Foldable Conveyor Chain for Compact Stepmill Design
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Solution Overview
Problem
Traditional stepmills are bulky, pose safety hazards due to their height, and are difficult to use, as they require users to step up to access them, limiting their adoption in gyms and home exercise settings.
Innovation Solution
A conveyor chain for stepmills that folds into a flat configuration when returning to the top, comprising trapezoidal prism segments with hinges and axial rods, allowing for an endless loop with reduced vertical height and improved safety by minimizing the distance of fall if a user loses balance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional stepmills use a standard conveyor chain design, then the stepmill can provide effective cardiovascular exercise, but the device becomes bulky and requires excessive vertical space
Solution Approach 1:
The conveyor chain is divided into modular link assemblies, where each assembly consists of multiple link segments that can fold relative to each other. This segmentation allows the chain to compact into a smaller vertical profile while maintaining the functional tread surface area needed for effective exercise.
Solution Approach 2:
The conveyor chain employs dynamic folding mechanisms that allow the link assemblies to change configuration between operational and compact states. During operation, the links extend to provide sufficient tread depth; during return cycles, the links fold to reduce vertical space requirements, enabling the stepmill to meet space constraints without compromising exercise effectiveness.
2Reliability
If traditional stepmills are designed with sufficient height for proper tread function, then the exercise function is maintained, but safety hazards increase due to greater fall distance
Solution Approach 1:
By segmenting the conveyor chain into foldable link assemblies, the overall vertical height of the stepmill can be reduced while maintaining adequate tread depth during the upward portion of the cycle. The folded configuration during the return cycle minimizes the base height, thereby reducing fall distance and improving user safety without compromising exercise functionality.
Solution Approach 2:
The dynamic folding action allows the stepmill to adapt its vertical profile throughout the operational cycle. When the tread is in the load-bearing position, it extends to provide proper exercise surface; when returning, it folds to minimize height. This dynamic behavior resolves the contradiction between maintaining exercise function and reducing safety hazards.
3Volume of moving object
If traditional stepmills use a compact design to reduce space requirements, then space efficiency improves, but the device becomes difficult to use and access
Solution Approach 1:
The conveyor chain's dynamic folding mechanism ensures that during the upward travel portion, the links are fully extended to provide adequate tread depth and surface area. This maintains proper ergonomics and ease of use for users stepping onto and off the moving staircase, while the compact folded configuration during the return cycle achieves space efficiency without compromising accessibility.
Data Source
AI summary
A conveyor chain which is designed to be used on a stepmill to form into steps on the side interacting with a user, but which can fold into a generally flat configuration when returning to the top of the tread. Each step is designed to be formed of four generally identical segments where both the segments forming the tread and kickplate can fold relative to each other and each of the tread and kickplate can fold at a midpoint between two segments.