending controller lifespan, and improving manufacturing flexibility and maintenance ease.
Implementation Method 1
an electromagnetic brake unit, installed in the cavity of the rotary housing, and having an annular core, a plurality of serrated parts formed at the outer periphery of the annular core, and a plurality of coils wound around the serrated parts respectively... a current being passed through the coils, such that the serrated parts generate an electromagnetic resistance
Implementation Method 2
the resistance device of the related art uses an iron housing as its rotating body without considering its cooling effect, and it may easily cause heat accumulation and high temperature of the internal electrical and electronic components... the first side cover and the second side cover being made of a non-magnetic metal
Data Source
AI summary
A rotary electromagnetically controlled resistance device not only installs a high-precision sensor module in the resistance device only, but also writes integrated 3-parameter actual measured data (speed, torque and current) into an EEPROM of the sensor module and installs the EEPROM in the resistance device. Software and hardware of a controller are installed externally, such that a signal cable of the sensor module can be passed through the rotary resistance device and connected to the external controller. Therefore, this invention can overcome the issue of setting the controller in the resistance device in the related art, and the resistance device can be developed independently and completely without being limited by the controller to greatly improve the flexibility in mass production and maintenance of the resistance device, while the high-precision 3-parameter real measured data can be moved and kept together with the resistance device to achieve a long-term high-precision effect.